20140916 ground support australia product and services brochure

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Bolts

Stratabolt™

Securabolt™

Securabolt™ – De-bonded

M24 Rock Bolts

Strata Tunnel Bolt

Dynamic® Bolts

Cable Bolts

Plates

Enduro™ Range

Self Drilling Anchors

Swellex Inflatable Bolts

Secura™ HGC system

GRP Bolts

Powerthread FiReP® Rockbolt System

Spinset anti-torsion Failure Rockbolt System

FiReP® HIPREX FRP High Pressure Injection Bolt

Powermesh FiReP® FRP Mesh

Resin Grouts/Capsules

Lokset™ Resin Capsules

Lokset™ TOOSPEEDIE™ Resin Capsules

Lokset™ Long Tendon Resin Capsules

Lokset™ X2 Resin Capsules

Lokset™ Supamix™ Resin Capsules

Lokset™ Resin Capsule

Quick-Chem™ Resin Capsule Insertion System

Mesh

Mine Mesh

Resin Anchors

Stratabinder HS

Stratabinder HS Slow Set

Conbex™ HES

Conbex™ HT

Conbex™ HF

Conbex™ UWP

FB400

Capcem

Carbothix™

Contents

Ground Support Product and Services Matrix – AustraliaPlease click on the Products and Services below to view further details

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Powders

Rappass™

Fastshot™

Sprayplast

Sprayplast UW

SP100™

Tekflex™

RD10 dust control

Injection Chemicals

Bevedol™/Bevedan™

Carbomine

Geoflex™

Carbofill™

Geofoam

Resin Grouts

Geofill™

Tekseal™

Rockfast – Hydrofoam

Rockfast – Hydroseal

Rockfast – Hydroblend

Hydropak

FB200™

CMT Grout

CMT Grout Hi Thix

Silent Seal®

Services

Tekpak™ Pumpable Crib

Accessories

Steel Accessories

Ventilation Control Devices

QBC

Blastflow™ Regulators

Meshblock™

Ground Support Product and Services Matrix – AustraliaPlease click on the Products and Services below to view further details

Strata (friction) Bolts have been manufactured in Australia for over 10 years. Strata Bolts are high tensile steel tubular bolts rollformed into a “C” shape.

Compression of the high tensile steel “C” shape into a hole diameter smaller than the tube diameter generates a load transfer from the steel to the rock.

This results in a frictional resistance to axial pull-out load of the tube from the hole. A steel ring is fixed to the collar end of the tube that will retain a plate on the installed tube to establish a compressive force against the rock.

Friction bolts have been used internationally in mining for decades and are considered the simplest form of ground support available in metal mining and tunnelling development. Strata Bolts benefit from a unique shape that enables increased contact surface of the steel with the hole, which provides higher pull out loads than traditional round friction bolts.

Strata Bolts provide an immediate frictional support at the face and can be installed with either hand held or mechanised equipment (Jumbos, Robolters etc.). For additional load bearing capacity Strata Bolts can be post grouted with cement grouts or Orica’s Capcem cement capsules.

Strata Bolts are available in black or hot dip galvanised steel, are manufactured in 34 mm, 40 mm and

47 mm diameters and various lengths from 600 mm to 3,000 mm. Strata Bolts are manufactured and supplied from Orica’s Sydney facility.

Orica also manufactures the Mesh Pin bolt for mesh overlapping applications. The Mesh pin consists of a modified 900 mm long 40 mm diameter Strata Bolt,™ with a 47 mm ring fixed to the collar end of the bolt. Mesh pins are installed into previously installed 47 mm Strata Bolts using the same 47 mm driver and same plate.

This reduces the amount of inventory necessary on sites.

The installation of mesh is more productive with the use of mesh pins by reducing the number of holes drilled and the use of standalone friction or resin bolts.

The Mesh Pin also eliminates the possibility of a driver designed to install 40 mm diameter bolts being used to install 47 mm diameter bolts. Bolts installed with an incorrect driver tool can result in significant damage to the collar end of the bolt during installation and possibly reduce the load capacity of the plate. Mesh Pins can also be post grouted to stiffen the support and are available in black or hot dip galvanised steel.

Strata Bolt™

of 3Strata Bolt™

ParametersHole LengthsCan be varied depending on application.

Installation AngleAlthough sometimes difficult to obtain, Strata Bolts should be installed within +/- 10 deg. Excessive angles of installation could create a point loading effect on the bolt ring, which in turn may effect the bolts performance.

Hole Size (diameter)• Strata Bolt™ 34 – typically 30 – 31 mm

• Strata Bolt™ 40 – typically 36 – 37 mm

• Strata Bolt™ 39.8 3.2 mm – typically 36 – 37 mm

• Strata Bolt™ 47 – typically 44 mm – 45 mm

Drive TimesCan be an indicator for correct or incorrect drill bit selection. For a typical 2400 mm Strata Bolt™ installation, the drive time should be in the range of 15 – 18 seconds.

Note: Different rock types / ground conditions may effect the actual hole size drilled. Orica’s Technical Service personnel can assist customers requirements with the use of borehole measuring equipment to determine correct drill bit sizes applicable.

Technical Data

Mechanical Properties

Strata Bolt™ 34 Minimum

Strata Bolt™ 34 Typical

Strata Bolt™ 40 / Mesh Pin Minimum

Strata Bolt™ 40 / Mesh Pin Typical

Strata Bolt™ 39.8 mm x 3.2 mm Minimum

Strata Bolt™ 39.8 mm x 3.2 mm Typical

Strata Bolt™ 47 Minimum

Strata Bolt™ 47 Typical

Bolt Diameter (mm) – 34 – 40 – 39.8 – 47

Yield Strength (MPa) 410 520 410 520 350 460 350 460

Yield Force (MT) 7.2 10.4 8.4 11.9 9.7 13.0 11.6 15.0

Tensile Strength (MPa) 520 600 520 600 430 520 430 520

Tensile Force (MT) 9.1 12.0 10.7 13.0 11.9 15.8 14.2 18.3

Elongation 80 mm sample (%)

18 22 – 28 18 22 – 28 20 – 20 –

Mass per metre – (kg/m) – 1.55 – 1.75 – 2.4 – 2.74

Note: Minimum yield and tensile forces are based on minimum material size and strength.

Testing Standards

Strata Bolt™ 34

Strata Bolt™ 40 / Mesh Pin

Strata Bolt™ 39.8 3.2 mm

Strata Bolt™ 47

Material AS1594 AS1594

Galvanising AS4680 AS4680 AS4680 AS4680

Steel Grade AB4121 HA350 HA350

PlatesOrica manufactures a comprehensive range of specially designed plates for use with rock bolts and cable bolts. Extensive product data is available on Orica’s full range of plates from Orica’s product catalogue and web site, www.orica.com.au

Plates most typically used with Strata Bolts are:

Dome Plate 150 x 150 x 4 mm – 7 mm

Dome Plate 200 x 200 x 4 mm

Combi Plate 280 x 300 mm – 240 x 300 mm

Crown Plate 150 x 150 x 5 mm

DriversOrica manufactures a full range of purpose designed Strata Bolt™ Drivers for use with hand held or mechanise bolting equipment. Extensive product data is available on Orica’s full range of drivers from Orica’s product catalogue and web site, www.orica.com.au

Drivers most typically used with Strata Bolts are:

Driver Strata Bolt™ 34 / 40 – Hand Held

Driver Strata Bolt™ 34 / 39.8 / 40 / 47 – R32 / R38 / T38

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All information contained in this document is accurate and up-to-date as at the date of issue. Since Orica Group Companies cannot anticipate or control the conditions under which this information and its products may be used, each user should review the information in the specific context of the intended application. To the maximum extent permitted by law, the Orica Group Companies will not be responsible for damages of any nature resulting from the use or reliance upon information in this document. No express or implied warranties are given, other than those implied mandatory by law. For more information please visit our website: www.orica.com

The word Orica and the Ring Device are trademarks of Orica Group Companies.

Page 3 of 3Strata Bolt™

The table below lists the typical Strata Bolts, descriptions, unit weights and pack sizes. Other sizes are available on request, depending on the number required.

Description, Dimensions and Weights

DescriptionUnit Weight

Pack Size

Strata Bolt™ 34 x 900 Galvanised 1.4 kg 300




Mesh Pin 40 x 900 47 Ring Black 1.6 kg 150

Mesh Pin 40 x 900 47 Ring Galvanised 1.7 kg 150

Strata Bolt™ 39.8 3.2 mm x 2400 Galvanised 6.0 kg 300

Strata Bolt™ 39.8 3.2 mm x 2400 Black 5.8 kg 300

Strata Bolt™ 47 x 900 Black 2.5 kg 150










Secura Bolts were first introduced into the Australasian mining and tunnelling industry in 1997. The Secura Bolt™ is a specifically designed solid reinforcing bar for use in strata reinforcement of underground mining and tunnelling excavations.

Secura Bolts include a unique paddle system to improve resin mixing and consequently provide higher bond strength in larger diameter boreholes. Secura paddles are formed using a unique shearing process which results in a more consistent specification along the bolt length compared with traditional stamp paddle processes. Extensive installation testing has confirmed that the Secura 3½ paddle configuration assists in resin film shredding and provides consistent and efficient mixing of resin capsule components. The Secura Bolt™ paddle configuration also does not become caught on mesh during installation as with other resin mixing systems.

The unique Nova thread (R thread) profile on the Secura Bolts incorporates a modified rope thread with large root and small crest areas. The R Thread is a more robust performing thread in the underground mining and tunnelling environment where bolts are often exposed to dirt and other contaminants. R thread profile Secura Bolts are available in R24 and R27 sizes.

A UNC thread is available with the ¾” size Secura Bolt.™ And a continuous T threadbar is also available with the T20 Secura bolts.

Standard Secura Bolts are supplied complete with either a slot pin integral domed washer torque nut, or with a separate dome washer and slot pin torque nut. Standardised paddle configurations and paddle diameters are available to maximise performance in various diameter boreholes. Secura Bolts are also available in various diameters and lengths to suit individual strata support, excavation dimensions and equipment requirements. All bolts can be supplied black or hot dip galvanised and are manufactured and supplied from Orica’s Sydney facility.

Secura Bolts have been successfully used as permanent support in mines and tunnels throughout Australia and New Zealand for over 10 years. Full technical and service support is available from experienced and trained personnel to all Secura Bolt™ customers.

Advantages• proven historical performance

• extensive quality controlled manufacture

• permanent primary support

• multiple lengths, diameters, paddle configurations

• consistent pin nut torque drive system

• high strength thread

• proven resin mixing performance

• high load transfer

Secura Bolt™

Resin Capsule Mixing ConsistencyAn extensive evaluation of Secura Bolts was completed in 2008 at Orica’s full-scale bolt simulation facility in Nowra NSW. The primary evaluation objective was to determine the best possible bolt, paddle and borehole diameter combinations to ensure consistent resin mixing during in-situ installations.

The following table indicates the most consistent performing bolt and paddle diameter combinations, plus the maximum suggested borehole diameter for each bolt/paddle combination:

Bolt Steel GradeTypical Bolt Diameter

Nominal Paddle Diameter

Nominal Borehole Diameter

3/4” Secura Bolt™ – 3 ½ paddles 300+ 3/4” 24.5 mm 28.0 mm

T20 Secura Bolt™ – 3 ½ paddles K1017 19.5 mm 30.0 mm 33.0 mm

R24 Secura Bolt™ – 3 ½ paddles K1045 21.75 mm 30.0 mm 33.0 mm

R24 Secura Bolt™ – 3 ½ paddles K1045 21.75 mm 32.0 mm 35.0 mm

R24 XHT Secura Bolt™ – 3 ½ paddles HSAC840 21.75 mm 30.0 mm 33.0 mm

R27 Secura Bolt™ – 3 ½ paddles 500N 23.0 mm 30.0 mm 33.0 mm

R27 Secura Bolt™ – 3 ½ paddles 500N 23.0 mm 32.0 mm 35.0 mm

Technical Data

Mechanical Properties

R27Min

R27Typical

R24Min

R24Typical

R24 XHT Min

R24 XHT Typical

T20 Min

T20 Typical

3/4”Min

3/4” Typical

Core Diameter (mm) 23 23.5 21.55 21.75 21.55 21.75 19.3 19.5 17.0 17.3

Bar Diameter Including Ribs (mm) 26 27 22.6 23.2 22.6 23.2 22.2 22.5 19.0 19.7

Nominal Cross sectional area – Bar (mm2)

415 450 361 370 361 370 293 299 227 242

Yield Strength (MPa) 500 550 400 445 600 650 500 550 300 340

* Yield Force Minimum Diameter (MT)

20.4 22.4 12.6 14.0 18.9 20.3 14.5 16.6 5.6 6.3

** Yield Force Typical Diameter (MT) 23.1 25.4 14.9 16.8 22.3 24.6 14.5 16.6 6.9 8.6

Tensile Strength (MPa) 600 650 600 730 840 890 600 640 440 490

* Tensile Force Minimum Diameter (MT)

24.4 26.5 18.9 23.0 26.5 28.1 17.9 19.3 8.6 9.1

** Tensile Force Typical Diameter (MT)

27.7 30.0 22.3 27.5 31.2 33.6 17.9 19.3 10.2 12.0

Elongation (%) 5D 12 22 14 22 15 19 12 21 22 27

Mass per metre – Bar (kg/m) 3.4 – 3.0 – 3.0 – 2.4 – – 1.90

Note: Metric Tonne (MT)

* Yield Force Minimum and Tensile Force Minimum values are calculated on the smallest diameter area of the bolt (thread root diameter) as per AS1275-1985 and ASTM F432-04.

** Yield Force Typical and Tensile Force Typical values are calculated on the nominal cross sectional area of the bar, as provided by the steel supplier.

Secura Bolt™Page 2 of 3

PlatesOrica manufactures a comprehensive range of specifically designed plates for use with rock bolts and cable bolts. Extensive product data is available on Orica’s full range of plates from Orica’s product catalogue and web site, www.orica.com.au

Plates most typically used with Secura Bolts are:


150 x 150 x 10 mm (HA300)

Combi Plate 240 x 300 mm

125 x 125 x 4 mm


The products listed below include left hand thread. Right hand threaded bolts are available on request. Other sizes and combinations are available on request.

Descriptions, Dimensions and Weights

Description Unit Weight Pack Size

Secura Bolt™ R27x1800 3½ x 30 mm Paddle Black 6.7 kg 100


Secura Bolt™ R27x1800 3½ x 32 mm Paddle Gal 6.7 kg 100










Secura Bolt™ T20x2400 3½ x 29 mm Paddle Black 6.0 kg 100

Secura Bolt™ T20x2400 3½ x 29 mm Paddle Gal 6.0 kg 100

Secura Bolt™ 3/4x2100 3½ x 22 mm Paddle Black 4.0 kg 100

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Secura Bolt™Page 3 of 3

Secura Bolts were first introduced into the Australasian mining and tunnelling industry in 1997. The Secura Bolt™ is a specifically designed solid reinforcing bar for use in the strata support of underground mining and tunnelling excavations.

Using all the normal standard configurations (listed below) of the R27 Secura Bolt™, Orica has now in addition developed the R27 De-bonded Secura Bolt™ for use in “squeezing” ground conditions.

1. 3.5 x 32 mm paddle system

2. New and improved R27 domed washer nut

3. Unique Nova (R) thread

4. Varied thread length to customers requirements

5. Either black or hot dipped galvanised steel

Orica have now developed the R27 De-bonded Secura Bolt™ by incorporating a specific sized polyethylene de-bonding sleeve that fits over the R27 secura bolt to allow the 500N steel D bar to elongate as the load enters into the minimum/typical yield. This simple system’s yielding capabilities are determined by the length of de-bonded polyethylene used to create the free bolt length which in turn is calculated in conjunction with the minimum 12% to typical 22% bar elongation.

The de-bonding of the R27 Secura Bolt™ can be set to different lengths/parameters depending on customer requirements. Common setting is for the polyethylene to start at the end of the thread or alternately 300 mm from the thread.

The application for the Orica R27 De-bonded Secura Bolt™ is in squeezing ground conditions where mine geotechnical engineers have calculated certain ground deformation through monitoring systems against their support system models. The R27 De-bonded Secura Bolt™ has been designed for these specific rock/ground squeezing conditions and not as a genuine dynamic support product.

The R27 De-bonded Secura Bolt™ is complimented in use with a specifically designed 10 mm dome plate, the plate’s load capacity is well beyond the 500N steel D bar typical tensile strength. This plate is a very important component that accepts the transferred load of the ground deformation to effectively stretch the de-bonded (“free” bar) section of the R27 D bar without the plate deforming/failing.

Secura Bolt™ – De-bonded

Advantages• Maintains it’s support capacity whilst

squeezing ground movement is taking place

• Can be adjusted to accommodate varied lengths of displacement within acceptable limits

• Allows for full encapsulation to be maintained

• Available in black or hot dipped galvanised steel

• Can be used in the most common actual 37 – 38 mm resin bolt hole size

• Installed using the same installation procedures as regular resin bolting

• Significant energy absorption before failure

• High load transfer

Considerable lab testing has been performed followed by in-situ trials. Further testing has also been carried out at the Orica test facility at Nowra, NSW. The Orica – Nowra test facility allows for the complete test bolt installation to be dissected so as a thorough examination can be made on all the aspects of the R27 De-bonded Secura Bolt™ i.e. bar stretch length, encapsulation length, resin mixing quality etc.

As detailed in the load displacement graph below the R27 500N D bar is loaded and brought into the minimum/typical yield strength before the elongation properties of the “free” bar length begins to re-act and stretch.

Technical Data

Bolt Steel GradeTypical Bolt Diameter

Nominal Paddle Diameter

Nominal Borehole Diameter

R27 Secura Bolt™ – 3 ½ paddles

HT Y500 N-Bar 23.5 mm 32.0 mm 35.0 mm

Mechanical PropertiesR27 Minimum

R27 Typical

Core Diameter (mm) 23 23.5

Rib Height (mm) 26 27

Cross Sectional Area – Bar (mm2) 415 450

Yield Strength (Mpa) 500 550

* Yield Force Minimum Diameter (MT) 20.4 22.4

** Yield Force Typical Diameter (MT) 23.1 25.4

Tensile Strength (Mpa) 600 650

* Tensile Force Minimum Diameter (MT) 24.4 26.5

** Tensile Force Typical Diameter (MT) 27.7 30.0

Elongation (%) 5D 12 22

Mass per metre – Bar (kg/m) 3.4 –

*** 1000 mm de-bonded ( mm ) Elongation 72 109

*** 1500 mm de-bonded ( mm ) Elongation 88 129

New Domed R27 Nut included on the R27 De-bonded Secura Bolt™

Note: * Yield Force Minimum and Tensile Force Minimum values are calculated on the smallest diameter area of the bolt as per AS1275-1985 and ASTM F432-04.

** Yield Force Typical and Tensile Force Typical values are calculated on the nominal diameter area of the bolt, as provided by the steel supplier.

*** Typical values are calculations based on lab test results.

The graph example shows the displacement/stretch capability using 1.5 m of polyethylene as the de-bonding agent.

Load Displacement Test Chart

Displacement (mm)

Test 1 Test 2

Load

(kN

)

00

100

200

300

10 20 30 40 50 60 70 80 90 100 110 120 130 140

Testing Standards

Steel Bar AS/NZS 4671

Threading AS1275

Galvanising AS4680

Polyethylene Tube

AS/NZS 4130:2009

Secura Bolt™ – De-bonded Page 2 of 4

R27 De-bonded Secura Bolt™ Lab Testing (Orica – Nowra Test Lab)

R27 De-bonded Secura Bolt™ before applying load R27 De-bonded Secura Bolt™ after load has been applied

Lab testing resin mix quality – toe end of bolt Lab testing resin mix quality – middle section of bolt


0.98

load kN

1.65 2.65 5.5 6.6

Dome Plate 150 x 150 x 10 Load Displacement – 100 mm Hole

7.6 9.0 9.7 11.60

100

200

300

400

displacement

PlateThe R27 De-bonded Secura Bolt™ has been developed through extensive testing using the Dome Plate 36 150x150x10.

The 10 mm dome plate has been load tested consistently to a minimum of 315kN which is in excess of the maximum tensile strength of the R27 De-bonded Secura Bolt™ 500N D-Bar.

The load tests on the dome plate were independently conducted.

Important parameters to consider for the installation of the R27 De-bonded Secura Bolt™

1 Use only Orica Lokset™ resin anchors or Orica “Supamix” resin anchors.

2 Require ACTUAL hole size 37.0 – 38.0 mm.

3 R27 De-bonded Secura Bolt™ requires the 3 ½ x 32 mm paddle system.

4 R27 De-bonded Secura Bolt™ should not be fed into the bolt hole any further than 200 mm before applying full rotation and feed.

5 Boltec’s, Robolter’s need to have their rotation speed set at approximately 280 rpm.

6 The general spin and feed times for i.e. a 2.4 m bolts should be 15 seconds plus additional 5 seconds spin when the bolt has reached the back of the hole. There may be a case where the medium/slow set resins need to be used in preference to fast/slow set so that the spin and feed times (above) are maintained.

7 It is important that the correct 10 mm dome plate is used for the installation of the R27 De-bonded Secura Bolt.™

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Product Description, Weight and Pack Size

Bolt


Secura Bolt™ R27 x 2400 mm LHT DBWSPNut 3.5 x 32 mm Pdl Gal – 1 m debonded 9.4 kg 100

Secura Bolt™ R27 x 3000 mm LHT DBWSPNut 3.5 x 32 mm Pdl Gal – 1.0 m debonded 11.7 kg 100

Secura Bolt™ R27 x 2400 mm LHT DBWSPNut 3.5 x 32 mm Pdl Blk – 1.5 m debonded 9.2 kg 100

Secura Bolt™ R27 x 2400 mm LHT DBWSPNut 3.5 x 32 mm Pdl Gal – 1.5 m debonded 9.3 kg 100

Plate


Dome Plate 36 150 x 150 x 10 Blk 2.1 kg 400

Dome Plate 36 150 x 150 x 10 Gal 2.2 kg 400

Resin

Description Box Qty Pallet Qty

Toospeedie™ Resin Anchor 1200/30 Fast/Slow x 2 QC Cap 7 294

Toospeedie™ Resin Anchor 1500/30 Fast/Slow x 2 QC Cap 6 252

Supamix Toospeedie Resin Anchor 1200/30 Fast/Slow x 2 QC Cap 7 294

Supamix Toospeedie Resin Anchor 1500/30 Fast/Slow x 2 QC Cap 6 252

Accessories


Driver Socket T38 x 600 Hex 42AF 7.5 kg Each

30 mm Quick-Chem™ Insertion Tube x 3.0 m Complete 20

30 mm Quick-Chem™ Insertion Tube x 3.6 m Complete 20

Product Service SupportOrica provides a full service support package to customers, including underground pull testing, operator awareness training, underground audits and stock control assistance. Each service package is developed to suit the individual customers requirements.

All aspects of Orica’s product service support service is provided by experienced trained and qualified personnel.

Additional InformationFor additional information relating to any aspect of this product specification data including product performance, quality, testing, specification, range, availability etc. please contact your nearest Orica office or email: [email protected]

Orica “M24 Rock Bolts” have been developed for use in point anchored or fully encapsulated roof and rib bolting applications.

All bolts are available in either Extra High Tensile “X” grade steel or standard “S” mild steel grade. All bolts are manufactured with a rolled M24 x 3.0 mm pitch right hand thread and are supplied complete with an anti-friction washer, dome washer and hexagonal 36 mm drive nut. Individual bolt lengths are visually identifiable by a coloured dome washer on each bolt. All Orica products including the M24 bolt are manufactured to strict quality control guidelines in accordance with Orica’s quality system. Product conformance certificates are available on request.

Orica utilises high grade steel with a ribbed surface profile for enhanced resin mixing and load transfer. Like all other Orica strata support products, “M24 Rock Bolts” have been thoroughly evaluated at Orica’s purpose designed test facility in Nowra NSW. Information on this facility and evaluation program is available on request.

Drive nut options available include resin nuts (available in multiple break out strengths) and pin nuts. Orica Chemdrive™ (resin) nuts have been used successfully in the Australian mining industry since 1984. The various breakout strengths are designated by the resin colour. Drive nut specifications including breakout torques is available on a separate Orica – Drive Nut PDS.

Secura paddle bolts are also available in ¾” UNC S grade steel for rib bolt applications. The unique Secura paddle system provides efficient resin mixing utilising a smaller diameter bolt in a standard <28 mm diameter hole. Additional information is available from the Orica – Secura Bolt™ PDS. Additional information on safe and correct resin bolting practices is available from the Orica – Lokset™ Resin Capsule PDS and the “Orica Guide to Resin Grouted Rockbolts”.

Qualified Orica representatives are available to assist in any necessary underground evaluation programs. Industry standard training and assessment procedures exist for all Orica products including “M24 Rock Bolts”. All Orica service representatives are accredited workplace trainer/assessors and are experienced in the use of all Orica products.

M24 “X” grade bolts are manufactured using Australian produced HSAC840 grade high tensile steel rebar. HSAC840 is a superior steel grade, offering greater potential performance in conditions subject to stress corrosion cracking.

M24 bolts are recommended for use in 27 – 28 mm diameter holes. If larger diameter holes are to be used, it is recommended to utilise a product from Orica’s Secura Bolt™ range. Secura Bolts include a specifically designed paddle configuration for improved resin mixing in larger diameter holes. Full information and specifications are available from the Orica – Secura Bolt™ PDS.

M24 Rock Bolts

M24 Rock Bolts Page 2 of 3

Technical Data

Mechanical PropertiesM24 X Grade Minimum

M24 X Grade Typical

M24 S Grade Minimum

M24 S Grade Typical

Nominal Bar Core Diameter (mm) 21.55 21.75 21.55 21.75

Nominal Rib Height Diameter (mm) 22.6 23.20 22.6 23.20

Nominal Cross Sectional Area – Bar (mm2) 365 370 365 370

Yield Stress (Strength – MPa) 600 650 300 340

* Yield Force Minimum Diameter (MT) 19.0 21.4 9.5 11.5

** Yield Force Typical Diameter (MT) 22.3 24.6 11.2 12.8

Ultimate Tensile Stress (Strength – MPa) 840 890 440 490

* Tensile Force Minimum (MT) 26.6 29.3 13.9 16.5

** Tensile Force Typical (MT) 31.2 33.7 16.4 18.6

Elongation (%) 5D 15 19 22 27

Mass per metre – Bar (kg/m) – 2.9 – 2.9


* Yield Force minimum and Tensile Force Minimum values are calculated on the smallest diameter area of the bolt (thread root diameter) as per AS1275-1985 and ASTM F432-04.


Testing Standards

M24 X Grade M24 S Grade

Steel Bar HSAC840 AS/NZS 3679.1-300

Galvanising AS4680 AS4680

Bar Straightness AS 1442-1991 AS 1442-1991

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M24 Rock Bolts Page 3 of 3

PackagingBolts are individually packaged in lots of 5 and grouped in bundles of 30. Bolt nuts and threads can be plastic wrapped, with bundles plastic strapped.

The products listed below include right hand thread. Left hand threaded bolts are available on request. Other sizes and combinations are available on request. Hot dip galvanised bolts are also available.

Description, Codes, Dimensions and Weights


M24 1.8 m Rock Bolt – X Grade Black, Chemdrive™ Green Nut 5.4 kg 30

M24 1.8 m Rock Bolt – X Grade Black, Pin Nut 5.4 kg 30





M24 1.2 m Rock Bolt – S Grade Black, Chemdrive™ Yellow Nut 3.6 kg 30



PlatesOrica manufactures a comprehensive range of specifically designed plates for use with rock bolts and cable bolts. Extensive product data is available on Orica’s full range of plates from Orica’s product catalogue and web site, www.orica.com.au

Plates most typically used with M24 Bolts are:


Dome Plate 150 x 150 x 6 mm, 8 mm, 10 mm


125 x 125 x 4 mm

The Strata Tunnel Bolt is a mechanical point anchored, pre-tensioned and post groutable rockbolt, incorporating a polyethylene sleeve and grout injection head.

Designed for installation into a nominal 45 mm diameter borehole, the Strata Tunnel Bolt is available in various bolt diameters and lengths, in either black or hot dip galvanised steel.

The specifically designed grout injection head enables easy connection to the grouting hose with a camlock fitting. The camlock fitting allows safe grout injection of the bolts using standard grouting equipment. The grout injection head is available in black, galvanised or stainless steel.

The Strata Tunnel Bolt assembly consists of a steel bolt threaded on both ends, with a mechanical anchor fixed on one end, a grout injection head, polyethylene sleeve and 36AF nut attached to the opposite end. Both the steel bolt and polyethylene sleeve have surface deformations to assist with load transfer.

The polyethylene sleeve offers a positive barrier against aggressive corrosive elements to a correctly installed and grouted bolt, making it ideal for long life tunnelling and mining applications. The mechanical anchor enables immediate point anchor support to assist in offering protection for operators and equipment at the development heading. This allows a single pass installation with an automated bolting rig and grout injection system, or manual post grouting at a later time.

Strata Tunnel Bolt

Technical Data

Mechanical PropertiesR24 HTMinimum

R24 HTTypical

R24 XHT Minimum R24 XHT Typical

Core Bolt Diameter – Bar (mm) 21.55 21.75 21.55 21.75

Outside Diameter – Tube (mm) 36.0 36.5 36.0 36.5

Cross Sectional area – Bar (mm2) 361 370 361 370

Yield Strength (MPa) 400 445 600 650

*Yield Force Minimum Diameter (MT) 12.6 14.2 18.9 20.5

**Yield Force Typical Diameter (MT) 15.1 16.8 22.3 24.6

Tensile Strength (MPa) 600 730 840 910

*Tensile Force Minimum Diameter (MT) 18.9 23.2 26.6 30.0

** Tensile Force Typical Diameter (MT) 22.7 27.5 31.7 34.3

Elongation (%) 14 22 14 22

Mass per metre – Bar (kg/m) 3.0 – 3.0 –


* Yield Force Minimum and Tensile Force Minimum values are calculated on the smallest diameter area of the bolt (thread root diameter) as per AS1275-1985 and ASTM F432-04.


Testing Standards

R24 HT R24 XHT

Galvanising AS4680 AS4680

Steel Grade BRBR K1045 HSAC840

PlatesOrica manufactures a comprehensive range of specially designed plates for use with rock bolts and cable bolts. Extensive product data is available on Orica’s full range of plates from Orica’s product catalogue and web site, www.orica.com.au. Various Dome Plates with a 50 mm hole can be supplied in either black, galvanised, or stainless steel. Plates most typically used with Strata Bolts are:


150 x 150 x 6 mm (Stainless Steel)

150 x 150 x 4 mm (Stainless Steel)


125 x 125 x 4 mm


150 x 150 x 4 mm

Strata Tunnel Bolt Page 2 of 3

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DriversOrica manufactures a full range of drivers for Strata Tunnel Bolts, for use with hand held or mechanised bolting equipment. Extensive product data is available on Orica’s full range of drivers from Orica’s product catalogue and web site, www.orica.com.au Drivers typically used with Strata Tunnel Bolts are:

Driver Socket R32 x 600 Hex 36AF generally used on Robolter or Boltec machines

Driver Socket R38 x 600 Hex 36AF

Driver Socket T38 x 600 Hex 36AF

Note: Driver sockets can be manufactured to any length for each of the different rockdrill thread types.

The table below lists the typical Strata Tunnel Bolts, product descriptions, unit weights and pack sizes. Other sizes are available on request, depending on the number required. All bolt descriptions listed include a left hand thread. Right hand threads are also available on request.

Descriptions, Dimensions and Weights


Strata Tunnel Bolt R24 x 1800 HT 6.5 kg 100



Strata Tunnel Bolt R24 x 1800 XHT 6.5 kg 100



Strata Tunnel Bolt Page 3 of 3

Orica are an authorised distributor of Australian mining industry renowned Garford® Bolts. Garford® have designed and manufactured Dynamic® bolts for Australian mining applications since 2005.

Garford® products are manufactured to quality accredited standards ISO:9001 at facilities in Perth, Western Australia.

Orica has supplied and serviced Garford® products for over 10 years and have enjoyed a beneficial relationship built on trust, communication and co-operation. Garford®’s Dynamic® bolt range includes 15.2 mm diameter Dynamic® cable bolts and 21.7 mm diameter Dynamic® solid bolts.

The Garford® Dynamic® bolts incorporate a specially designed mechanical Dynamic® device which is attached to the bar or cable at a specified point depending on the yield requirement of the bolt. The Dynamic® device is anchored in the borehole using cement or resin grout. A polyethylene debonding sheath along

the bolt length prevents bonding of the steel element with the cement or resin grout, enabling the bolt to be pulled through the Dynamic® device repeatedly.

The Garford® Dynamic® solid bolt incorporates a 21.7 mm diameter smooth surface profile 5152AVH grade steel bar. A large diameter mixing element is attached to the end of the bolt to enable effective mixing of the resin capsule components in large diameter boreholes (typically 45 mm). Intensive testing programs have proven the mixing effectiveness of this element.

The Garford® Dynamic® cable bolt also incorporates the Dynamic® device and polyethylene debonding sleeve. In addition the king wire is removed from the cable and replaced with a larger 8 mm

diameter spring wire. The Dynamic® cable bolt works in principle the same as the Dynamic® solid bolt, wherein the cable pulls through the Dynamic® device enabling the bolt to absorb energy and remain intact.

Dynamic® cable bolts and solid bolts are available in various lengths. Orica also provides a full range of cable bolt and solid bolt accessories including various barrel and wedges and numerous plate designs.

Dynamic® Bolts

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The word Orica and the Ring Device are trademarks of Orica Group Companies. Garford and Dynamic are registered trademarks of Garford Pty Ltd.

Technical Data

Cable/Bar Mechanical PropertiesDynamic® Cable Bolt Minimum

Dynamic® Cable Bolt Typical

Dynamic® SolidBolt Minimum

Dynamic® SolidBolt Typical

Core Bolt Diameter – Plain section (mm) – 15.2 21.45 mm 21.7 mm

Cross Sectional area – Plain section (mm2) – 143 361 370

Number of Strands – 7 N/A N/A

Yield Strength (MPa) 185 – 205 202 550 580

Yield Force – 0.2% (kN) 212 235 – –

Yield Force (kN) – – 199 215

Mass per metre – (kg/m) – 1.125 – 3.0

Dynamic® Device PropertiesDynamic® Cable Bolt Minimum

Dynamic® Cable Bolt Typical

Dynamic® SolidBolt Minimum

Dynamic® Solid Bolt Typical

Static Force Capacity (kN) 130 150 – 140

Dynamic Force Capacity (kN) 80 120 – 100

Displacement Capacity up to 300 mm – up to 500 mm

Testing Standards

15.2 mm Dynamic® Cable Bolt 21.7 mm Dynamic® Solid Bolt

Material AS1311 AS1442

Steel Grade 5152AVH

Threading N/A AS1275

Galvanising N/A AS4680


Page 2 of 2Dynamic® Bolts

Orica are an authorised distributor of Australian mining industry renowned Garford® Cable Bolts. Garford® have designed and manufactured cable bolts for Australian coal mining, metal mining and civil construction applications for over 20 years.

Garford® products are manufactured to quality accredited standards ISO:9001 at facilities in WA, NSW and QLD.

Orica has supplied and serviced Garford® products for over 10 years and have enjoyed a beneficial relationship built on trust, communication and co-operation. Garford®’s cable bolt range includes continuous roll or cut to length 15.2 mm plain and bulbed cables, twin strand plain and bulbed cables, as well as the resin anchored 21.8 mm diameter Superstrand and 50T fully bulbed Strata Cables for coal mining applications. All cut to length cables and cable rolls are available in various lengths and bulb configurations.

Cut to length 15.2 mm cable bolts are supplied as a single unit complete with a fish hook to anchor the cable into the borehole prior to grouting. The bulb diameter can be changed to suit individual requirements and typical bulb diameter on 15.2 mm cables range from 26 mm to 28 mm with up to 6 bulbs per metre available.

Orica also provides a full range of cable bolt accessories including various barrel and wedges, numerous plate designs, rolls of grout and breather tube and several hole plugging products including cotton waste, Silent Seal® and Conbex™ Plug.

Cable Bolts

Product Specific Information

Strata Cable – resin point anchored high capacity cable bolt• 3 x 38 mm diameter bulbs at the top of the cable to assist

Lokset™ resin capsule mixing and allow point anchoring and pre-tensioning of cable

• Resin retention device is attached to the cable to optimise resin point anchorage, this device can be placed at any point along the cable length

• 32 mm diameter reinforced bulbs every 500 mm down the groutable length of the cable

• Breather tube attached to the cable using metal ties to facilitate bottom up grouting

• Tensionable to 25 tonnes

Superstrand Cable – resin point anchored high capacity cable bolt• Available as either plain strand lengths or with 3 x bulbs at

the top of the cable to assist Lokset™ resin capsule mixing and allow point anchoring and pre-tensioning of cable

• Various bulb diameter options are available (32 mm, 38 mm, 48 mm) to suit different diameter boreholes

• Resin retention device can be attached to the cable to optimise resin point anchorage and this device can be placed at any point along the cable length

• Breather tube can be attached to the cable using metal ties to facilitate bottom up grouting

• Tensionable to 25 tonnes

15.2 mm Cable• Single strand or twin strand options available in numerous

lengths

• Plain or bulbed options available, bulbs available at either 0.5 m or 1 m spacing

• Single or double tails available on twin strand cables for tensioning or trusses

• Fish hooks fitted to cables for retention in holes prior to grouting

• Continuous rolls of either plain or bulbed single strand cable available for mechanised bolting

Barrel and Wedges• Various barrel and wedges are available to suit all cables (see

information below)

Cable Bolt Grout • Specially developed high strength cable bolt grouts available

Resin Capsules• Full range of Lokset™ resin capsules are available for point

anchoring

Technical Data

Mechanical Properties15.2 mm CableTypical

21.8 mm SuperstrandTypical

21.8 mm Strata CableTypical

Core Bolt Diameter – Plain section (mm) 15.2 21.8 21.8

Typical Bulb Diameter – (mm) 25 – 30 32 – 38 32 – 48

Cross Sectional area – Plain section (mm2) 143 313 313

Number of Strands 7 19 19

Yield Strength (MPa) 202

Yield Force – 0.2% (kN) 235 525 525

Tensile Strength (MPa) 1850 1800 1800

Tensile Force (kN) 270 590 590

Elongation on 600 mm length (%) 6.5 6 – 7% 6 – 7%

Mass per metre – Cable (kg/m) 1.125 2.482 2.482

Cable Bolts Page 2 of 4

Testing Standards

15.2 mm Cable 21.8 mm Superstrand 21.8 mm Strata Cable

Material AS1311AS/NZS 4672.1:2007

JISG 3536

AS/NZS 4672.1:2007

JISG 3536

Steel Grade


Plates most typically used with Cable Bolts are:

15.2 mm Cable Bolts Dome Plate 150 x 150 x 7 mm

15.2 mm Cable Bolts Combi Plate 240 x 300 mm 125

21.8 mm Superstrand/Strata Cable Dome Plate 200 x 200 x 12 mm

200 x 200 x 16 mm

Barrel and WedgesOrica can provide a range of Barrel and Wedges to suit the use of either 15.2 mm cable bolts or a 21.8 mm cable bolts with flat or domed plates. Barrel and Wedges consist of either two or three triangular shaped wedges placed inside a case hardened cylindrical barrel and are used to secure plates to the rock surface and in some instances to provide pre-tension to a resin point anchored cable bolt. The wedges have hardened serrations machined internally, providing grip to allow cable loading to be taken up.

Barrel and Wedges are supplied fully assembled in plastic buckets containing thirty units.

Technical Data – Barrel and Wedges

Item Length Diameter

2 Leaf Flat or Domed to suit 15.2 mm diameter Cable 45.5 mm 42 mm

3 Leaf Flat or Domed to suit 15.2 mm diameter Cable 45.5 mm 42 mm

2 Leaf Flat or Domed to suit 21.8 mm diameter Cable


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The word Orica and the Ring Device are trademarks of Orica Group Companies. Garford is a registered trademark of Garford Pty Ltd. Silent Seal is a registered trademark of FOMO USA.

Description, Dimensions and WeightsThe table lists the typical Cable Bolts and Barrel and Wedge, purchase descriptions and unit weights. Other sizes are available on request, depending on the number required.


Cable Bolt 6 m x 15.2 mm Single 1 Bulb/1.0 m 338 kg 50

Cable Bolt 6.5 m x 15.2 mm Single 1 Bulb/1.0 m 365 kg 50

Cable Bolt 4 m x 15.2 mm Twin Plain 900 kg 100

Cable Bolt 4 m x 15.2 mm Twin 1 Bulb/1.0 m 900 kg 100

Cable Bolt 6 m x 15.2 mm Twin Plain 675 kg 50




Cable Bolt 700 m x 15.2 mm 1 Bulb/1.0 m 788 kg 1



Cable Bolt Superstrand 4.1 m x 21.8 mm Plain 496 kg 50



Cable Bolt Superstrand 4.0 m x 21.8 mm Bulbed 496 kg 50



Strata Cable 6.1 m x 21.8 mm Fully Bulbed – 50 Tonne 758 kg 50



Barrel and Wedge Flat 2 Leaf to suit 15.2 mm Cable 0.42 kg 30

Barrel and Wedge Domed 2 Leaf to suit 15.2 mm Cable 0.42 kg 30

Barrel and Wedge Flat 3 Leaf to suit 15.2 mm Cable 0.42 kg 30

Barrel and Wedge Domed 3 Leaf to suit 15.2 mm Cable 0.42 kg 30

Barrel and Wedge Flat 2 Leaf to suit 21.8 mm Cable

Barrel and Wedge Domed 2 Leaf to suit 21.8 mm Cable


Orica manufactures a wide range of plates and combination plates for use with rockbolts and cable bolts.

Orica plates are designed in-house to provide optimal surface support in a range of strata conditions.

Options of each plate type are available in numerous dimensions to suit any bolt type and diameter in the Orica range.

Plates are available with or without a hanger loop in black steel or hot dip galvanised. Plates can also be manufactured in stainless steel if required.

Plate Range

Plate Type Description

Dome Plate High load bearing capacity, available in sizes 125 mm, 150 mm and 200 mm square, typically used with Solid Bolts, Strata Bolts and Cable Bolts.

Strata Plate™ Light gauge plate for larger span use such as supporting mesh or low strength shotcrete, typically only used with Strata Bolts.

Combi Plate Combination plate consisting of a Dome Plate or a Crown plate fixed to a Strata Plate.™ Cuts down on the number of items and handling required on site.

Crown Plate Developed for load bearing capacity equal to solid bolts. Specifically designed for use with M24 rock bolts and Secura Bolts.

Flat Plate Numerous sizes and thickness available for use with cable bolting. Single or multiple hole options also available.

Plates

Technical Data

Dome Plate Dimensions(mm)

Thickness (mm)

Dome Height (mm)

Hole Size(mm)

TestHole Diameter (mm)

Typical Yield Strength (MPa)

Typical Tensile Strength (MPa)

Plate Load (kN) Typical Bolt Used

125 x 125 4.0 18.0 36 50 210 – 310 330 – 370 79 Strata Bolt™ 34

125 x 125 4.0 19.0 49 50 210 – 310 330 – 370 140 Strata Bolt™ 47, Strata Tunnel Bolt

150 x 150 4.0 25.0 43.0 50 210 – 310 330 – 370 108 Strata Bolt™ 40

150 x 150 4.0 24.0 49.0 50 210 – 310 330 – 370 147Strata Bolt™ 47, Strata Tunnel Bolt, Secura Bolt®

150 x 150 7.0 22.5 36.0 80 210 – 310 300 – 400 197 Secura Bolt,® Cable Bolt

200 x 200 4.0 24.0 49.0 50 210 – 310 330 – 370 147 Strata Bolt™ 47, Strata Tunnel Bolt

150 x 150 6.0 21.5 36 100 210 – 310 300 – 400 100 M24 Rockbolts, Cable Bolts

150 x 150 8.0 23.5 36 100 210 – 310 300 – 400 169 M24 Rockbolts, Cable Bolts

150 x 150 10.0 25.5 36 100 210 – 310 300 – 400 265Secura Bolt,® M24 Rockbolts, Cable Bolts

150 x 150 10.0 25.5 36 100 300 – 360 430 – 480 300Secura Bolt,® M24 Rockbolts, Cable Bolts

200 x 200 12.0 31.0 42.0 100 300 – 360 430 – 480 460 Cable Bolts

250 x 250 12.0 31.0 42.0 100 300 – 360 430 – 480 460 Cable Bolts

300 x 300 12.0 31.0 42.0 100 300 – 360 430 – 480 460 Cable Bolts

200 x 200 16.0 35.0 42.0 100 300 – 360 430 – 480 640 Cable Bolts

250 x 250 16.0 35.0 42.0 100 300 – 360 430 – 480 640 Cable Bolts

300 x 300 16.0 35.0 42.0 100 300 – 360 430 – 480 640 Cable Bolts

Strata Plate Dimensions(mm)

Thickness(mm)

Dome Height (mm)

Hole Size(mm)

TestHole Diameter




280 x 300 1.9 N/A 50 N/A 230 – 330 360 – 330 N/A Strata Bolt™ 47




Combi Plate Dimensions(mm)

Thickness(mm)

Dome Height (mm)

Hole Size(mm)

TestHole Diameter




240 x 300 Strata Plate

125 x 125 Dome Plate

1.9

4.0

18.0 38 50 230 – 330

210 – 310

360 – 430

330 – 370

200Secura Bolt®



1.9

4.0

25.5 50 50 230 – 330

210 – 310

360 – 430

330 – 370

150 Strata Bolt™ 47, Strata Tunnel Bolt



1.9

4.0

25.5 50 50 230 – 330

210 – 310

360 – 430

330 – 370

150 Strata Bolt™ 47, Strata Tunnel Bolt

Plates Page 2 of 4

Crown Plate Dimensions(mm)

Thickness(mm)

Dome Height (mm)

Hole Size(mm)

TestHole Diameter(mm)




150 x 150 5.0 35 38 – 42 100 410 – 510 470 – 550 180 M24 Bolt, Secura Bolt®

150 x 150 5.0 35 38 – 42 100 410 – 510 470 – 550 240 M24 Bolt, Secura Bolt®

Flat Plate Dimensions(mm)

Thickness(mm)

Dome Height (mm)

Hole Size(mm)

TestHole Diameter(mm)




200 x 200 10.0 N/A 18.0 N/A 210 – 310 300 – 400 N/A Cable Bolt






Plate Load (kN) is defined as the point where the plate offers minimal additional load carrying capacity accompanied by large plate deflections

N/A = Not Applicable for this particular plate type

Product Standards

Plate Type Material Galvanising

Dome Plates AS1594 AS4680

Strata Plates AS1594 AS4680

Combi Plates AS1594 AS4680

Crown Plates AS1594 AS4680

Flat Plates AS1594 AS4680

Plates Page 3 of 4

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Descriptions and WeightsThe following table includes the most typical plates. Other sizes, dimensions and combinations are available on request.

DescriptionUnit Weight

Pack Size

Dome Plate 34 125x125x4 Galvanised 0.5 kg 1,000


Dome Plate 40 150x150x4 Black 0.7 kg 1,000







Dome Plate 47 200x200x4 Black 1.3 kg 500

Dome Plate 47 200x200x4 Galvanised 1.3 kg 500

Dome Plate 36 200x200x8 Galvanised 2.6 kg 500

Strata Plate 280x300x1.9 Black 1.3 kg 1,000

Strata Plate 280x300x1.9 Galvanised 1.3 kg 1,000

Strata Plate 280x400x1.9 Galvanised 1.8 kg 500

Combi Plate 280x300 150 47 Black 2.0 kg 300

Combi Plate 280x300 150 47 Galvanised 2.1 kg 300

Combi Plate 240x300 125 36 Gal 1.7 kg 300

Combi Plate 280x300 125 34 Gal 2.0 kg 300

Crown Plate 42 150 x 150 x 5 mm Black (no hanger loop) 0.9 kg 1,000

Crown Plate 42 150 x 150 x 5 mm Black (with hanger loop) 0.9 kg 1,000

Crown Plate 42 150 x 150 x 5 mm Gal (no hanger loop) 0.9 kg 1,000

Crown Plate 42 150 x 150 x 5 mm Gal (with hanger loop) 0.9 kg 1,000

Flat Plate 200x200x12 20 2 Hole Black 4.6 kg 200



Flat Plate 300x300x10 18 2 Hole Galvanised 7.4 kg 200

Plates Page 4 of 4

Oricas mining offer delivers highly performing ground support and consolidation products and services to people working in underground coal mining, hard rock and civil/infrastructure operations anywhere around the world. Our expertise has been developed through innovation, growing our people complimented by our long and solid history in global mining, tunnelling and infrastructure works.

Orica’s Enduro™ system brings new technology to provide tough and chip resistant protection to steel products which provides excellent corrosion and UV protection and enhances their useful life. This means products last longer in service before replacement is required, saving considerable rehabilitation costs. The Enduro™ range of products is suitable for underground coal, hard rock mining and civil applications and is effective in both Alkaline and Acidic conditions.

Orica’s Enduro™ system can be incorporated onto various products such as steel strata and secura (friction and resin) bolts, plates, threaded bars and selected accessories, to maximise product life in harsh corrosion conditions.

Orica’s Enduro™ system is a two part sequentially processed system that offers high level corrosion resistance. The Enduro™ system is highly resistant to liquid permeability and combustion.

Customer Benefits• Simplicity of use – products can

be installed using current tools and techniques, no need for new tools or installation techniques

• Improved product life – significantly reduced corrosion and material decay in harsh corrosion environments when compared against hot dip galvanised products

• Operating environment – can be effectively used in both Alkaline and Acidic conditions

• Cost effective – compared to stainless steel and other high tech products with reduced replacement costs

• Integrity under load – retains bonding integrity and maintains effective corrosion resistance

• Stress corrosion cracking – retards stress corrosion cracking by resisting and avoiding further oxidation

• Consistent performance – compared to hot dip galvanised products

• High strength – Impact resistant, tough, yields/elongates with parent material

Enduro™ RangeAdvanced Corrosion Resistance

Physical CharacteristicsOrica’s Enduro™ range of steel products has been subjected to extensive lab tests followed by in-situ trials. Further testing has also been carried out at the Orica test facility at Nowra, NSW. The Orica – Nowra test facility allows for the complete testing of a bolt installation, including dissection so a thorough examination can be made on all the aspects of installation.

Physical Characteristics

Description Characteristics

Corrosion resistance Best in class

Chemical resistance pH 1 to 10

Corrosion resistance Acids Excellent

Alkalis Excellent

Solvent Good

Salt spray resistance < 2 mm (3,600 hrs)

Taber abrasion resistance 17 mg

Edge covering ****

External application – weathering resistance Yes

Long term durability ****

Width (mm) Thickness (mm) Gauge Length (mm)

Dogbone Test Specimen* 10.6 0.35 100

*Samples compliant with ISO-597-2 Type 1A dogbones.

Lab TestsTensile TestsTensile tests performed on Orica’s Enduro™ system demonstrate its capability to be highly elastic (150%), has high strength and is a tough system which offers extremely good bonding with the parent steel material.

Average result

Elongation 150 %

Yield stress 6.8 MPa

Break stress 11.6 MPa

Modulus 96.6 MPa

Orica’s Enduro™ System Tensile Testing

Sample 3Sample 1 Sample 2

Strain (%)

Stre

ss (

%)

00

2

4

6

8

10

12

50 100 150 200

Neutral Salt Spray TestsAccelerated corrosion tests by neutral salt spray (1,008 hours ASTM B117) performed on Orica’s Enduro™ bolt range confirms the high level corrosion resistance offered by this technology. Steel bolts incorporating the Orica’s Enduro™ system showed no signs of corrosion while the bare bolt developed surface pitting during actual tests.

Scribed Un-scribed

1,008 hours ASTM B117

Substrate

Enduro™ Range Page 2 of 4

Effect Of Resin Capsule Mastic On Orica’s Enduro™ SystemOrica’s Enduro™ system doesn’t react with resin mastic. No effects of mastic (slow polyester) were observed after 6 months of intimate contact.

Smooth Finish Textured Finish

In-situ Trials

Rock Bolt Trial – Customer SiteIn-situ trials at a hard rock mine in Australia conclusively demonstrate the ability of Orica’s Enduro™ system to resist corrosion in harsh conditions. Bolts left in an approximately 3 pH environment for approximately one month demonstrate the integrity of Orica’s Enduro™ technology.

Orica’s Enduro™ Product Bare bolt without corrosion protection

Measurements were made before trials

Products post trial for a month and excess rust removal

Enduro™ Bolt

Hot dip galvanised bolts

Acid test 50 days


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Bolt ID # 7 Bolt Bolt

Pre acid diameter (mm) 23.16 20.55

Six measurements taken per bolt (mm) 23.00 20.59

22.77 20.91

23.21 20.74

23.22 20.70

23.07 20.70

Average pre acid diameters (mm) 23.07 20.70


Post acid diameters (mm) 23.04 17.27

Six measurements taken per bolt (mm) 22.95 15.29

23.55 14.72

23.41 13.98

23.39 9.62

20.69 10.44

Average post acid diameters (mm) 22.84 13.55

Rock Bolt Trial Data


Pre acid weight (g) 2,109 1,545

Post acid weight (g) 2,002 673.6

Total weight loss (g) 107.1** 871.1

Decrease in diameter (mm) 0.23** 7.14

** Weight and diametrical loss due to cut end exposure.

pH Conditions

Date pH Temp

May 29 3 29.0

June 6 3 34.5

June 11 3 31.3

June 18 3 29.6

June 24 3 28.2

June 30 3 29.0

Enduro™ Product RangeOrica’s Enduro™ range is available in a selected range a of rock bolts, plate products, strata bolts, etc, as listed below:

• M24 coal bolts in 1.8 m, 2.1 m and 2.4 m lengths

• R27 secura (resin) bolts in 2.1 m and 2.4 m bolts

• Strata (friction) bolt 2.4 m in length

• Crown 24 plate, and combination plate for selected bolts

Pack SizeOrica’s Enduro™ product range comes in standard pack sizes. Consult with Sales Team for additional information and specific recommendations.

Product Service SupportOrica provides a full service support package to customers, including underground pull testing, operator awareness training, underground audits and stock control assistance. Each service package is developed to suit the≈individual customer requirements.

All aspects of Orica’s product service support service are provided by experienced trained and qualified personnel.

Additional InformationFor additional information relating to any aspect of this product specification data including product performance, quality, testing, specification, range, availability etc. please contact your nearest Orica office or email: [email protected]


MAI SDA self-drilling anchors provide a unique bolting solution for unstable ground conditions such as sand, gravel, silt, clay and in soft to medium fractured rock formations. For projects facing such ground conditions, MAI SDA self-drilling anchors should be considered as the most productive reinforcement solution.

The anchor rod features a hollow bore for flushing or simultaneous drilling and grouting and has a left-hand rope thread for connection to standard drill tooling.

It is manufactured from API standard heavy walling steel tubing, cold rolled to form a standard ISO rope thread profile. The rolling process refines the grain structure of the steel, increasing the yield strength and producing a durable drill rod suitable for a range of applications.

The sacrificial drill bit is the most crucial part of the anchoring system and is responsible for the productivity of the installation.

In order to improve on performance and cost efficiency, data is collected from projects around the world and incorporated into the design with the aim to improve penetration rate and bit quality and to reduce manufacturing costs.

MAI SDA self-drilling anchors are rigorously tested to ensure the best quality and reliability.

MAI SDA self-drilling anchors are also available in a hot dip galvanised version for corrosion protection and also as CE certified products.

Main componentsMAI SDA self-drilling anchors consists of five basic components:

• A hollow rod

• One or more extension couplings which act as connectors between the rods

• A sacrificial drill bit

• A nut and

• A plate

Nut

Anchor plate

Hollow rod

Hollow rod

Extension coupling

Sacrificial drill bit

MAI SDA self-drilling anchorMAI SDA self-drilling anchor

MAI SDA quick referenceMAI SDA anchor rods

Description Unit R32 L R32 N R32 S R38 N R51 L R51 N T76 N T76 S T111 L T111 N

Outer diameter mm 32.0 32.0 32.0 38.0 51.0 51.0 76.0 76.0 111.0 111.0

Inner diameter mm 20.6 18.5 15.0 19.0 33.3 30.2 51.0 44.0 85.0 75.5

Cross–sectional area mm² 350 430 520 750 900 1070 1870 2400 3185 4395

Ultimate tensile load (UL) kN 210 280 360 500 550 800 1600 1900 2640 3650

Yield load (YL) kN 160 230 280 400 450 630 1200 1500 2000 2750

Yield strength N/mm² 460 530 530 530 500 590 640 630 630 630

Tensile strength N/mm² 600 650 690 660 610 750 860 790 830 830

Weight kg/m 2.8 3.4 4.1 5.9 7.0 8.4 14.7 18.9 25.0 34.5

Standard delivery lengths for MAI SDA self-drilling anchors are 2.0, 3.0, 4.0 and 6.0 metres.

Additional lengths up to 12 metres are available on request.

MAI SDA extension couplings


Diameter mm 42.4 42.4 42.4 51.0 63.5 63.5 95.0 95.0 140.0 140.0

Length mm 145.0 145.0 190.0 220.0 170.0 220.0 220.0 220.0 250.0 250.0

Weight kg 0.8 0.8 1.0 1.7 1.7 2.2 4.7 4.7 11.5 11.5

MAI SDA nuts


Key size mm 46.0 46.0 46.0 50.0 75.0 75.0 100.0 100.0 150.0 150.0

Length mm 45.0 45.0 45.0 60.0 70.0 70.0 80.0 80.0 120.0 120.0

Weight kg 0.4 0.4 0.4 0.5 1.6 1.6 2.7 2.7 9.0 9.0

MAI SDA anchor plates


Domed anchor plates

Dimension mm 150 x 150 200 x 200 200 x 200 200 x 200 – – – – – –

Thickness mm 8.0 8.0 10.0 12.0 – – – – – –

Hole diameter mm 35.0 35.0 35.0 41.0 – – – – – –

Weight kg 1.4 2.6 3.2 3.8 – – – – – –

Solid anchor plates

Dimension mm – 95 x 95 120 x 120 140 x 140 150 x 150 180 x 180 250 x 250 250 x 250 300 x 300 350 x 350

Thickness mm – 25.0 30.0 35.0 40.0 45.0 60.0 60.0 80.0 90.0

Hole diameter mm – 35.0 35.0 41.0 56.0 56.0 90.0 90.0 130.0 130.0

Weight kg – 1.6 3.2 5.0 6.2 10.5 26.4 26.4 47.8 76.8

MAI SDA spacers


Outside diameter mm 72.0 72.0 72.0 78.0 91.0 91.0 130.0 130.0 170.0 170.0

Length mm 30.0 30.0 30.0 30.0 30.0 30.0 40.0 40.0 50.0 50.0

Weight kg 0.3 0.3 0.3 0.3 0.3 0.3 0.9 0.9 1.6 1.6

Page 2 of 16MAI SDA self-drilling anchor

MAI SDA quick reference

MAI SDA drill bits

Bit shape

Bit type Clay bit XX EX EC ES-F ES-D EY EYY ECC EXX ESS-F

Typ

e o

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SPT–N Value < 40 < 40 < 50 < 50 > 50 > 50 > 50 – – – –

UCT (N/mm

2) – – – – < 10

Mpa< 10 Mpa

< 10 Mpa

< 50 Mpa

< 50 Mpa

< 70 Mpa

< 100 Mpa

R32 (L&N&S)

76 51 51 51 76 76 51 51 51

90 76

110 90

with R38 adaptor 130 90

R38 (N)

90 110 76 76 76 76 90 76

110 130 90

130 150

with R51 adaptor

150

175

R51 (L&N) 76 100 100 100 115 76

90 130 130 100

150 150

175 170

200

T76 (N&S) 130 130 130 120

150 145 150

175 175

200 200

T111 (L&N) 220 220 170

Main selection criteria for MAI SDA drill bitsA successful installation of MAI SDA self-drilling anchors depends to a large extent to the correct selection of suitable drill bits. Compared to conventional drill bit types offered globally for maximum standing performance for rock or soil, the criteria for MAI SDA drill bits are defined by consideration of the following factors:

• Service life of the drill bits should be at least equal to the anchor length.

• Selecting the right bit design and inserts to reach optimum performance depended on the different ground formations encountered.

• Diameter depending on geology and design requirements.

MAI SDA self-drilling anchor Page 3 of 16

MAI SDA R32

MAI SDA R32 anchor rods

Size Length* (m) Weight (kg) Outer Ø (mm) Inner Ø1 (mm) Area2 (mm²) UL3 (kN) YL4 (kN)

R32 L 2.0 5.4 32.0 20.6 350 210 160

R32 L 3.0 8.1 32.0 20.6 350 210 160

R32 L 4.0 10.8 32.0 20.6 350 210 160

R32 N 2.0 6.8 32.0 18.5 430 280 230

R32 N 3.0 10.2 32.0 18.5 430 280 230

R32 N 4.0 13.6 32.0 18.5 430 280 230

R32 S 2.0 8.2 32.0 15.0 520 360 280

R32 S 3.0 12.3 32.0 15.0 520 360 280

R32 S 4.0 16.4 32.0 15.0 520 360 280

Corrosion protected (Galvanised in accordance with EN ISO 1461:1999)

R32 L 2.0 5.4 32.0 20.6 350 210 160

R32 L 3.0 8.1 32.0 20.6 350 210 160

R32 L 4.0 10.8 32.0 20.6 350 210 160

R32 N 2.0 6.7 32.0 18.5 430 280 230

R32 N 3.0 10.0 32.0 18.5 430 280 230

R32 N 4.0 13.4 32.0 18.5 430 280 230

R32 S 2.0 8.2 32.0 15.0 520 360 280

R32 S 3.0 12.3 32.0 15.0 520 360 280

R32 S 4.0 16.4 32.0 15.0 520 360 280

* Additional lengths available on request

MAI SDA R32 extension couplings

Size Type Length (mm) Weight (kg) Outer Ø (mm)

R32 L&N 145.0 0.8 42.4

R32 S 190.0 1.0 42.4


R32 N&S 160.0 0.8 42.4

MAI SDA R32 nuts

Size Type Length (mm) Weight (kg) Key size (mm)

R32/SW46 L&N&S 45.0 0.4 46.0


R32/SW46 L&N&S 45.0 0.4 46.0

1 Average internal diameter2 Cross sectional area3 Ultimate load4 Yield load


MAI SDA R32

MAI SDA R32 anchor plates

MAI SDA R32 domed plates

Size Type Dimension (mm) Thickness (mm) Weight (kg) Dome height (mm) Hole Ø (mm)

R32 L 150 x 150 8.0 1.4 25.0 35.0

R32 N 200 x 200 8.0 2.6 28.0 35.0

R32 S 200 x 200 10.0 3.2 28.0 35.0


R32 L 150 x 150 8.0 1.4 25.0 35.0

R32 N 200 x 200 8.0 2.6 28.0 35.0

R32 S 200 x 200 10.0 3.2 28.0 35.0

MAI SDA R32 solid plates

Size Type Dimension (mm) Thickness (mm) Weight (kg) Hole Ø (mm)

R32 N 95 x 95 25.0 1.6 35.0

R32 S 120 x 120 30.0 3.2 35.0


R32 N 95 x 95 25.0 1.6 35.0

R32 S 120 x 120 30.0 3.2 35.0

MAI SDA R32 drill bits

Size Type Weight (kg) Outer Ø (mm)

Drill bit R32 L&N&S X 0.3 51.0

Drill bit R32 L&N&S EX 0.3 51.0

Drill bit R32 L&N&S EX 1.2 76.0

Drill bit R32 L&N&S/L74 EXX 0.5 51.0

Drill bit R32 L&N&S EY 1.2 76.0

Drill bit R32 L&N&S EYY 1.2 76.0

Button bit R32 L&N&S ES–F 0.4 51.0

Button bit R32 L&N&S ESS–F 0.4 51.0

Split arc bit R32 L&N&S EC 0.4 51.0

Split arc bit R32 L&N&S ECC 0.4 51.0

Drill bit R32 L&N&S/Clay Clay 0.9 76.0



MAI SDA R32 spacers

Type Outer Ø (mm) Length (mm) Weight (kg)

L&N&S 72.0 30.0 0.3


MAI SDA R38



R38 N 2.0 12.0 38.0 19.0 750 500 400

R38 N 3.0 18.0 38.0 19.0 750 500 400

R38 N 4.0 24.0 38.0 19.0 750 500 400


R38 N 2.0 12.0 38.0 19.0 750 500 400

R38 N 3.0 18.0 38.0 19.0 750 500 400

R38 N 4.0 24.0 38.0 19.0 750 500 400




R38 N 220.0 1.7 51.0


R38 N 220.0 1.7 51.0

MAI SDA R38 nuts


R38/SW50 N 60.0 0.5 50.0


R38/SW50 N 60.0 0.5 50.0

1 Average internal diameter2 Cross sectional area3 Ultimate load4 Yield load


MAI SDA R38


MAI SDA R38 domed plates

Size Type Dimension (mm) Thickness (mm) Weight (kg) Dome height (mm) Hole Ø (mm)

R38 N 200 x 200 12.0 3.8 41.0


R38 N 200 x 200 12.0 3.8 41.0



R38 N 140 x 140 35.0 5.0 41.0


R38 N 140 x 140 35.0 5.0 41.0



Drill bit R38 N/Clay Clay 1.0 90.0

Drill bit R38 N/Clay Clay 110.0

Drill bit R38 N/Clay Clay 1.3 130.0

Drill bit R38 N XX 1.4 110.0



Drill bit R38 N EX 1.2 76.0

Drill bit R38 N EX 1.3 90.0

Button bit R38 N ES–F 1.0 76.0

Drill bit R38 N EY 0.9 76.0

Drill bit R38 N EYY 0.9 76.0

Drill bit R38 N EYY 1.0 90.0

Drill bit R38 N EXX 1.3 90.0

Button bit R38 N ESS–D 2.6 115.0

Button bit R38 N ESS–F 1.0 76.0

MAI SDA R38 spacers


N 78.0 30.0 0.3


MAI SDA R51



R51 L 2.0 14.0 51.0 33.3 900 550 450

R51 L 3.0 21.0 51.0 33.3 900 550 450

R51 L 4.0 28.0 51.0 33.3 900 550 450

R51 L 6.0 42.0 51.0 33.3 900 550 450

R51 N 2.0 16.8 51.0 30.2 1070 800 630

R51 N 3.0 25.2 51.0 30.2 1070 800 630

R51 N 4.0 33.6 51.0 30.2 1070 800 630

R51 N 6.0 50.4 51.0 30.2 1070 800 630


R51 L 2.0 14.0 51.0 33.3 900 550 450

R51 L 3.0 21.0 51.0 33.3 900 550 450

R51 L 4.0 28.0 51.0 33.3 900 550 450

R51 N 2.0 16.8 51.0 30.2 1070 800 630

R51 N 3.0 25.2 51.0 30.2 1070 800 630

R51 N 4.0 33.6 51.0 30.2 1070 800 630




R51 L 170.0 1.7 63.5

R51 N 220.0 2.2 63.5


R51 N 200.0 1.9 63.5

MAI SDA R51 nuts


R51/SW75 L&N 70.0 1.7 75.0


R51/SW75 L&N 70.0 1.7 75.0

1 Average internal diameter

2 Cross sectional area

3 Ultimate load

4 Yield load


MAI SDA R51




R51 L 150 x 150 40.0 6.3 56.0

R51 N 180 x 180 45.0 10.6 56.0


R51 L 150 x 150 40.0 6.3 56.0

R51 N 180 x 180 45.0 10.6 56.0



Drill bit R51/Clay Clay 1.0 76.0




Drill bit R51 XX 2.1 110.0





Drill bit R51 EX 1.7 100.0

Drill bit R51 EX 1.9 130.0

Button bit R51 ES–F 1.8 100.0

Button bit R51 ES–D 2.0 115.0

Button bit R51 ESS–F 1.7 76.0

Button bit R51 ESS–F 1.8 100.0

Button bit R51 ESS–D 2.0 115.0

MAI SDA R51 spacers


L&N 91.0 30.0 0.3


MAI SDA T76

MAI SDA T76 anchor rods


T76 N 2.0 30.0 76.0 51.0 1870 1600 1200

T76 N 3.0 45.0 76.0 51.0 1870 1600 1200

T76 N 4.0 60.0 76.0 51.0 1870 1600 1200

T76 N 6.0 90.0 76.0 51.0 1870 1600 1200

T76 S 2.0 39.4 76.0 44.0 2400 1900 1500

T76 S 3.0 59.1 76.0 44.0 2400 1900 1500

T76 S 4.0 78.8 76.0 44.0 2400 1900 1500

T76 S 6.0 113.4 76.0 44.0 2400 1900 1500


T76 N 2.0 30.0 76.0 51.0 1870 1600 1200

T76 N 3.0 45.0 76.0 51.0 1870 1600 1200

T76 N 4.0 60.0 76.0 51.0 1870 1600 1200

T76 S 2.0 39.4 76.0 44.0 2400 1900 1500

T76 S 3.0 59.1 76.0 44.0 2400 1900 1500

T76 S 4.0 78.8 76.0 44.0 2400 1900 1500


MAI SDA T76 extension couplings


T76 N&S 220.0 4.7 95.0


T76 N&S 220.0 4.7 95.0

MAI SDA T76 nuts


T76/SW100 N&S 80.0 2.7 100.0


T76/SW100 N&S 80.0 2.7 100.0



3 Ultimate load

4 Yield load


MAI SDA T76

MAI SDA T76 anchor plates

MAI SDA T76 solid plates


T76 N&S 250 x 250 60.0 26.4 90.0


T76 N&S 250 x 250 60.0 26.4 90.0

MAI SDA T76 drill bits


Drill bit T76/Clay Clay 3.2 130.0




Drill bit T76 XX 4.5 130.0




Drill bit T76 EX 6.0 130.0

Drill bit T76 EX 6.5 150.0

Drill bit T76 ESS–F 4.6 120.0

MAI SDA T76 spacers


N&S 130.0 40.0 0.9


MAI SDA T111

MAI SDA T111 anchor rods


T111 L 2.0 56.8 111.0 85.0 3185 2640 2000

T111 L 3.0 85.2 111.0 85.0 3185 2640 2000

T111 L 4.0 113.6 111.0 85.0 3185 2640 2000

T111 L 6.0 170.4 111.0 85.0 3185 2640 2000

T111 N 2.0 72.6 111.0 75.5 4395 3650 2750

T111 N 3.0 108.9 111.0 75.5 4395 3650 2750

T111 N 4.0 145.2 111.0 75.5 4395 3650 2750

T111 N 6.0 217.8 111.0 75.5 4395 3650 2750


T111 L 3.0 85.2 111.0 85.0 3185 2640 2000

T111 N 3.0 108.9 111.0 75.5 4395 3650 2750


MAI SDA T111 extension couplings


T111 L&N 250.0 11.5 140.0


T111 L&N 250.0 11.5 140.0

MAI SDA T111 nuts


T111/SW150 L&N 120.0 9.3 120.0


T111/SW150 L&N 120.0 9.3 120.0



3 Ultimate load

4 Yield load


MAI SDA T111

MAI SDA T111 anchor plates

MAI SDA T111 solid plates


T111 L 300 x 300 80.0 47.8 130.0

T111 N 350 x 350 90.0 76.8 130.0


T111 L 300 x 300 80.0 47.8 130.0

T111 N 350 x 350 90.0 76.8 130.0

MAI SDA T111 drill bits



Drill bit T111 EX 10.7 220.0

Drill bit T111 ESS–F 8.2 170.0

MAI SDA T111 spacers


L&N 170.0 50.0 1.8


MAI SDA Accessories

MAI SDA Coupling boxes – Adapters – Injection adapters

MAI SDA Coupling boxes

Description Type Weight (kg)

MAI Adaptor coupling R25–R32 with middle stop l=200 mm L&N&S 1.6

MAI Adaptor coupling R25–R38 with middle stop l=200 mm N 2.6



MAI Adaptor coupling R32–T38 with middle stop l=200 mm 2.6


MAI Adaptor coupling H55–T76 with middle stop l=220 mm N&S 6.6


MAI Adaptor coupling R38–R38 with middle stop l=200 mm 2.2

MAI Adaptor coupling R38–T45 with middle stop l=200 mm N 2.9

MAI Adaptor coupling R51–R38 with middle stop l=235 mm L&N 5.1

MAI Adaptor coupling R51–T38 with middle stop l=235 mm L&N 5.0

MAI Adaptor coupling R51–T45 with middle stop l=235 mm L&N 4.7

MAI Adaptor coupling T51–T76 with middle stop l=220 mm 7.8

MAI Adaptor coupling T51–R51 with middle stop l=235 mm 4.4

MAI SDA Drill bit adapters

Description Type Weight (kg)

MAI Drill bit adapters R38/R32 0.1

MAI Drill bit adapters R51/R38 0.1

MAI SDA Grout swivel systemSelection guide

MAI SDA Grouting swivel When to use

MAI Grout swivel body, Ø 75 mm R32/R38 for up to T45 thread, on rock drill/drifter side

MAI Grout swivel body, Ø 100 mm R51 and R32/R38 for bigger thread than T45, on rock drill/drifter side

MAI Grout swivel body, Ø 120 mm T76

MAI Grout swivel body, Ø 150 mm T111


MAI SDA Accessories

MAI SDA Grout swivel system

MAI SDA Swivel bodies

Description Diameter (mm) Thread connection Weight (kg)

Swivel body 75.0 – 5.0




MAI SDA Body seal kits


Body seal kit 75.0 – 0.2




MAI SDA Swivel shafts


Swivel shaft for Ø 75 mm, Box R32/Box R32 75.0 Box R32/Box R32 6.0

Swivel shaft for Ø 75 mm, Box T38/Box R32 75.0 Box T38/Box R32 6.0

Swivel shaft for Ø 75 mm, Box R38/Box R32 75.0 Box R38/Box R32 6.0



Swivel shaft for Ø 100 mm, Box H55/Box R32 100.0 Box H55/Box R32 13.0



Swivel shaft for Ø 100 mm, Box T45/ Box R51 100.0 Box T45/Box R51 13.0


Swivel shaft for Ø 120 mm, Box H90/Box T76 120.0 Box H90/Box T76 20.0

Swivel shaft for Ø 150 mm, Box H90/Box T111 150.0 Box H90/Box T111 31.0

MAI SDA Anchor seals


Anchor seal R32 32.0 – 0.1



Anchor seal T76 76.0 – 0.1

Anchor seal T111 111.0 – 0.2


MAI SDA AccessoriesMAI SDA Pull test equipment

SDA-SWX-Rx Pull test equipment complete (includes Ref. no. 1, 2, 3, 4, 5)

Description Weight (kg)

Pull tester SDA manual hydraulic 300 kN 66.0

Components

Ref. Description Weight (kg)

1 SWX-SDA-Rx Pull tester hydraulic set manual 19.0

2 SWX-SDA-Rx Pull test frame complete 20.8

3 SWX-SDA-Rx Pull tester gripping kit for SDA 2.8

4 SWX-SDA-Rx Pull tester tools and accessory set 4.0

5 Box for pull tester 18.5

Please note: According to design and/or technical requirements, there are different types of Pull test methods which can be applied on MAI SDA self-drilling anchors. Please consult with engineers in charge for verifications and instructions.

MAI Grout pump M400NT

MAI Grout pump M400NT

Description

MAI Grout pump M400NT (standard)

Other pump constructions available on request

Technical Data

Delivery rate 400 – 2000 l/h

Delivery distance 40 – 60 m max.

Delivery pressure 40 bar, approx.

Electricity supply 400 V, 50 Hz

Amperage 12.1 A

Main supply fuse 25 A

Power requirement Min. 16 KVA

Normal output 6.2 kW

Dimensions

Total length 1730 mm

Total width 570 mm

Length without motor and pump 1040 mm

Total height 960 mm

Weights

Total weight 217 kg

Weight without dismantled parts 125 kg

Accessories

Description

Spur–wheel gear motor 6 kW/200 rpm

Worm pump MP 3 “L” (Standard) 600 l/h

High pr. mortar hose with quick–release coupling

– Vibrator – Automatic reverse drive – Automatic screen safety feature – Tools – Cleaning equipment – Water pump optional – Automatically polarity control

Ø 25 mm

MAI SDA anchor mortar

Description

MAI mortar, sulphate resistant

MAI mortar, normal/standard

Description data

Max. grain size 0.3 mm

Bulk weight ~ 1200 kg/m³

Water consumption ~ 20% of dry mass

Cube strength 1d 15 N/mm²




www.orica.com




Ongoing development of faster, safer and more exotic tunnelling techniques places a constant pressure on manufacturers to provide more efficient rock support solutions which will help the shortening of cycle time.

As ground conditions get more and more demanding, emphasis is placed on flexible and intelligent support systems in which rock and soil reinforcement is expected to contribute to the productivity and safety of the operation. The trend has been to provide rock support and reinforcement systems that are easy to install, assure efficiency and provide safety.

Atlas Copco offers Swellex rock bolts as a unique, safe and reliable system of rock support, with the development of safer and more efficient rock reinforcement products such as Swellex Manganese line rock bolts, which are manufactured from a special type of steel; the Swellex Premium line of rock bolts, for use where high yield load and stiffness are expected from reinforcement systems and the Swellex Spartan line of rock bolts for use in areas that do not transfer much convergence, or much energy within the bolt.

Swellex rock bolting systemThe Swellex rock bolting system has gained wide recognition in mining and tunnelling works. It is a unique rock bolt, as it is made out of a welded tube folded onto itself and sealed at one extremity. It is re-expanded using a high pressure water flow provided by a special pump and adapter. The bolt is expanded inside the borehole drilled into the excavation wall.

The installation process is easy and very similar as with other rock bolts, making Swellex rock bolts accessible to all operators.

Extensive application rangeThe speed and quality of installation and the extensive application range have solved support problems and increased profitability for contractors and mine operators all over the world. As mine and tunnel safety requirements have become more stringent, the prompt, reliable and versatile support available with Swellex rock bolts has made them the best for solving most problems and one of the best for rock reinforcement in general.

Atlas Copco Swellex Rock Reinforcement System

Versatile technologyThrough a process of continuous improvement, Atlas Copco has refined Swellex to offer the most versatile portfolio of rock bolts available on the market. Swellex rock bolts from Atlas Copco are offered in three typical versions

• Swellex Premium line, a relatively stiff rock bolt for tunnelling and mining in moderate stress conditions

• Swellex Manganese line, a highly deformable rock bolt for large rock deformation solutions

• Swellex Spartan line, to maximise cost effectiveness and profitability

Special application products From the well accepted plastic coating for highly corrosive environments, Atlas Copco covers all demands for corrosion protection and long life rock bolts. For special applications like hangers and deep reinforcement, Atlas Copco has perfected a version of Swellex to perform these tasks with the same easy system. With the Swellex Hanger Pm24H, the operator can install their service hanger(s) in the same reinforcement operation as the primary support while the Swellex connectable rock bolt Pm24C is a modern replacement to medium length cable bolts, with high productivity, quality control and safety components.

Load capacity and “ASTM” colour / length chart

Description

Min

imu

m b

reak

ing

load

, ex

pan

ded

pro

file

(kN

)

Min

imu

m y

ield

ing

load

, ex

pan

ded

pro

file

(kN

)

Min

imu

m e

lon

gat

ion

"A

" (%

)

Pro

file

dia

met

er

Mat

eria

l th

ickn

ess

(mm

)

Ori

gin

al t

ub

e d

iam

eter

(m

m)

Up

per

bu

shin

g d

iam

eter

(m

m)

Bu

shin

g h

ead

dia

met

er (

mm

)

Bo

re h

ole

dia

met

er (

mm

)

Infl

atio

n p

ress

ure

(b

ar)

Pm12 110 90 10 28 2 41 28 30/37 32-39 300

Mn12 110 90 20 28 2 41 28 30/37 32-39 300

Pm16 160 140 10 36.5 2 54 38 41/50 43-52 240

Mn16 150 100 20 36 2 54 38 41/48 43-52 240

Pm24 240 200 10 37 3 54 38 41/50 43-52 300

Pm24C 240 200 10 37 3 54 38 41/53 48-52 300

Pm24H* 200 190 10 37 3 54 38 43-52 300

Mn24 220 180 20 37 3 54 38 41/50 43-52 300

SP12 110 90 6 28 2 41 28 30/37 32-39 300

SP16 160 140 6 37 2 54 38 41/50 43-52 240

SP24 240 200 6 37 3 54 38 41/50 43-52 300

Bolts also available in PlastiCoated version * If borehole diameter < 51 collaring of 51 mm is required to allow insertion of bushing head in rock mass.

Colour plug Bolt length

Red 1.5 m / 5 ft

Dark blue 1.8 m / 6 ft

Orange 2.1 m / 7 ft

White 2.4 m / 8 ft

Fluorescent green 2.7 m / 9 ft

Safety yellow 3.0 - 3.3 m / 10 - 11 ft

Dark green 3.6 - 4.0 m / 12 - 13 ft

Brown 4.5 m / 14 - 15 ft

Uncoloured 5.0 m / 16 - 17 ft

Light blue 5.5 m / 18 - 19 ft

Black 7.0 m / 22 - 23 ft

Pink 7.0 m / 22 - 23 ft

Atlas Copco Swellex Page 2 of 19

Atlas Copco Swellex Pm12 rock bolts

Size Length (m) Weight (kg)

SWX Pm12

1.2 2.5

1.5 3.1

1.8 3.7

2.1 4.3

2.4 4.9

2.7 5.5

3.0 6.0

3.3 6.6

3.6 7.2

3.8 7.6

3.9 7.8

4.0 8.0

4.5 8.9

5.0 10.0

6.0 11.9

6.5 12.9

Plastic coated

SWX Pm12

1.2 2.5

1.5 3.3

1.8 3.8

2.1 4.4

2.4 5.0

3.0 6.2

3.3 6.62

3.6 7.21

3.8 7.65

4.0 8.25

4.5 8.96

5.0 10.25

6.0 11.92

6.5 12.95

General information Atlas Copco Swellex Pm12

Minimum breaking load 110 kN

Minimum yielding load 90 kN

Minimum elongation 10%

Inflation pressure 300 bar

For further information, see also technical data page 2. Minimum elongation "A": According to EN ISO 6892-1 where applicable.




SWX Pm16

1.5 4.3

1.8 5.1

2.0 5.6

2.1 5.8

2.4 6.7

2.7 7.4

3.0 8.2

3.3 8.9

3.6 9.7

4.0 10.7

4.5 12.0

5.0 13.3

6.0 15.9

6.5 17.2

Plastic coated

SWX Pm16

2.4 7.4

1.8 5.6

2.7 8.1

3.6 10.7

Other lengths available upon request. Cone installed bolts available on request. Refer to colour chart page 2.









SWX Pm24

1.8 7.2

2.1 8.4

2.4 9.5

2.7 10.6

3.0 11.8

3.3 12.9

3.6 14.0

3.9 15.2

4.0 15.6

4.5 17.4

4.9 18.9

5.0 19.3

5.5 21.2

6.0 23.1

6.5 25.0

7.0 26.9

Plastic coated

SWX Pm24

1.8 7.2

2.4 9.5

2.4 10.9

3.0 11.8

3.6 14.0









Atlas Copco Swellex Pm24C connectable rock bolts

Size Description

Length (m) Weight (kg)Assembled Overall

SWX Pm24

Blind segment 1.62 1.62 6.3






Middle segment 1.62 1.72 6.6






Injection segment 1.52 1.62 6.4






Swellex plug-on retainer

SWX Pm24C Optional blind segment retainer 0.05


General information Atlas Copco Swellex Pm24C







Atlas Copco Swellex Pm24C connectable rock bolts – plastic coated

Size Description

Length (m) Weight (kg)Assembled Overall

SWX Pm24C
















Swellex plug-on retainer

SWX Pm24C Optional blind segment retainer 0.05


General information Atlas Copco Swellex Pm24C







Atlas Copco Swellex Pm24H hanger rock bolts

Size Description Length (m) Weight (kg)

SWX Pm24H

M36 thread 1.5 6.3

M36 thread 2.1 9.9

M36 thread 2.4 11.1

M36 thread 3.0 13.4

M36 thread 4.5 18.9

M36 thread 5.0 21.0

Plastic coated

SWX Pm24H

M36 thread 1.5 7.7

M36 thread 2.1 9.9

M36 thread 2.4 11.1

M36 thread 3.0 13.4

Swellex Pm24H accessories

Size Description Weight (kg)

SWX Pm24H M36 eyebolt 2.8

Swellex Pm24H inflation adapter

SWX Pm24H

Inflation adapter M36 for Pm24 chuck

0.3

Inflation adapter M36 for Pm12 chuck

0.3

General information Atlas Copco Swellex Pm24H







Atlas Copco Swellex Mn12 rock bolts


SWX Pm24H

1.2 2.5

1.5 3.1

1.8 36

2.1 4.3

2.4 4.9

2.7 5.5

3.0 6.0

3.3 6.6

3.6 7.2

4.0 8.0

4.5 8.9

5.0 10.0

6.0 11.9

6.5 12.9

Plastic coated

SWX Pm24H

1.2 3.94

1.5 4.92

1.8 5.91

2.1 6.89

2.4 7.87

2.7 8.86

3.0 9.84

3.3 10.83

3.6 11.81

4.0 13.12

4.5 14.76

5.0 16.40


General information Atlas Copco Swellex Mn12









SWX Mn16

0.9 2.6

1.5 4.3

1.8 5.2

2.0 5.6

2.1 6.0

2.4 6.6

2.7 7.4

3.0 8.2

3.3 9.0

3.6 9.7

3.9 11.2

4.0 11.6

4.5 12.0

5.0 13.2

6.0 15.9

6.5 17.1











SWX Mn24

1.5 5.6

1.8 7.2

2.0 8.3

2.1 9.4

2.4 9.4

2.7 10.5

3.0 11.7

3.3 12.8

3.6 13.9

3.9 15.2

4.0 15.4

4.5 17.3

5.0 19.2

5.8 22.0

5.5 21.1

6.0 22.9

6.5 24.8

7.0 26.7

Plastic coated

SWX Mn24

1.8 8.3

2.4 10.8

3.0 13.5

3.3 14.7

3.6 15.9

4.9 22.1









Atlas Copco Swellex Sp12 rock bolts


SWX Sp12

1.2 2.5

1.5 3.1

1.8 3.7

2.1 4.3

2.4 4.9

2.7 5.5

3.0 6.0

3.3 6.6

3.6 7.2

4.0 8.0

4.5 8.9

5.0 10.0

6.0 11.9


General information Atlas Copco Swellex Sp12








SWX Sp16

1.2 3.4

1.5 4.3

1.8 5.1

2.1 5.8

2.4 6.7

2.7 7.4

3.0 8.2

3.3 8.9

3.6 9.7

4.0 10.7

4.5 12.0

5.0 13.3

6.0 15.9

6.5 17.2











SWX Sp24

1.2 4.0

1.5 5.6

1.8 7.2

2.1 8.4

2.4 9.5

2.7 10.6

3.0 11.8

3.3 12.9

3.6 14.0

4.0 15.6

4.5 17.4

5.0 19.3

6.0 23.1

6.5 25.0









Atlas Copco Swellex face plates and washers

Swellex face plates

Name DescriptionASTM Grade

Indicate load capacity (kN) Mn/Pm

Geometry (mm x mm)

Hole Size(mm)

Weight(kg)

P12 Performance plate for 12 range bolts, domed 3 100 152 x 152 31.0 1.02

M12 MID performance plate for 12 range bolts, domed 2 80 152 x 152 31.0 1.02

F12 Flat plate for 12 range bolts N/A 70/90 127 x 127 31.0 0.71

V12 Value plate for 12 range bolts, domed N/A 50 150 x 150 31.0 0.80

P16/24 Performance plate for 16 and 24 range bolt, domed 3 170/190 152 x 152 40.6 1.02

P24L Performance plate for 16 and 24 range bolts, domed with lance 3 170/190 152 x 152 40.6 1.02

P24C Performance plate for Pm24 connectable bolt, domed 3 180 52 x 152 44.5 1.02

V16/24 Value plate for 16 and 24 range bolts N/A 50 150 x 150 41.5 0.82

RE12 4"x 4" Rabbit ears plate for chain 1/3" or 3/8" chain, 4" square x 4" square L shaped N/A

*Capacity safety factor 6 Hanging capacity 5.4

102 x 102 31.0 0.25

RE12 5" x 5" Rabbit ears plate for chain 1/3" or 3/8" chain, 5" square x 5" square L shaped N/A

*Capacity safety factor 6 Hanging capacity 5.4

127 x 127 31.0 0.39

* The load capacity specified is for static load only, with no cyclic, dynamic or shock load permitted. The plate is to be used only as a hanging device with no function as a rock support element.

Atlas Copco Swellex washers

Size Description Geometry (mm) Indicative load capacity (kN)

MWR12 Mesh washer round for 12 range bolts 100 Round 10

MWS12 Mesh washer square for 12 range bolts 125 x 125 10

MWS24 Mesh washer square for 16 and 24 range bolts 125 x 125 10


Atlas Copco Swellex pneumatic pumps

PSP 300 RDP


PSP 300 RDP (no installation arm included) 30.0

PSP 300 RDP including arm, chuck, manometer and hose for Pm/Mn 12 bolts (installation arm I=1.6 m) 38.5

PSP 300 RDP including arm, chuck, manometer and hose for Pm/Mn 12 bolts (installation arm I=1.6 m) 39.5

Technical data

Max. working pressure for water 300 bar

Min. working pressure for air 6 bar

Air consumption at 6 bar, average 53 L/s

Inlet water pressure 2 – 6 bar

Connections – air Claw coupling (1/2")

Connections – water Claw coupling (1/2")

Noise level op. ear, 4 m away Below 96 dB (A)

Vibrations in the installation arm Not measurable

Depth x width x height 280 x 850 x 320 mm

Weight installation arm with valve and chuck 7.0 kg


Atlas Copco Swellex hydraulic pumps

H1, HC1, H1R and HC1-D


H1 36.0

HC1* 38.0

H1R high corrosion resistance, ALU/Bronze 36.0

HC1-D (for use with dolly kit) 38.0

Technical data

Max. inlet water pressure 2 – 20 bar

Max. outlet water pressure 320 bar max

Max. water temperature 70 °C

Max. water consumption 17 L/min.

Hydraulic pressure 120 – 160 bar

Hydraulic flow 40 L/min.

Vibrations in the installation arm Not measurable

CE marked Yes


Installation arm with valve and chuck 6.5 kg

Pump with arm, chuck, manometer and hose 43 kg

Chuck only 1.0 kg


Atlas Copco Swellex electric pumps

Pump E1

Description Voltage Weight (kg)

E1 Electric pump

200-220VD 80.0

400 VY 80.0

440VY-60Hz 80.0

480VY-60Hz CSA 80.0

525VD-50Hz 80.0

575VD-60Hz CSA 80.0

Technical data

Max. working pressure for water 320 bar

Supply water pressure 2 – 20 bar

Max. supply water temperature 40 °C

Flow rate 12 L/min. at 50 Hz

Connection water Claw coupling (1/2")

Noise level at op. ear, 4 m away Below 60 dB (A)

Vibration in the installation arm Not measurable


Weight installation arm with valve and chuck 6.5 kg

Pump weight 80 kg

Weight for hoses 2 kg

Weight for chuck 1 kg


Atlas Copco Swellex quality control

Swellex pull test equipment

Rfe. Description Weight (kg)

Pull tester SWX manual hydraulic 300 kN (includes ref. no. 1,2,3,4,5) 72.0

1 SWX-SDA-Rx pull tester hydraulic set manual 19.0

2 SWX-SDA-Rx pull test frame complete 20.8

3 SWX-SDA-Rx pull tester tools and accessory set 4.0

4 SWX for Pm/Mn 12/16/24 grip kit 9.7

5 Box for pull tester 18.5

Swellex steel sleeves


Mn/Pm 12 bolts Sleeve, length 300 mm 0.5

Mn/Pm 16/24 Sleeve, length 300 mm 0.81

Swellex bit control gauges


Mn/Pm12 Bit control gauge 32 – 38 mm 1.5

Mn/Pm 16/24 Bit control gauge 43 – 51 mm 2.1


Atlas Copco Swellex accessories

Installation arms with chuck for PSP300 RDP

Size Description Length (mm) Weight (kg)

Pm12/Mn12 Installation arm with chuck and manometer 1.6 12.0

Pm/Mn 16 & 24 Installation arm with chuck and manometer 1.6 13.0

Installation arms with chuck for HC1

Size Description Length (mm) Weight (kg)

Pm12/Mn12 Installation arm with chuck and manometer 1.6 17.0

Pm/Mn 16 & 24 Installation arm with chuck and manometer 1.6 18.0

Chucks


Mn12 Chuck for installation arm 1.0

Mn16 & 24 Chuck for installation arm 1.4

Pm/Mn 12 Sealing set* 0.01

Pm/Mn16 & 24 Sealing set* 0.01

*Sealing sets for all chucks include 1 set piston seals, 10 sets of seal rings

Swellex pressure gauges


Mn/Pm12 chuck Pressure gauge, 30 mm 0.70

Mn/Pm 16/24 chuck Pressure gauge, 40 mm 0.70


Dolly kits


SWX Dolly kit 12 10.3

SWX Dolly kit 24 11.4

SWX Dolly control 8.0

Hose set


Hose set PSP (high and low pressure) 1.5

Hose set HC1/EC1 (high and low pressure) 1.5

www.orica.com

Swellex® is a registered trademark of Atlas Copco Geotechnical Drilling and Exploration. All trademarks remain property of their respective holder, and are used only to directly describe the products being provided.




Orica Secura™ HGC systemAn advanced Support System

Orica’s Secura™ Hollow Groutable Cable system (HGC) offers an advanced support system with all the installation versatility of the traditional cable bolts.

Orica’s Secura™ HGC system offers enhanced system stiffness and ensures superior load transfer along the length of the bolt and, in addition, offers the flexibility of either pumpable resin or cementitious grouting.

The Secura™ HGC system is suitable for underground Coal and Hard Rock Mining application where high load carrying capacity is needed. The Secura™ HGC system can be used as primary support and/or secondary support in applications where traditional cable bolts are used. In addition, pumpable resin grouted HGC system offers faster development rate and improved productivity when used in critical areas such as development headings and long wall takeoff sections.

Common application areas include tail gates, bleeder, recovery room, set-up room, head gates, intersections and other mine areas where longevity and additional support is required.

Customer benefits Simplicity of use – products can be installed using existing bolting equipment, tools and techniques.

Productivity gain – improved productivity due to fast set pumpable resin grouting system.

Improved product performance – superior load transfer due to assured full encapsulation.

Improved system stiffness – stiffer system due to bulbs, along the length of the bolt, at pre-determined intervals.

Flexibility – grouting media can be either pumpable resin or cement.

Safety – fully encapsulated rapid set grouted system, avoids working under suspended load.

Quality assurance – cables can be traced back to the heat numbers through stamped numbers on the cable.

Operating environment – can be effectively used as primary and secondary support.

Integrity under load – hybrid layout, assured full encapsulation with thixotropic grouting, retains bonding integrity between wires under load.

Consistency in performance – tested and proven system, uniform homogeneous mixing of pumpable resin via integrated static mixer.

Orica Secura™ HGC system Page 2 of 4

DescriptionOrica’s Secura™ HGC system is a complete system comprising individually traceable cable bolts, fully tested dome barrel and wedges, high capacity dome plate and grouting sleeve. The package is complete with specially designed Grout lances and Orica pumpable resin or cement grouts, to ensure optimum system performance.

Patented Hybrid layout of Orica’s Secura™ HGC system ensures gap between adjoining wires and grout flow between the wires, assuring full encapsulation, along the length of the bolt.

System installationThe Secura™ HGC system is installed similar to a traditional cable bolt. The Secura™ HGC cables bolts are installed in holes drilled with 42-45 mm bit, point anchored with Orica’s J1000/120036SZ/MZ resins and pre-tensioned with high quality barrel and wedges supplied by Orica. The grouting sleeve is fitted to the hex adaptor, attached to the cable end for ease of installation, for grouting with either cementitious or liquid resin grouting, in-line or sequentially, post tensioning.

Technical properties and lab testsOrica’s Secura™ HGC system has been subjected to extensive lab tests followed by in-situ trials. Further testing has also been carried out at the Orica test facility at Nowra, NSW. The Orica – Nowra test facility allows for the complete testing of a bolt installation, including dissection so a thorough examination can be made on all the aspects of installation.

Laboratory tests

Load transfer testsLoad transfer results using plain section of the cable, core diameter of 30 mm, with 270 mm encapsulation with a J series resin anchor in a 42 mm hole. The failure was observed to be at the resin and bore hole interface.

Hollow cable load vs displacement – Load transfer test

0

50

100

150

200

250

Load

(kN

)

Displacement (mm)

0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

Tensile testsTensile tests performed on Orica’s HGC system at independent test facility demonstrates the cable capable of withstanding a typical load 560 kN or 57.14T before failing in tension at the collar, B&W interface. Test specimen length – 470 mm

Hollow cable load vs displacement – Tensile testing

0

200

100

300

400

500

600

Load

(kN

)

Displacement (mm)

0 2 4 6 8 10 12 14 16 18 20

of 4Orica Secura™ HGC system

Tensile and shear tests*

0

200

100

300

400

600

800

700

500

Load

(kN

)

Displacement (mm)

0 2 4 6 8 10 12 14 16 18

Tension 1 Tension 2 Tension 3Shear 1 Shear 2 Shear 3

*Independent Testing DEBT for Tensile and Shear to BS7861-2

Double concrete block shear tests (FB400)*

0

600

400

200

800

1000

1400

1800

1600

1200

Load

(kN

)

Shear Displacement (mm)

0 20 40 60 80 100 120

Axial load 1-kN Axial load 2-kN Shear load (kN)

Independent Testing – UOW Double concrete block shear tests (FB400)*

Double concrete block shear tests (Carbothix)*

0

600

400

200

800

1000

1400

1800

1600

1200

Load

(kN

)

Shear Displacement (mm)

0 20 40 60 80 100 120

Axial load 1-kN Axial load 2-kN

Secura™ HGC – Independent Testing – UOW Double concrete block shear tests (Carbothix)

Tensile failure Shear failure

www.orica.com

Orica Secura™ HGC system Page 4 of 4


The word Orica, the Ring Device and Secura are trademarks of Orica Group Companies.

Technical data7 mm PC wires with spiral indentation produced to the AS/NZS 4672 standard and Executive standard BS 5896.

Property 30 mm HGC Cable

Core bolt diameter – Plain section (mm) 30

Typical bulb diameter (mm) 36

Number of Strands 9

Yield Strength – Typical (MPa) 1470

Yield Force – Typical (kN) 565

Yield Force Cable Typical (MT) 57.61

Tensile Strength – Minimum (MPa) 1725

Tensile Force PC Wire – Minimum (kN) ≥ 66.4

Tensile Force PC Wire – Typical (kN) 69.05

Tensile Force PC Wire – Typical (MT) 7.04

Tensile Force Cable – Minimum (kN) 597.6

Tensile Force Cable – Typical (kN) 621.45

Tensile Force Cable – Typical (MT) 63.4

Elongation over 250 mm – Minimum (%) ≥ 4

Elongation over 250 mm – Typical (%) 4.45

Bending over R20 – Minimum (times/180°) ≥ 4

Bending over R20 – Typical (times/180°) 6.85

Orica Secura™ HGC Range Orica’s Secura™ HGC system is a complete package, aimed at delivering optimum system performance and productivity, consisting of the following:

• Hollow 30 mm cable available in lengths of 4.1, 6.1, 8.1, 10.1 metres

• Dome plate in 12 or 16mm thickness in 200, 250 or 300 mm square

• Dome barrel and wedges to suit hollow cable

• Grouting sleeve

• Grouting lance

• Resin

• Cementitious or liquid resin

Pack sizeOrica’s HGC System comes in standard pack sizes. Consult with Sales Team for additional information and specific recommendations

Product service supportOrica provides a full service support package to customers, including installation training, underground pull testing, operator awareness training, underground audits and stock control assistance. Each service package is developed to suit the individual customer requirements.

All aspects of Orica’s product service support service are provided by experienced trained and qualified personnel.

Additional informationFor additional information relating to any aspect of this product specification data including product performance, quality, testing, specification, range, availability etc. please contact your nearest Orica office or email: [email protected]

The FiReP® Powerthread GRP Rockbolt was developed for strata support in mining and tunnelling as well as for slope and face stabilisation.

Due to its continuous thread the bolt can be trimmed if needed. The bolt has a high ultimate load and due to its profile it offers a maximum bond strength with all grouting materials. The cuttability protects machinery and equipment and prevents damage to machinery while drifting and enlarging tunnels.

The bolt has a high corrosion resistance and is well suited for permanent support. The high flexibility is well suited for application without couplings in confined locations. Due to its high tensile strength the bolt has a high and immediate load bearing capacity if applied with fast setting resin capsules. The low weight facilitates handling.

Unit

Tubular Bolt Solid Bolt

J64-25 J64-28 K60-20 K60-22 K60-25 K60-27 K60-30 K60-32 K60-38

Outer diameter (mm) 25/12 28/12 20 22 25 27 30 32 38

Tensile stress area (mm2) 250 357 200 250 346 400 510 580 830

Ultimate load (kN) 250 350 200 250 350 400 490 560 750

Breaking load thread (kN)

Steel Nut 150 200 80 100 180 200 200 320 –

FRP Nut 70 80 60 60 70 80 80 80 –

POWER Nut 150 180 80 100 180 180 – – –

Ultimate strength (N/mm2) 1,000 1,000 1,000 1,000 1,000 1,000 960 960 900

Torsion resistance (Nm) 100 110 60 70 120 130 180 230 –

Shear resistance (N/mm2) 400 400 460 460 460 460 430 430 400

Tensile E-Modulus (N/mm2) 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000

Strain at failure (%) 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5

Weight (g/m) 630 880 560 690 900 1,040 1,330 1,500 2,100

www.orica.com


The word Orica and the Ring Device are trademarks of Orica Group Companies. FiReP is a registered trademark of FiReP International AG.

Powerthread FiReP® Rockbolt System

Benefits of FiReP® Powerthread• High corrosion resistance

• Permanent application

• Cuttability

• Continuous threaded bar

• High tensile strength

• High end loading

• Flexibility

• Low weight

• Easy handling

The purpose of the new FiReP® SPINSET system is to provide a quick and safe bolt installation for a two step application of GRP Rockbolts for underground mining and tunnelling applications.

SPINSET ensures safe strata control and safe installation of tensioning the bolt with resin capsules. The rock bolt can be installed time and cost

effectively, whilst not allowing the SPIN Bolt to be over spun.

SPINSET is composed by SPIN BOLT K61 and SPIN NUT, also SPIN PLATE.

FiReP® Spin Nut

Torsion Strength [Nm]

Outer Diameter (mm) K61 Standard GRP Rockbolt

18 80 50

20 100 60

22 130 80

23 150 100

25 180 120

27 200 130

FiReP® Spin Nut

Torsion Strength [Nm]

Colour Code Torque level Shear Pin Shear Nep

40 35 – 45 –

60 46 – 65 60 – 70

80 65 – 85 80 – 90

100 85 – 105 100 – 110

120 105 – 125 120 – 130

140 125 – 145 140 – 150

160 – 160 – 170

Spinset Anti-Torsion Failure Rockbolt System

Benefits of Spinset FiReP® Rockbolt Setting System• High torsion GRP Rockbolt

• Anti over spin function

• Easy handling

• Continuous installation process

• Installation time saving

www.orica.com



FiReP® Spin Plate

Plate Diameter Plastic FRP*

[mm] PP/Black ABS/White Natural

130 – – > 10 tons

200 6 – 8 tons 10 – 12 tons > 10 tons

250 6 – 8 tons 10 – 12 tons > 10 tons

Bolt Diameter 23 mm

Bolt Core Diameter 21 mm

Thread Pitch 10 mm

Effective Bolt Cross Section 368 mm2

Bolt Weight 750 g/m

Tensile Strength 300 kN

Torsion Strength 150 Nm

Shear Strength 130 kN

Spinset Anti-Torsion Failure Rockbolt System Page 2 of 2

The FiReP® HIPREX FRP high pressure injection and bolting system is a new development of a FRP high torque tube, valves and integrated packer for use in stabilising fractured rock and mineral by combining resin injecting and bolting.

The high torsion hollow bar is fitted with an expansion packer and integrated non-return valve. Two additional valves are fitted to both ends of the tube, the top valve to burst when the packer is inflated, the bottom valve to prevent backflow after injec tion.

When starting the injection process the check valve will be opened and the medium will run through the hollow bar filling it and inflating the packer. The non-return valve opens but ensures that the medium will not flow backwards if the hydraulic pressure is reduced. After filling the bolt and packer to a certain pressure the disc will burst and allow rock injection.

After injection is complete the non-return valve will close and prevent backflow of the resin. After the resin has cured the hollow bar will be fixed in the hole with a high bond strength.

The FRP system allows cutting during heading or mining of ore. Rapid heading will not be delayed. High corrosion resistance allows permanent application with high durability and the light weight makes handling easy, even in confined underground conditions.

FiReP® HIPREX FRP High Pressure Injection Bolt

Benefits of FiReP® HIPREX• High hydraulic burst pressure > 240 bars

• High corrosion resistance

• Permanent application

• Cuttability

• Continuous threaded bar


• High end loading

• Flexibility

• Low weight

• Easy handling

• Anti-static

www.orica.com



Technical Data

HIPREX 25/8

Outer / Inner diameter (mm) 28 / 8

Tensile stress area (mm2) 350

Ultimate load (kN) 350

Breaking load thread (kN)Steel Nut 180

FRP Nut 70

Ultimate strength (N/mm2) 1,000

Tensile E-Modulus (N/mm2) 45,000

Bending strength (N/mm2) 560

Burst pressure (bars) 240

Strain at failure (%) 2.5

Weight (g/m) 780

Standard length (m) 2.0 / 2.5

FiReP® HIPREX FRP High Pressure Injection Bolt Page 2 of 2

FiReP® FRP Powermesh was developed to comply with standard grid applications while providing the added benefits of durability or cuttability.

The high load capacity at each joint, comparable to that of welded steel mesh, is unique and makes the design of FRP grid reinforced RC structures viable option for engineers and architects.

Options:• Available rod size 3 mm – 12 mm

• Other mesh sizes available on request

• Polyester / Epoxy / Vinyl ester resin

• Non flammable

• Anti-static coating

Product Data

Standard 100 x 100 x 6 mm

Rod diameter (mm) 6

Spacing (mm) 100 x 100

Breaking load of 6 mm rod (kN) > 28.3

Ultimate strength of 6 mm rod (N/mm2) > 1,000

Tensile E-Modulus (N/mm2) 60,000

Load at knot (kN) > 3 and > 5

Overall dimensions (mm) 2,000 x 800

Weight (g) 1,800


The word Orica and the Ring Device are trademarks of Orica Group Companies. FiReP® is a registered trademark of FiReP International AG.

www.orica.com

Powermesh FiReP® FRP Mesh

Benefits of FiReP® Powermesh• High corrosion resistance

• Cuttability


• Flexibility

• Low weight

• Anti-static coating (optional)

• Anti-magnetic

• High thermal isolation

• No electrical conductivity

• Wide range of various meshes and spacing sizes

For over 30 years Orica has lead the world in the development, manufacture and supply of resin capsules for rock bolting.

Lokset™ resin capsules are used primarily as an anchoring medium for rock bolts and cable bolts to provide roof (backs) and sidewall support to underground excavations. Orica’s Lokset™ resin capsules are industry renowned for consistent quality and performance. With state of the art technical and manufacturing facilities, Orica provides an extensive and flexible range of resin capsules to suit all types of bolting parameters including variations in equipment, environment and strata conditions.

Lokset™ resin capsules consist of a reinforced thixotropic polyester resin mastic in one compartment and organic peroxide catalyst separated by a physical barrier in the other compartment. The rotation of a rock bolt during installation ruptures the capsule, shreds the skin and mixes the two components causing a chemical reaction and transforming the resin mastic into a solid anchor.

Over the past 30 years Orica has successfully introduced a range of revolutionary developments in resin capsules including the Lokset™ TOOSPEEDIE™ (1993), Lokset™ Long Tendon (1996), Lokset™ X2 (2000) and more recently the Lokset Supamix™ (2008) series. These developments have ensured that Australian mining and tunnelling industries continue to lead the world in safe, efficient and consistent resin bolting. Orica Australia resin capsule series are available in multiple configurations of length, double length combinations (X2), diameter, set time, set time combinations (TOOSPEEDIE™) and viscosity.

Australian development and manufacture ensures 100% security of supply to every customer regardless of the location. Experienced technical and mining personnel are involved in the development, daily service and support of Orica’s range of Lokset™ resin capsules.

Orica’s range of resin capsule systems includes the following:

Lokset™ Resin Capsule• the original single speed

polyester resin capsule

Lokset™ TOOSPEEDIE™

• two separate speeds in a single capsule eliminates the need to use multiple single speed resin capsules in a single bolt hole

Lokset™ Long Tendon• specifically developed range

of capsules for use with point anchored or fully encapsulated cable bolts

Lokset™ X2• double length (joined) capsules

enable full encapsulation mechanised bolting, for use in conjunction with Orica’s Quickchem™ resin capsule insertion system

Lokset Supamix™

• low mastic to catalyst ratio for improved mixing consistency and installed bolt quality, extended shelf life

Quick-Chem™

• Resin capsule insertion system

Lokset™ Resin Capsules

AdvantagesSelection of the appropriate Lokset™ capsule enables a wide variety of applications:

• Full encapsulation with pre-tensioning utilising combination TOOSPEEDIE™ capsules

• Point anchor installation with fast set single speed Lokset™ resin capsules

• Full encapsulation without pre-tensioning using slow set single speed Lokset™ capsules

• Unique capsule configuration design enabling extremely effective mixing of resin mastic and catalyst compartments

• Rapid insertion, easy and quick to use

• High compressive strength, strong, rapid & consistent anchorage

• High modulus

• Protects bolt from corrosion, can be used in wet or underwater conditions

• Unaffected by vibration

• No expansion stresses, can be used in weak strata

Product Information

Capsule DescriptionCapsule Colour

Label Colour

Approx Spin Time (seconds)

Approx Hold Time (seconds)

Gel Time 25OC (seconds)

SF Super Fast Yellow White 8 > 4 10 – 11

XF Extra Fast Yellow Orange 8 > 4 12 – 13

F Fast Yellow Yellow 10 > 4 15 – 16

M Medium Red Red 15 > 4 19 – 23

M Medium – J Series Red Red 12 Tension > 5 minutes 15 – 23

S Slow Blue Blue 20 > 70 80 – 140

S Slow – J Series Blue Blue 20 Tension > 10 minutes 60 – 110

FRS F Series Slow L Green Green 20 > 120 100 – 160

FRXXS F Series XX Slow L Pink Pink 20 > 1200 1200 – 1500

XFMExtra Fast/Medium

50:50 TOOSPEEDIE™Yellow/Red Orange/

Red 11 12 – 19 –

SFSSuper Fast/Slow

50:50 TOOSPEEDIE™

Yellow/Blue White/Blue 11 10 – 60 –

FSFast/Slow

50:50 TOOSPEEDIE™

Yellow/Blue

Yellow/Blue 14 12 – 60 –

MSMedium/Slow

50:50 TOOSPEEDIE™

Red/ Blue

Red/

Blue16 19 – 60 –

XFS Extra Fast/Slow 40:60 TOOSPEEDIE™

Yellow/Blue

Orange/Blue 12 12 – 60 –

FSFast/Slow

40:60 TOOSPEEDIE™

Yellow/Blue

Yellow/Blue 14 12 – 60 –

MSMedium/Slow

40:60 TOOSPEEDIE™

Red/ Blue

Red/

Blue16 19 – 16 –

XFS Extra Fast/Slow 50:50 TOOSPEEDIE™

Yellow/Blue

Orange/Blue 12 12 – 60 –

The hold time is the minimum time allowed after completion of the spin time before bolt tensioning is attempted. In many cases the hold time will be greater than that listed. The times listed are an indication only, they may vary with temperature, mining conditions, equipment, hole: bolt annulus, age and storage conditions of resin capsules. Each mine site should be evaluated to determine optimum installation parameters. The following graph shows the effect of temperature on gel times.

Lokset™ Resin Capsules Page 2 of 5

QualityThe superior quality of Lokset™ resin capsules is assured through a four-part quality control program:

1. Raw Material Testing

2. In-process quality control testing

3. Finished product acceptance testing

4. Quality system management to ISO 9001

Testing levels and specifications for each of the above programs have been established statistically, based on actual historical data to ensure the customer receives a uniform quality product which will perform dependably under field conditions.

Product Testing SpecificationsA combination of testing is completed to ensure the ongoing quality control of Orica’s Lokset™ resin capsule range. Each of the following tests forms an important part of this process.

Push out testMeasured to determine bond strength using a 22 mm bolt, 50 mm encapsulation in 28 mm I.D. threaded cylinder, with slow set Lokset™ resin.

Pull out testThis is a routine test commonly performed on in-situ bolts to confirm effective anchorage. It is important to note that only short encapsulation in-situ tests can provide meaningful results. Orica’s QC tests are measured with fast set resin. 300 mm encapsulation in 80 MPa grout using 21.7 mm core diameter high tensile grade bolts in 28 mm diameter hole.

Punched ShearMeasured according to BS 2782 (part 3). The appropriate quantities of resin mastic and catalyst are mixed together for six (6) seconds. The resultant mixture squashed between two uniform flat steel plates and allowed to gel. The plates are taken apart and the cured slice of resin is placed between two steel templates. The device is placed in a tensiometer and a plunger is forced into a hole in the plates at a predetermined rate thus pushing a flat circular disc out of the resin slice (ie shearing the resin). The force applied to shear the resin is recorded electronically by the tensiometer and converted to shear stress in MPa using the thickness of the disc in mm.

This test provides excellent correlation with mine pull out tests (without the variances) and is directly related to the strength of the resin. With fast setting resins the test can be performed in a very short time after the resin mixture has gelled (15 seconds).

5

Xfast: 12-13 secs @ 25ºC Fast: 15-16 secs @ 25ºC

Slow: 80-140 secs @ 25ºC Medium: 19-23 secs @ 25ºC

10 15 20 25Temp (ºC)

Effect of Temperature on Mastic Gel Time

30 35 40 45 500

20

40

60

80

100

120

Get

Tim

e (s

ec)

140

160

180

200

220

2 min

SF F

XF M

5 min 10 min 30min 60 minTime

Laboratory Punched Shear Strength vs Time (Samples cured at 25oC)

4 hrs 24 hrs 7 days 28 days10

15

20

25

30

S

Pun

ched

Sh

ear

(MPa

)


Application instructionsIt is essential good bolting procedures are followed and the instructions on the box are observed. As a guide the following steps must be taken:

1. Drill hole to correct diameter ensuring water/air flush is used. The hole should be clean and free from dust and other loose particles. In Coal mining 27 – 28 mm hole diameters are normally preferred with 22 mm core diameter roof bolts. Do not exceed the manufacturers recommended diameter.

2. Drill hole to correct length for bolt. The ideal hole length should be 100 mm – 140 mm shorter than the bolt, depending on attachments such as dome ball washer, nut, plate etc. Do not deviate from the manufacturer’s recommended length of hole in relation to the bolt.

3. Select the correct resin capsule that has been specified for the job.

4. Check that the use by date on the box label has not expired.

5. Where FAST (or MEDIUM) and SLOW set capsules are used together, when pre-tensioning, it is essential that the FAST (or MEDIUM) set (yellow or red) capsule be inserted first followed by SLOW set (green) capsule. Push the capsule(s) until the first capsule touches the top of the hole using the bolt (or other insertion device if available).

Ensure the capsule reaches the top of the hole

Should insertion problems occur then the problem must be investigated.

6. Connect the bolt to the spinning dolly/spanner.

7. The bolt is pushed AND spun at maximum rpm at a constant feed rate through the entire length of the capsule, when the top of the hole is reached a further 2 – 4 seconds spinning will suffice to ensure complete mixing. Total spin time through the capsule and at the top of the hole should not exceed the “approximate spin time” on the box label. It is essential the bolt is pushed AND spun to the top of the hole before mixing is completed.

8. Do not over mix the resin. If mixing continues beyond the recommended spin time and into the gel time, the solidifying chemical may be ground up and destroyed.

9. The bolt is then held stationary and after the hold time has elapsed the bolt may by tensioned as required. The hold time is the minimum time allowed after completion of the spin time before bolt tensioning can be attempted. In many cases the hold time will be greater than that listed.

10. The following items must also be checked where hand held (air operated) equipment is utilised:

• Compressed air supply should be clean and dry

• Air supply from roof bolter to miner should not be more than 100 metres of 2” hose

• Air pressure must be between 85 – 100 psi (586 – 690 KPa) when bolter(s) are operating

• Water pressure should be between 80 – 90 psi (550 – 620 KPa) and hoses flushed out prior to connection.

LimitationsThe annular gap between bolt and hole diameter should be at a minimum. It is recommended the annular gap be between 4 – 6 mm e.g.:

• Bolt core diameter: 22 mm

• Hole diameter: 27 mm

• Annular gap: 5 mm

Where annular gaps larger than this are encountered (e.g. in metal mines) then the bolt must possess larger deforms or a mixing device such as Secura Bolts etc and the installation guidelines followed. Larger hole diameters/annular gaps can result in extended cure times, less efficient mixing, finger gloving of the bolt into the resin capsule, a reduction in load transfer (strength) and encapsulation length.

In all cases it is strongly recommended that short encapsulation pull tests be performed to verify that required load strengths are being achieved.

Extended tensioning times may be due to:

• Low temperatures

• Broken ground, large hole diameters

• Insufficient spinning

• High nut break out loads

• High machine torque load levels

• Excessive thrust/feed on the installation rig

• Over mixing of the resin well above the appropriate spin time

• Attempting to tension the bolt too soon and damaging the resin as it cures

The resin appearing to be “too quick” with the bolt not reaching the top of the hole may be due to:

• High temperatures

• Smaller hole diameters

• Hole closure

• Angled holes

• Misaligned holes/rigs

• Low feed pressure

• Premature nut break out

• Old/out of date resin

All bolting parameters will vary depending on a number of factors such as:

• Strata condition/type

• Temperature

• Hole: bolt annulus

• Age of resin capsule

• Equipment

• Installation method

PackagingLokset™ Resin Capsules are available in standard diameters of 20 mm, nominal 25 mm (actual 23.6 mm), 26 mm, 30 mm, 36 mm and 38 mm. Lengths range from 300 mm to 1700 mm, with X2 providing additional length. They are packaged in water resistant cardboard cartons labelled with colour codes and supplied on wooden pallets.

VolumeIt is essential the correct length of capsule is selected to fill the volume left in the hole after allowing for the volume of the bolt.

It is good practice to use a capsule size which exceeds this volume by around 10% to allow for variations in hole diameter and length, bolt size and strata conditions. Refer to encapsulation chart available at www.orica.com.au


Storage

Shelf LifeThe Lokset™ resin capsule suggested shelf life is 4 months when stored between 20 – 25°C. Storage at lower temperatures such as in cool rooms is highly recommended and will extend the shelf life when stored at 0 – 5°C. Stock rotation is strongly recommended. Storage at higher temperatures will reduce shelf life.

Storage conditionsLokset™ resin capsules should be stored in a cool dry place away from direct sunlight. When using cool room storage the resin capsules should be allowed time to attain ambient temperature before use otherwise SPIN and HOLD TIMES will be extended.

Health and Safety• Wear suitable protective clothing,

gloves and eye/face protection

• In case of contact with skin remove contaminated clothing and immediately wash with soap and water, seek medical attention if skin irritation persists. In case of contact with eyes, flush with copious amounts of water and seek medical assistance

• If inhaled remove from exposure and seek medical advice if effects persist

• If ingested wash out mouth with water and obtain medical attention

• For further information see the relevant material safety data sheet

Lokset™ resin capsules are a single speed polyester resin mastic and organic peroxide catalyst system used for standard point anchor or fully encapsulation bolting requirements. Available in multiple lengths, diameters and set times, Lokset™ resin capsules have been the benchmark for quality and performance in resin bolting for over 30 years.

Resin capsule product code breakdown:

Typical code RA65025F(C)

RA Lokset™ resin anchoring capsule

650 Capsule length (650 mm)

25 Nominal capsule diameter (25 mm)

F Set time (Fast)

C A range of inclusions or attachments are also available such as cardboard cylinders (C), and are indicated by an additional letter at the end of the typical code.

Punch Shear TestMeasured according to BS 2782 (Part 3), with slow set Lokset™ resin. Typical results:

Age (hours) 24

Shear strength (MPa) > 32

Push Out TestMeasured on 22 mm bolt, 50 mm encapsulation in 28 mm I.D. threaded cylinder, with slow set resin. Typical results:

Age (hours) 24

Push out force (kN) > 72

Pull Out TestMeasured with fast set Lokset™ resin. 300 mm encapsulation in 60 MPa grout using 21.7 mm core diameter high tensile grade bolts in 28 mm diameter hole: Typical results:

Age (hours) 1

Load (T) > 16

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In 1993 Orica Australia completed the development and introduction of Lokset™ TOOSPEEDIE™ resin capsules, the world’s first two speed resin capsule.

A development that remains to be the most ground breaking evolution in resin bolting, the Lokset™ TOOSPEEDIE™ eliminates the need to use multiple resin capsules to achieve pre-tensioning of fully encapsulated resin grouted rock bolts.

Lokset™ TOOSPEEDIE™ capsules are available in multiple set time ratios, as designated by the product codes typically displayed below. Combinations of set times are possible using any of Orica’s resin mastic formulations.

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TOOSPEEDIE™ capsule product code breakdown

TS TOOSPEEDIE™ 50% fast set, 50% slow set

46 TOOSPEEDIE™ 40% fast set, 60% slow set

Other ratios available on request

Typical code TS120025FS

TS TOOSPEEDIE™ 50% fast set (F), 50% slow set (S)

1200 Capsule length (1200 mm)

25 Capsule diameter (25 mm)


Age (days) 28



Age (hours) 24


Pull Out TestMeasured with fast set Lokset™ resin. 300 mm encapsulation in 60 MPa grout using 21.7 mm core diameter high tensile grade bolts in 28 mm diameter hole: Typical results:

Age (hours) 1

Load (T) > 16

Lokset™ TOOSPEEDIE™ Resin Capsules

To assist in the advancement of cable bolt technology, Orica developed and introduced the Lokset™ Long Tendon resin capsule range in 1996.

The Lokset™ Long Tendon range contains specially formulated resin mastics to aid insertion and push through where long tendon support is required.

The Lokset™ Long Tendon range (F Series and J Series) have been developed for use with all resin anchored cable bolts, options include:

• Point anchoring installation with Slow set (F) or (J) capsules

• Full encapsulation with pre-tensioning

• Full encapsulation without pre-tensioning

Punch Shear TestMeasured according to BS 2782 (Part 3), with F Series slow set and J Series slow set Lokset™ resin. Typical results:

Age (days) 28

Shear strength (MPa) F Series > 32 J Series > 27

Push Out TestMeasured on 22 mm bolt, 50 mm encapsulation in 28 mm I.D. threaded cylinder, with F Series XX Slow set, and J Series slow set resin. Typical results:

Age (hours) 24

Push out force (kN) F Series > 70 J Series > 56

Pull Out TestMeasured with F Series slow set and J Series slow set resin. 300 mm encapsulation in 60 MPa grout using 21.7 mm core diameter hi tensile grade bolts in 28 mm diameter hole: Typical results:

Age (hours) 1

Load (T) F Series > 12.5 J Series > 15

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Long Tendon capsule product code breakdown:

Typical code F130025FRXXS

F Lokset™ Long Tendon F Series (alternatively J Series)

1300 Capsule length (1,300 mm)

25 Capsule diameter (25 mm)

FRXXS F Series Extra Extra Slow

Lokset™ Long Tendon Resin Capsules

Lokset™ X2 resin capsules have been developed to enable full encapsulated mechanised resin bolting, utilising the Quick-Chem™ resin capsule insertion system.

The Lokset™ X2 system incorporates two resin capsules joined and folded in half for packaging, and is available in either single speed or TOOSPEEDIE™ configurations.

Lokset™ X2 resin capsules are typically installed using development Jumbos in underground headings with an excavation height of 4 – 6 mm, where hand insertion is not safe or practical. Individual Quick-Chem™ caps are supplied in the boxes with the resin capsules, and one cap is fitted to the fast set end of each X2 capsule unit before being inserted into a Quick-Chem™ tube for installation into the borehole.

A Quick-Chem™ insertion tube is attached to the Jumbo drifter, and

used to safely insert resin capsules undamaged to the back of each borehole. Quick-Chem™ caps and insertion tubes are available to suit 25 mm, 26 mm, 30 mm and 36 mm diameter resin capsules. 25 mm, 26 mm and 30 mm Quick-Chem™ caps are designed for use in 33 mm – 35 mm diameter boreholes. 36 mm Quick-Chem™ caps are designed for use in 45 mm diameter boreholes.

The Lokset™ X2 range is available with any single (RA) or combination (TS) of Orica resin capsule mastics. Any capsule combination can be ordered by simply adding an X2 or X2Q (including Quick-Chem™ cap) to the end of an existing Lokset™ Resin Capsule or Lokset™ TOOSPEEDIE™ resin capsule code.

Description and Dimensions

Description Total Length

Lokset™ Resin Anchor 800/30 Medium X2 including Quick-Chem™ Cap 1600 mm




Lokset™ TOOSPEEDIE™ 1050/26 Medium/Slow X2 including Quick-Chem™ Cap 2100 mm



www.orica.com



Lokset™ X2 Resin Capsules

In 2008 Orica completed an extensive product development program focusing on improving the quality of installed resin bolts.

Key product development objectives included improved mixing quality, and encapsulation consistency, reduction of hole back pressure, extended shelf life and a lower cost formulation. All the proposed development objectives were achieved culminating in the launch of the Lokset Supamix™ range of resin capsules.

The Lokset Supamix™ range incorporates significant improvements:

• Lowest available mastic: catalyst ratio of 2:1 – improving mixing quality and consistency

• Lower viscosity and modified rheology – easier push through and improved encapsulation

• Improved formulation providing extended shelf life – 6 months at 25OC to reduce wastage

• Larger catalyst compartment – improved catalyst compartment mixing, bolt should not miss

• Lower cost

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Age (days) 28



Age (hours) 24


Pull Out TestMeasured with fast set Lokset™ resin. 300 mm encapsulation in 60 MPa grout using 21.7 mm core diameter hi tensile grade bolts in 28 mm diameter hole: Typical results:

Age (hours) 1

Load (T) > 16

Lokset Supamix™ Resin Capsules

Oricas offer delivers highly performing ground support and consolidation products and services to people working in underground coal mining, hard rock and civil/infrastructure operations anywhere around the world.

Our expertise has been developed through innovation, growing our people complimented by our long and solid history in global mining, tunnelling and infrastructure works.

UsesThe Lokset™ resin capsule is used as an anchoring medium for rockbolts and long tendons to provide primary roof and side wall support in mines and tunnels. It can be used with both hydraulic and pneumatic type bolters.

DescriptionThe Lokset™ resin capsule consists of accurately proportioned fast and slow speeds, reinforced, thixotropic polyester resin mastic in one compartment. The other compartment contains an organic peroxide catalyst separated by a physical barrier. The capsule is available in 50:50 ratio of fast:slow speeds. The rotation of the bolt during installation ruptures the capsule, shreds the skin and mixes the two components causing a chemical reaction and transforming the resin mastic into a solid anchor.

Technical SupportOrica, together with your local distributor offers a complete technical and field support service.

AdvantagesWith fast and slow speeds, each colour coded capsule provides the following advantages:

• Reduced handling

• Reduced wastage

• Rapid installation, easy and quick to use

• Helps ensure fast end of capsule inserted first

• Guarantees both fast and slow set capsules are installed

• Both speeds compatible giving reduced back pressure and easier penetration

• No plastic or cardboard joiners required

• Allows roof bolt to be pretensioned quickly

• A unique design of capsule configuration enabling extremely effective mixing of resin mastic and catalyst compartments

• Act as a reinforcement that clamps the individual strata layers together into a single high strength beam

A specially formulated resin mastic and catalyst paste to give:

• Higher compressive strength

• Higher modulus

• Higher push and pull out strengths

• Shorter installation times with no hold time required

• No expansion stresses, can be used in weak strata

• Protects bolt from corrosion, can be used in wet or underwater conditions

Lokset™ Resin Capsule

Properties

Set TimeTypical insertion properties at 25°C are as follows:

Fast:SlowApproximate Spin Time (secs)

50:50 12–15

The times listed are an indication only, they may vary with temperature, mining conditions, equipment, hole:bolt annulus, age and storage conditions of resin capsules. Each mine site should be evaluated to determine optimum installation parameters.

For further information on capsule types, size and speed consult Orica or your local distributor.

Pull TestMeasured on 21.7 mm bolt, 250 mm encapsulation length in 28.5 mm hole with STS100025 Lokset™ STS resin capsule using split bolt method in 60 MPa substrate.

Age (hours)Pull Out Force (tonnes)

1 > 16

Push Out TestMeasured on 22 mm bolt, encapsulated in 100 mm section in 28 mm hole, typical results:

Age (hours)Push Out Force (kN)

24 > 130

Punched ShearMeasured according to BS 2782 (part 3). The appropriate quantities of resin mastic and catalyst are mixed together for 6 seconds. The resultant mixture squashed between two uniform flat steel plates and allowed to gel. The plates are taken apart and the cured slice of resin is placed between two steel templates. The device is placed in a tensiometer and a plunger is forced into a hole in the plates at a predetermined rate thus pushing a flat circular disc out of the resin slice (i.e. shearing the resin). The force applied to shear the resin is recorded electronically by the tensiometer and converted to shear stress in MPa using the thickness of the disc in mm.

This test provides excellent correlation with mine pull out tests (without the variances) and is directly related to the strength of the resin. With fast setting resins the test can be performed in a very short time after the resin mixture has gelled.

Age (hours) Speed

Punched Shear (kN)

1 Fast set > 16

1 Slow set > 20

Application InstructionsIt is essential that good bolting procedures are followed and the instructions on the box are observed. As a guide the following steps must be taken:

1. Drill hole to correct diameter ensuring water/air flush is used. The hole should be clean and free from dust and other loose particles. In coal mining 27–28 mm hole diameters are normally preferred with 22 mm core diameter roof bolts. Do not exceed the manufacturers recommended diameter.

2. Drill hole to correct length for bolt. The ideal hole length should be 50 – 60 mm shorter than the bolt. Do not deviate from the manufacturers recommended length of hole in relation to the bolt.

3. Select the correct length resin capsule that has been specified for the job.

4. Check that the use by date on the box label has not expired.

5. Insert one capsule, yellow (FAST) end first. Push it gently all the way until the capsule touches the top of the hole using the bolt (or other insertion device if available).

Ensure the capsule reaches the top of the hole.

Under no circumstances should the capsule be inserted upside down.

The correct length and diameter are selected to enable full column encapsulation. Should insertion problems occur then the problem must be investigated.

6. Connect the bolt to the spinning dolly/spanner.

Lokset™ Resin Capsule Page 2 of 4

7. The bolt is pushed and spun at maximum rpm through the entire length of the capsule, when the top of the hole is reached continue spinning until the nut breaks out and tensioned to ensure complete mixing.

8. The following items must also be checked where hand held (air operated) equipment is utilised:

• Compressed air supply should be lean and dry

• Air supply from roof bolter to miner should not be more than 100 metres of 2” hose

• Air pressure must be between 85 – 100 psi (586 – 690 KPa) when bolter(s) are operating

• Water pressure should be between 80 – 90 psi (550 – 620 KPa) and hoses flushed out prior to connection

LimitationsThe annular gap between bolt and hole diameter should be at a minimum. It is recommended the annular gap be between 4–6 mm e.g.:

Bolt Core Diameter 22 mm

Hole Diameter 27 mm

Annular Gap 5 mm

Where annular gaps larger than this are encountered (e.g. in hardrock mines) then the bolt must possess larger deforms or a mixing device such as posimix wire or paddles etc. and the installation guidelines followed. Larger hole diameters/annular gaps may result in extended cure times, less efficient mixing, finger gloving of the bolt into the resin capsule, a reduction in load transfer (strength), a reduction in encapsulation length.

In all cases it is strongly recommended that short encapsulation pull tests be performed to verify that required load strengths are achieved.

Extended tensioning times may be due to:

• Low temperatures

• Broken ground

• Large hole diameters

• Insufficient spinning

• High nut break out loads

• High machine torque load levels

• Excessive thrust/feed on the installation rig

The resin appearing to be “too quick” with the bolt not reaching the top of the hole may be due to:

• High temperatures

• Smaller diameter holes

• Hole closure

• Angled holes

• Misaligned holes/rigs

• Low feed pressure

• Premature nut break out

• Old/out of date resin

All bolting parameters will vary depending on a number of factors such as:

• Strata condition/type

• Temperature

• Hole:Bolt annulus

• Age of resin capsule

• Equipment

• Installation method

PackagingLokset™ resin capsules are available in lengths from 880 – 1,500 mm with 25 mm “nominal” diameter, packed in cardboard cartons labelled with colour codes and supplied on wooden pallets.

VolumeIt is essential the correct length of capsule is selected to fill the volume left in the hole after allowing for the volume of the bolt. It is good practice to use a capsule size which exceeds this volume by around 10% to allow for variations in hole diameter and length, bolt size and strata conditions. Consult Orica for further information on encapsulation, refer Orica web site for resin encapsulation sheet.

Shelf LifeThe Lokset™ resin capsule suggested shelf life is 4 months when stored between 20–25 °C. Storage at lower temperatures such as in cool rooms is highly recommended and will extend the shelf life when stored at 0–5 °C. Stock rotation is strongly recommended. Storage at higher temperatures will severely reduce shelf life.

Storage ConditionsStore in a cool, dry place away from direct sunlight. Do not double stack pallets. When using cool room storage the resin capsules should be allowed time to attain ambient temperature before use otherwise spin times will be extended.

QualityThe superior quality of the Lokset™ resin capsule is assured through a four-part quality control program:

1. Raw material testing




Testing levels and specifications for each of the above programs have been established statistically, based on actual historical data to ensure the customer receives a uniform quality product which will perform dependably under field conditions.


www.orica.com



Health and SafetyWear suitable protective clothing, gloves and eye/face protection:

• In case of contact with skin remove contaminated clothing and immediately wash with soap and water, seek medical attention if skin irritation persists

• In case of contact with eyes, flush with copious amounts of water and seek medical assistance

• If inhaled remove from exposure and seek medical advice if effects persist

• If ingested wash out mouth with water and obtain medical attention

For further information see the relevant material safety data sheet, copies of which are available on our website.

Additional InformationOrica offer a comprehensive range of strata control products, all of which have been developed after extensive research and testing on a global scale via our international network of operations. These products include:

• Resin anchor systems

• High yield grouts and foams

• High volume output grouts

• Monolithic chock systems

• High performance cable bolt grouts

• Polyurethane resin systems

• Binder systems and accelerators for backfilling

• Pre-packaged high build spray

cements

• Sprayable coatings for ventilation control

• Water stop grouts

• Ventilation formwork systems including: meshblock, gunmesh, tecmesh and tecplastic

• Grout mixers and batchers both air and hydraulically operated

• Contract installations

• Flexible membranes for strata support and waterproofing applications

If further information is required consult Orica.

Cap

sule

Len

gth

(m

m)

2,000

1,800

1,600

1,400

1,200

1,000

800

600

400

2,200

25 mm nominal diameter capsule with 22 mm core diameter bolt Theoretical encapsulation + 10%

Bolt Length (mm)

1.2 m 1.5 m 1.8 m 2.1 m 2.4 m 3.0 m561680804

714866

1,023

8671,0511,243

1,0201,2371,462

1,1721,4221,681

1,4781,7932,120

27 mm Hole28 mm Hole29 mm Hole


Quick-Chem™ is a patented system developed to remotely install resin capsules into boreholes for rock bolting.

The Quick-Chem™ system has been developed to mechanically install resin capsules where hand installation is not safe or practical. Historical methods of hand installation from man baskets etc. into boreholes in high headings have now been eliminated by an extremely safe and simple system.

Quick-Chem™ consists of purpose designed retaining caps (which are attached to resin capsules) and insertion tubes. The insertion tubes consist of a specific diameter tube and R32 threaded adaptor.

The tubes are fitted into the drifter of development Jumbos. Caps are fitted to the resin capsules and inserted into the tubes. The jumbo boom is then used to insert the tube and resin capsules undamaged to the back of the hole. Orica has developed the Lokset™ TOOSPEEDIE™ X2 range of resin capsules for exclusive use with the Quick-Chem™ system, and Quick-Chem™ caps are supplied in the boxes with the resin capsules. The joined resin capsule system eliminates the requirement for multiple capsules and hole insertions.

Technical Data

Quick-Chem™ Tube Size Tube ID Tube ODTotal Length (including adaptor)

26 mm (and 25 mm) 26.8 – 27.5 mm 31.4 – 31.8 mm 3.15 metres

30 mm 30.35 – 30.85 mm 33.5 – 33.75 mm 3.15 metres

36 mm 36.3 – 36.8 mm 40.75 – 41.25 mm 3.75 metres

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Quick-Chem™ Resin Capsule Insertion System

Advantages• Safe and simple system, suitable for any

remote installation

• Available in various lengths and diameters

• Clear tube enables visual confirmation of resin capsule position

• Up to 200 hole insertions is possible with each tube

• Insertions are completed from under supported ground

• Quick and efficient installation method

• Caps are supplied inside the resin capsule boxes

Mine Mesh provides surface support coverage to loose rock between installed rock bolts in underground mining excavations.

Orica is an exclusive Australian distributor of ASW mine mesh and has supplied both welded mesh and AUSRO straps to mining customers throughout Australia since October 2008. ASW mine mesh is manufactured in Australia to strict quality control guidelines and relevant Australian Standards and product conformance certificates are available on request.

Multiple configurations of mesh are available including numerous sheet sizes, apertures, wire diameters and black or galvanised wire.

Specific mesh products are available to suit metal mining and coal mining requirements. ASW manufactures mine mesh for Orica at their Sydney facility. ASW’s manufacturing capacity, facilities and quality control standards have been thoroughly evaluated by Orica in accordance with our AS/NZS ISO9001:2000 accredited quality system.

Mine Mesh

Testing Standards

Mesh Manufacture AS4671

Welding AS1304 – 1991

Galvanising AS2423

Destructive Test Frequency

Every 500 sheets

Non-destructive Test Frequency

Every 25 Sheets

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Technical Data: Weld MeshSheet Size (mm)

Wire Diameter (mm)

Aperture (grid spacing – mm)

Black or Galvanised

Weight per Sheet (kg)

Wire Tensile strength MPa

Break Force of Weld

1500 x 1200 3.15 100 x 100 Black 2.4 500 – 650 2.5 kN

1700 x 1200 4.0 100 x 150 Black 3.6 500 – 650 4.7 kN

1700 x 1200 4.0 100 x 100 Black 5.4 500 – 650 4.7 kN

3000 x 2400 4.0 75 x 50 Galvanised 24.3 500 – 650 4.7 kN

1700 x 4000 5.6 100 x 100 Galvanised 30.0 500 – 650 9.5 kN

3000 x 2400 5.6 100 x 100 Galvanised 30.0 500 – 650 9.5 kN

3000 x 2400 5.6 100 x 100 Black 30.0 500 – 650 9.5 kN

4500 x 1700 5.6 100 x 100 Galvanised 33.0 500 – 650 9.5 kN

4000 x 2400 5.6 100 x 100 Galvanised 40.0 500 – 650 9.5 kN

4500 x 2400 5.6 100 x 100 Galvanised 44.0 500 – 650 9.5 kN

6000 x 2400 5.6 100 x 100 Galvanised 60.0 500 – 650 9.5 kN

2400 x 1500 4.0 100 x 100 Galvanised 15.0 500 – 650 4.7 kN

3000 x 1700 5.6 100 x 100 Galvanised 22.0 500 – 650 9.5 kN

6000 x 1700 5.6 100 x 100 Galvanised 43.0 500 – 650 9.5 kN

Technical Data: AUSRO Strap

Length (mm)

Width (mm)

Line Wire Diameter (mm)

Cross Wire Diameter (mm)

Line Wire Spacing (mm)

Cross Wire Spacing (mm)

Material Yield Stress (Mpa) Weight/m

Transversal Load Capacity (kN)

Longitudinal Load Capacity (kN)

3000 300 10 6.3 75 155 >500 4.1 >30 >130

3500 300 10 6.3 75 155 >500 4.1 >30 >130

4000 300 10 6.3 75 155 >500 4.1 >30 >130

5800 300 10 6.3 75 155 >500 4.1 >30 >130

6000 300 10 6.3 75 155 >500 4.1 >30 >130

Page 2 of 2Mine Mesh

AdvantagesSelection of the appropriate cement anchoring grout can provide many of the following advantages:

• rapid strength gain

• excellent pumpability

• durability of high strength and low porosity for long term life

• resistance to high saline and acidic ground water

• shrinkage compensated

• chloride free

Orica commenced the development and manufacture of a range of specially designed rapid strength cable bolt grouts in the mid 1980’s.

With the help of a global research and development resource base, this product range has grown and diversified into a comprehensive group of products for general and specific bolting applications in coal mining, metal mining and tunnelling. In addition to cable bolt grouting, this product range is also used for general strata injection and consolidation applications.

Orica’s cement anchoring range includes products suitable for all forms of manual and mechanised cable bolt grouting. Products have been developed for a range of applications including thixotropic grouting, long distance pumping, water stop grouting and rapid advance drill and blast development. The development of specific purpose designed grout products is also possible to suit unique applications. The development of many now routine Orica cable bolt grouts commenced with the requirement to satisfy a unique application.

All products are supplied pre-blended and pre-packaged requiring only the addition of set amounts of water in a high shear mixer to produce high

quality grouts. All grout formulations include a non-shrink expansion compensation system. Orica grouts are available in either 1.2 tonne bulk bags, or 20 kg High Wet Strength (HWS) multi wall plastic lined paper bags. Orica’s 20 kg HWS paper bags have been aggressively evaluated to confirm their superior performance to traditional stitched or glued plastic bags in relation to strength, durability and moisture absorption. All grouts are supplied on shrink wrapped 2,000 kg rated pallets.

Full training procedures exist for the application of all Orica Cement Anchoring products and comprehensive training and assessment by qualified Orica representatives is available to all customers. It is highly recommended that the individual product training procedure be reviewed prior to the application of any Orica cement grout. In addition, on site quality control programs can be specifically developed and managed to suit individual customer requirements, ensuring the consistent quality of placed grout.

Anchoring Grouts

Orica’s comprehensive range of cement anchoring grouts includes the following:

Stratabinder HSHigh strength grout for bottom up cable bolt grouting. Bolt hole collar will need to be plugged or sealed prior to grout pumping.

Stratabinder HS Slow SetHigh strength low viscosity grout for maximum strata penetration which remains workable for several hours.

Conbex™ HESHigh early strength cable bolt grout for rapid advance development. Bolt hole collar will need to be plugged or sealed prior to grout pumping. Excellent resistance to high saline and acidic ground water. Product must be continuously mixed to avoid premature setting.

Conbex™ HTLong life thixotropic grout for use on mechanised cable bolt rigs. High early strength cable bolt grout for rapid advance development. Excellent resistance to high saline and acidic ground water. Product must be continuously mixed to avoid premature setting.

Conbex™ HFDual shrinkage compensated rapid set high strength grout, conforming to ASTM C1107.

FB400High strength thixotropic grout for top down cable bolt grouting that is also available including a migrating corrosion inhibitor (FB400C). FB400C should not be used in areas where ground water contains high Chloride concentrations.

Conbex™ UWPWater resistant cement grout for wet hole bolting and strata injection.

Capcem 60 CapsulesCement grout capsules for non-mixing/pumping bolt applications. Available in various lengths and diameters. Capsule skin is designed to absorb water into grout to eliminate mixing.

Product Specifications (Typical Results)

Product Family Name

28 day Flexural (MPa)

UCS 2 hours(MPa)

UCS 4 hours(MPa)

UCS 6 hours(MPa)

UCS 1 Day (MPa)

UCS 7 days(MPa)

UCS 28 days(MPa)

Stratabinder HS 9.9 – – – 50 75 100

Stratabinder HS Slow Set 6.0 – – – 12 32 39

Conbex™ HES 7.0 20 40 50 60 75 80

Conbex™ HT 5.3 14 31 33 48 54 62

Conbex™ HF 10.0 – 46 – 67 75 93

FB400 7.1 – – – 40 74 85

FB400C 7.1 – – – 40 74 85

Conbex™ UWP – – – – 25 44 53

Anchoring Grouts Page 2 of 3

Product Specifications (Typical Results)

Product Family NameWater per 20 kg bag (litres)

Yield per 20 kg bag (litres)

20ºCSet Time

Stratabinder HS 6 – 8 12.5 7 hours

Stratabinder HS Slow Set 9 14 8 hours

Conbex™ HES 4 11.4 1 hour

Conbex™ HT 5 – 6 12 – 13 80 minutes

Conbex™ HF 3.0 – 3.8 10.5 25 minutes

FB400 6 – 8 15 7 hours

FB400C 6 – 8 15 7 hours

Conbex™ UWP 3.6 – 4 12 5.5 hours

Quality ControlThe superior quality of Orica cement anchoring grouts is assured through a four-part quality control program:





All quality control testing is completed by trained personnel using industry recognised equipment, regularly calibrated by an independent and authorised testing company in accordance with Orica’s quality management system.

Water QualityAll Orica cement grouts are tested with and should be used with potable water. If water quality is of concern for any proposed application, a 20 litre sample of the intended water should be sent to Orica’s Nowra laboratory for grout comparison testing. This testing will confirm the compatibility for use with the selected Orica grout and ensure that the design specifications of the grout can be achieved.

Storage

Shelf LifeOrica cement grouts have a shelf life of 12 months when stored in dry conditions. High temperature and high humidity may reduce the shelf life.

Storage ConditionsOrica cement grouts should be stored in original packaging under dry warehouse conditions. If grouts are to be stored underground they should be stored in a dry area, free from water ingress.

Health and SafetyOrica cement grouts are non-toxic and non-flammable.

• Irritating to respiratory system and skin

• Risk of serious damage to eyes

• Do not breath dust, use suitably approved dust mask

• Avoid contact with skin and eyes

• In case of contact with eyes, rinse immediately with plenty of clean water and seek medical advice

• After contact with skin, wash immediately with plenty of clean water

• Wear suitable protective clothing, gloves and eye/face/breathing protection

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Anchoring Grouts Page 3 of 3

Carbothix™ is an instantly thickening fast curing two component silicate resin for high strength bonding of solid bolts and cable anchors.

Carbothix™ was developed to improve the productivity of ground support installation in underground mining and tunnelling applications. Using the pumpable resin enables load to be taken up in minutes rather than the typical 24 hours from cementitious grouted systems. Typical applications of Carbothix™ include grouting of cable bolts, solid steel or GRP bolts, self drilling anchors and one-step bolting systems.

During application, the two components of Carbothix™ are intimately mixed and achieve a grease-like viscosity (the so called Thix effect) so that the grout stops flowing and cures to form a tough elastic and non-porous resin that will not mix with water or be diluted in wet holes. As the system is under pump pressure,

some grout is pushed into minor cracks and fissures around the anchor hole, ensuring full encapsulation of the anchor is achieved.

Different versions of Carbothix™ are available to suit the various mine site environmental conditions and desired load capacities.

As the two resin components are mixed at a set volume, consistent mixing of the grout is guaranteed, an advantage over cementitious grouts. This delivers a reliable quality of grout and anchoring performance. Operator safety and handling issues are also improved over cement grout systems.

As a pumpable resin system, Carbothix™ can be handled over long distances (up to 500 m) improving operational flexibility.

Technical Data

Component A Component B Standard

Density KG/M2 1445 +/- 50 1150 +/- 25 DIN 12 791

Colour Light brown Dark brown / red tinge –

Flash point oC – > 140 DIN 53 213

Viscosity @ 25oC mPas 320 – 420 250 – 350 ISO 3219

Carbothix™ Resin Anchoring Grout

Benefits of Carbothix™: • Immediate loading capacity

• Faster re-entry and support installation

• Full encapsulation of anchors

• Improved operator safety

• Consistent grout quality

• Resistance of grout to water

• Longer shelf life than resin capsules

• Ease of storage

• Long distance pumping

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Tests performed at 22ºC

Ratio A:B1:2

Punched Shear Strength (MPa)

3 mins 5

5 mins 14

1 hour 25

Gel Time (secs) 10

Cure Time (Penetrometer hardness test) (secs) 33

UCS (MPa)1 hour 70

24 hours 75

Store D

Hardness

2 mins 42

5 mins 55

10 mins 62

30 mins 70

Note: The properties listed are an indication only, they may vary with temperature, mining conditions, strata conditions, equipment, bolt hole annulus, injection quantity etc.

PackagingAll forms of packing are approved to the relevant dangerous goods regulation.

Carbothix™– Component A

20 litres per steel pail (weight 24 kg)

Carbothix™– Component B

20 litres per steel pail (weight 19 kg)

Other packing options are available on request.

Storage and Shelf-LifeShelf life of Carbothix™ is at least six months from the date of delivery or twelve months from the date of production when stored in a dry place. If this time is exceeded, it is recommended to have the material checked by Orica for compliance with specification.

It is also recommended that Carbothix™ is stored at <25°C and achieves that temperature before use. Storage should be away from humid environments and away from direct sunlight.

ProcessingThe two components are pumped by a dual component SK90 gear pump, usual volume flow of 4-6 litre/minute, at the volumetric ratio of 1:2 and mixed thoroughly in a specific static mixer.

Health and SafetyCarbothix™ contains substances that may be an irritant to some persons. Orica strongly recommends that the individual Material Safety Data Sheet and operating procedures are thoroughly reviewed prior to handling or use , copies of which are available on our website.

Orica recommends disposing of liquid residues and empty drums in an authorised incineration plant. Cured resin product can be disposed of in domestic waste landfill area.

Carbothix® Resin Anchoring Grout Page 2 of 2

Orica manufactures and supplies an extensive range of sprayed coating and sealing systems for use in a large range of applications in mining and civil engineering, including a range of dry bagged shotcretes and specially developed plaster.

Products and systems include Fastshot™ for structural sprayed support, Rappas™ for applications requiring abrasion and impact resistance and Sprayplast for low strength and cost sensitive applications.

All products are supplied pre-blended and pre-packaged requiring only the addition of set amounts of water with appropriate equipment to produce high quality products. Orica products are available in either bulk bags, or 20 kg High Wet Strength (HWS) multi wall plastic lined paper bags. Orica’s 20 kg HWS paper bags have been aggressively evaluated to confirm superior performance to traditional stitched or glued plastic bags in

relation to strength, durability and moisture absorption. All grouts are supplied on shrink wrapped 2,000 kg rated pallets.

Full training procedures exist for the application of all Orica Sprayed Systems and comprehensive training and assessment by qualified Orica representatives is available to all customers. It is highly recommended that the individual product training procedure be reviewed prior to the application of any Orica product. In addition, on site quality control programs can be specifically developed and managed to suit individual customer requirements, ensuring the consistent quality of placed product.

Orica’s comprehensive range of sprayed cement systems includes the following:

Rappas™

Abrasion and impact resistant high performance concrete and dry sprayed shotcrete.

Fastshot™

High build, minimum rebound, dry sprayed shotcrete.

SprayplastRapid hardening, single component sprayable coarse plaster for surface support and ventilation sealing applications (water proofing agent available for use with plaster).

SP100™

High build, wet mix, sprayable cementitious sealant used for temporary ventilation stoppings.

Sprayed Cement Systems

Individual Product Information

Fastshot™

Fastshot™ is a high build general purpose sprayable cement based shotcrete, specially designed with low rebound and low dust for dry sprayed shotcrete applications.

• High build, up to 150 mm in one pass

• Minimum rebound, reduced waste

• Non-caustic admixtures, safe to handle

• Chloride free

• Fibre reinforced option available

UCS at 20ºC MPa

1 day 20

2 days 30

7 days 40

28 days 60

Thickness (cm) kg per m2

4 85

6 128

8 170

9 212

Sprayplast/Sprayplast UWSprayplast is a rapid hardening, single component, product used primarily in the construction of rated ventilation structures and scat control using dry shotcrete application equipment.

• High build and high yield

• High early strength development

• Minimal respirable dust content

• Natural product, gypsum based, non-flammable and non-toxic

• Quickly self supporting due to rapid set

• Can be sprayed onto almost any surface with minimal rebound

• Designed and live tested explosion rated 2 psi and 5 psi ventilation stoppings

• 75 mm thickness will provide over 1 hour fire protection rating to AS 1530.4-1997

• Water absorption is < 3% (Sprayplast UW at 28 days)

Strength 7 MPa within 1 hour

Dry Strength 18 MPa at water:powder ratio of 0.5:1.0

Tensile Strength 2.8 MPa

Yield (1 tonne) 0.75 M3 at WP ratio 0.45:1

Should not be used below 5ºC

SP100™

SP100™ has been designed as a high build wet mix sprayable cementitious sealant, used for ventilation stoppings, overcast and general sealing, repair work.

• Convenient – easy to use, just add water

• Easily applied – high build capability in one pass

• Good flowability – easily pumped without blocking hoses

• High strength – reinforced to reduce cracking

• Minimum rebound and dust

• Non-caustic admixtures – safe to handle

• Chloride free

Pumping Life @ 25ºC (hours) 2

Drying Time @ 25ºC (hours) 12

UCS @ 1 day 5 MPa

UCS @ 7 days 11 MPa

UCS @ 28 days 14 MPa

Wet Density 1,300 kg/m3

Yield (per 20 kg bag) 18 litres

Water requirement (per 20 kg bag) 4 litres

Sprayed Cement Systems Page 2 of 3

Rappas™

Rappas™ is a high strength abrasion and impact resistant dry or wet mix shotcrete, specially designed for lining ore passes, draw points, crushers, chutes and other areas subjected to heavy and frequent equipment impact. A trowellable version is also available for concrete floor repairs.

• High early strength

• Excellent abrasion resistance

• Excellent impact resistance

• Minimum rebound

• Chloride free, non-corrosive to steel

• Flexural strength, independently tested to AS 1012.8.2 @ 28 days cure 8 MPa

• Yield: 611 litres per 1.2 tonne of Rappas™

• Typical peak exotherm of 100 x 100 x 50 mm sample: 48ºC

• Typical wet density: 2,200 kg/m3

Abrasion Resistance Testing – typical Chaplin rotation disc abrasion test results (complying with BS 8204:1987 – part 2). Independently tested at 28 days cure. Results are available on request.

• Rappas™ – 0.17 mm abrasion

• 36 MPa Concrete – 0.51 mm abrasion

Impact Resistance Testing – four 220 g cubes tumbled for 10 minutes at 17 rpm in Y shaped rotating drum mixer containing seven 130 g steel balls. Samples cured for 28 days prior to testing.

• Rappas™ – 3.18% weight loss

• 36 MPa Concrete – 6.39% weight loss

Water QualityAll Orica plaster and cementitious sprayed systems are tested with and recommended to be used with potable water. If water quality is of concern for any proposed application, a 20 litre sample of the intended water should be sent to Orica’s Nowra laboratory for grout comparison testing. This testing will confirm the compatibility for use with the selected Orica product and ensure that the design specifications of the grout can be achieved.

Storage

Shelf LifeOrica plaster and cementitious sprayed systems have a shelf life of 12 months when stored in dry conditions. High temperature and high humidity may reduce the shelf life.

Storage ConditionsOrica sprayed systems should be stored in original packaging under dry warehouse conditions. If products are to be stored underground they should be stored in a dry area, free from water ingress.

Health and Safety• Orica plaster and cementitious

sprayed systems are non-toxic and non-flammable








• Refer to individual MSDS for further information

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Rappas™ GD Rappas™ C/GW Rappas™ CF

UCS @ 20ºC – 2 hours 29 MPa N/A 15 MPa

UCS @ 20ºC – 4 hours 41 MPa N/A 26 MPa

UCS @ 20ºC – 1 day 55 MPa 61 MPa 62 MPa

UCS @ 20ºC – 7 days 67 MPa 71 MPa 72 MPa

UCS @ 20ºC – 28 days 90 MPa 87 MPa 87 MPa

Typical pot life @ 20ºC 20 minutes 2 hours 40 minutes

Rappas™ GD Dry mix shotcrete

Rappas™ GW Wet mix shotcrete

Rappas™ C Concrete mix

Rappas™ CF Fast setting concrete mix

Sprayed Cement Systems Page 3 of 3

Orica manufactures and supplies an extensive range of sprayed support and sealing systems for use in a large range of applications in mining and civil engineering, including Tekflex™ (TSL – Thin Spray-on Liner).

Tekflex™ was developed in Australia in 1999/2000 for specific use as an alternative to the use of steel mesh for scat control in underground mining excavations. Since that time Tekflex™ has been successfully applied in a large range of applications in mining and civil construction.

Tekflex™ is safe to handle and apply using conventional systems and can be hand applied or mechanically applied. No specific ventilation requirements are necessary for the application of Tekflex,™ with only conventional PPE required.

Tekflex™ provides several benefits over the use of steel mesh including:

• Sealing of the rock surface against weathering

• Not effected by corrosion

• Active surface support rather than passive support

Tekflex™ has been successfully used over the past 9 years for applications including:

• Rock surface support and scat control in development roadways

• Rock surface sealing and support in escape ways and ventilation shafts

• Water sealing for seasonal water ingress

• Sealing of ventilation devices to improve efficiency

• Longwall face support for install and take-off roadways

• Tunnel lining between shotcrete/concrete layers

Full training procedures exist for the application of all Orica Systems including Tekflex™ and comprehensive training and assessment by qualified Orica representatives is available to all customers.

It is highly recommended that the individual product training procedure be reviewed prior to the application of any Orica product. In addition, on site quality control programs can be specifically developed and managed to suit individual customer requirements, ensuring the consistent quality of applied products.

Product InformationTekflex™ is a high strength cement based TSL (Thin Spray on Liner) specially designed to permanently stabilise the integrity of rock structures whilst accommodating the stresses associated with strata movement and providing a barrier to moisture degradation.

• Available in black or white

• Excellent tensile strength with high flexibility maintains coating integrity

• Excellent adhesion to rock surface assures long life coating

• Easily applied using standard equipment

• Non-toxic and non-flammable

• No unusual storage or ventilation requirements during application, clean up or waste disposal

Pumping Life @ 20ºC 25 – 30 minutes

Initial Set Time 50 – 60 minutes

Tekflex™

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Surface PreparationAll surfaces should be cleaned down prior to the application of Tekflex™. This is normally achieved with the use of water to remove surface debris and dirt. It is important that any water to be used for surface preparation be free of contaminants such as oils and lubricants.

YieldOne bag and two pails produces 14 m2 of a 4 mm thick coating.

Storage

Shelf LifeTekflex™ has a shelf life of 12 months when stored in dry conditions. High temperature and high humidity may reduce the shelf life.

Storage ConditionsTekflex™ should be stored in original packaging under dry warehouse conditions. If products are to be stored underground they should be stored in a dry area, free from water ingress.

Health and Safety• Tekflex™ is non-toxic and

non-flammable








• Refer to individual MSDS for further information

Tekflex™Page 2 of 2

Dust is a genuine health concern for people and livestock and a general safety and environmental hazard. The control of dust is a serious issue for mining and infrastructure projects operating near or within areas of primary production, community and protected areas.

The control of dust, typically by the topical application of water, can be a costly and disruptive process that can on hot dry days be only effective for a limited time period.

RD10 is a water soluble non hazardous emulsion that is specifically designed for:

• Soil stabilisation

• Soil solidification

• Erosion control – stock piles

• Suppression of dust

RD10 is environmentally friendly and can be applied through either topical means or mixed in with the soil.

The application of RD10 is completed by adding a percentage of the product to the water being used to control dust. Any water source can be used as the water is simply a carrier for the RD10 agent. Depending on the application various rates of RD10 can be used.

Properties

Physical Form Liquid

Colour Milky White

Odour Mild

Freezing Point <0ºC

Solubility in Water 100%

pH 4.5 – 6.0

Specific Gravity 1.05 – 1.10

RD10 Dust Control

Advantages• Environmentally friendly and

biodegradable

• Dries clear and odourless

• Is water resistant once cured (will not wash away)

• Non flammable and non toxic

• Non corrosive and non tracking or transferable (will not collect on vehicle tyres)

• UV and alkaline soil resistant

• Single product suitable for a variety of applications

• No unusual storage or ventilation requirements during application

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YieldSee below dilution and application rate based on requirements.

Topical Application

Litres per m2 RD10 Concentrate + parts water

Litres per m2 RD10 Dilution

Unpaved Heavy Haul Roads 0.75 5 4.5

Unpaved Roads Heavy Traffic 0.70 6 4.9

Unpaved Roads Light Traffic 0.60 7 4.8

Trails and paths 0.50 8 4.5

Slope erosion control 0.40 3 1.6

Stock Pile Dust control 0.20 9 2.0

Dust control 6 months 0.10 13 1.4

Dust control 12 months 0.15 10 1.6

Pack sizeRD10 is supplied in 200L (220 kg) drums. All drums are supplied strapped to wooden pallets.

Application Instructions

Preparation of siteThe site should be completely dry and free from water for a period of 72 hours following RD10 application.

The site should be compacted to a minimum of 95% and contoured to allow for proper drainage. If the site is very dry pre-wetting may be required at a rate of 1 L of water per 2.5 m² to break the ground surface tension and allow better RD10 penetration.

Any loose aggregate should be removed from the application area.

Preparation of equipment Set spray nozzles to the desired height, width and output rate. The spray nozzles should provide an even coat with each pass.

The spray rate should be set to allow for even coverage with multiple coats to avoid RD10 from draining away.

A suitable release agent can be used to prevent RD10 overspray from bonding to equipment.

Preparation of RD10 dilutionFill application equipment with recommended volume of water.

Add the recommended volume of RD10 to the water.

Note: adding water to the RD10 will result in foaming.

Application of RD10 dilutionApply the RD10 diluted solution in even coats over application site. Generally 4 – 5 even coats should be sufficient.

Each successive coat should be applied whilst the application area is still wet otherwise a skin layer will form without soil penetration.

Allow site to completely cure for a minimum of 6 hours and preferably 24 – 72 hours before allowing traffic access. The longer the product has to cure prior to traffic movement the longer the durability of the application.

After 3 – 6 months following initial application a further application of RD10 at 30% of the initial concentration level can reactivate the surface.

CleaningRinse off equipment with water until clean. If RD10 has been allowed to cure a hot pressure washer or surface scrubbing may be required.

Storage

Shelf LifeRD10 has a shelf life of 12 months.

Storage ConditionsRD10 should be stored in a cool, dry and well ventilated area out of direct sunlight. Avoid high temperatures (store below 50°C) and freezing conditions (store above 0°C).

Health and SafetyRD10 is non-toxic and non-flammable.

For further information see the relevant Material Safety Data Sheet, access to which is available on the Orica website: www.orica.com.au

Page 2 of 2RD10 Dust Control

Orica are the global leader in the development, manufacture and supply of chemical strata injection and cavity filling products and systems.

Strata injection chemicals have been successfully used throughout the global mining and tunnelling industries for many decades to consolidate fractured strata and prevent the ingress of water. Chemical foams have been used for almost 10 years to rapidly fill cavities in underground mining and tunnelling applications.

Orica has over 40 years experience in the development, manufacture and application of these style of products, including more than 20 years in the provision of specialist contract application services in Australia. Orica employs a qualified team of experienced technical personnel who work exclusively on product development of strata injection and cavity filling chemicals. All Orica’s Strata Injection and Cavity Filling chemicals used in coal mines hold the German Authority permit (LOBA compliant), an Internationally accepted standard for the safe and correct manufacture and application of these systems. In addition to products, Orica’s contract services division maintains a large fleet of application equipment including pumps, hoses, equipment/material PODS and injection consumables.

Strata injection applications are routinely conducted to stabilise longwall faces in underground coal mines and prevent falls of ground during production. These applications can be undertaken

as a preventative measure prior to mining or subsequent to mining when poor strata conditions are encountered. Polyurethane products can be injected under high pressures and consequently have a long and successful history in the prevention of water ingress of varying magnitudes into mine or tunnel excavations.

Cavity filling resin systems are used to rapidly fill underground voids where timing is critical. Applications are regularly carried out to fill cavities resulting from roof collapse above longwall mining supports and in development roadways. Cavity filling is also carried out behind steel sets and arches to stabilise the ground and prevent movement, and many other general underground applications. Orica’s foaming resin systems require minimal if any containment formwork and can be placed at a rate of up to 50m3 per hour.

Orica maintains product stock, equipment, and several teams of designated trained and highly experienced full time personnel, available at short notice to complete emergency strata injection, water stopping and cavity filling applications. All equipment and processes are fully risk assessed and industry standard safe operating procedures (SOP’s) exist for all materials, equipment and applications techniques.

Strata Injection and Cavity Fill Chemicals

Strata Injection ChemicalsOrica’s comprehensive range of Strata Injection Chemicals includes Polyurethane (PUR), Silicate and Phenolic based systems. All systems are LOBA and NSW DII licensed and are consequently approved for injection in underground coal mines.

Bevedol™/Bevedan™

Two component foaming PUR injection system for consolidation, stabilisation and sealing of highly convergent wet or dry strata.

CarbomineExtremely fast reacting two component alkaline phenolic resin injection system with high bond strength for solidification of dry or slightly moist strata.

Geoflex™

Non foaming two component silicate injection system with extremely high bond strength for strata injection, sealing of injection anchors, and stabilisation of debris.

Advantages Bevedol™ / Bevedan™

• A variety of grades to suit numerous application situations

• Low viscosity allowing good penetration into small fissures

• Excellent adhesive strength forming strong bond with strata

• Quick reaction time to reduce migration and loss of material

• Yields to ground pressure, accommodating subsequent movement

• High mechanical resistance gives improved support of strata

• Consolidates brittle and fractures wet and water bearing strata

• Seals against water with hydrostatic pressure

Carbomine• Very low exothermic reaction

• Low viscosity allowing good penetration into small fissures

• Excellent adhesive strength forming strong bond with strata

• No exothermic reaction when in contact with water

• Common application equipment (Carbofill™)

Geoflex™

• Rapid reaction and strength development

• High adhesive strength after 1 hour

• Low exothermic reaction

• Fire resistant

• High elasticity

Typical PropertiesBevedol™ (PUR S component A)

Bevedan™ (PUR S component B)

Bevedol™ (PUR WF component A)

Bevedan™ (PUR WF component B)

Carbomine component A

Carbomine component B

Geoflex™ component A

Geoflex™ component B

Density @ 25ºC 1.03 g/cm3 1.23 g/cm3 1.03 g/cm3 1.23 g/cm3 1.29 g/cm3 1.05 g/cm3 1.48 g/cm3 1.14 g/cm3

Colour honey dark brown honey dark brown dark brown/red light brown colourless brown

Viscosity @ 25ºC

280 ±40 mPas

210 ±70 mPas

280 ±40 mPas

210 ±70 mPas

170 ±30 mPas 10 ±2 mPas 260 ±40

mPas150 ±30 mPas

Flash Point 200ºC 200ºC 200ºC 200ºC N/A 100ºC N/A >100ºC

Mix Ratio 1 : 1 1 : 1 4 : 1 1:1

Foam Factor 1.7 – 5.0 1.0 Non-foaming Non-foaming

Maximum Temperature of Reaction

100 – 150ºC 100 – 150ºC 40 – 50ºC 80 – 90ºC

Adhesive Strength

> 3 MPa

(unfoamed)> 3 MPa 7.3 MPa 5.8 MPa

Flexural Strength

90 MPa

(unfoamed)90 MPa N/A N/A

Compressive Strength 20 MPa

80 MPa

(unfoamed)N/A N/A

Tensile Strength

45 MPa

(unfoamed)

45 MPa

(unfoamed)N/A N/A

Modulus of Elasticity @ 7 days

N/A N/A N/A 250 MPa

Reaction Time @ 25ºC 80 seconds 30 seconds 120 seconds 225 seconds

Strata Injection and Cavity Fill Chemicals Page 2 of 4

Storage, Packaging, Shelf Life

Packaging Storage Shelf Life

Bevedol™ (PUR Part A) 20 litre or 205 litre White Steel Drum

1,000 litre IBC Cool, dry and ventilated area, away from direct sunlight, between 5ºC and 40ºC

12 months when stored as per instructions

Bevedan™ (PUR Part B) 20 litre or 205 litre Blue Steel Drum

1,000 litre IBC As above As above

Cabomine (Part A) 20 litre or 205 litre Steel Drum Cool, dry and ventilated area, away from direct sunlight, between 5ºC and 20ºC


Cabomine (Part B) 20 litre or 205 litre Steel Drum As above As above

Geoflex™ (Part A) 20 litre or 205 litre Steel Drum Recommended between 10ºC and 30ºC, Note that frost may damage Component A (flocculation)


Geoflex™ (Part B) 20 litre or 205 litre Steel Drum As above As above

Cavity Fill ChemicalsOrica’s range of foaming cavity filling chemicals includes Silicate and Phenolic based systems. All systems hold the German Authority Permit (LOBA compliant).

Carbofill™

Instant foaming two component phenolic resin system for the filling of cavities in underground roadways and longwalls for stabilisation and the prevention of gas accumulation. NSW Injection Licence granted.

GeofoamRapidly reacting and strongly expanding two component urea silicate resin system

for immediate stabilisation via strata injection or cavity filling applications.

AdvantagesCarbofill™

• Rapid reaction time minimises formwork requirements

• High foam factor (low product consumption for transport and handling)

• Low reaction temperature

• Fire resistant

• Can be used to form temporary ventilation seals

• Long shelf life under correct storage conditions

• Low formaldehyde emissions during product reaction

• Rapid placement speed

• Common application equipment (Carbomine)

Geofoam• Extremely fast reaction time minimises

formwork requirements

• Dual purpose system (strata injection and cavity filling)

• High foam factor (low product consumption for transport and handling)

• Injection against water flow possible

• Low reaction temperature

Typical Properties

Carbofill™ component A

Carbofill™ component B

Geofoam component A

Geofoam component B

Density @ 25ºC 1.29 g/cm3 1.54 g/cm3 1.45 g/cm3 1.22 g/cm3

Colour beige-pink blue-black dark brown brown

Viscosity @ 25ºC 200 – 400 mPas >100 mPas 270 ±70 mPas 140 ±15 mPas

Flash Point N/A N/A N/A 200ºC

PH Value 8 – 9 0 – 1 N/A N/A

Mix Ratio 4:1 (pbv) 1:1

Foam Factor 32 – 38 15 – 30

Maximum Temperature of Reaction <90ºC N/A

Start of Foaming @ 25ºC < 10 seconds 20 seconds ± 10 seconds

End of Foaming @ 25ºC 190 seconds ± 50 seconds 45 seconds ± 15 seconds

Consumption (yield) 36 – 42kg’s/m3 N/A

Compressive Strength N/A N/A

Modulus of Elasticity @ 7 days N/A N/A


Application Limitations The application of all Orica Cavity Fill Chemicals must be performed by or under the guidance of Orica operators

who have been trained in accordance with Orica’s strata injection training manual to ensure the safe and efficient application of all systems.

Storage, Packaging, Shelf Life

Packaging Storage Shelf Life

Carbofill™ (Part A) 20 litre or 205 litre Steel Drum Should be stored at 5ºC – 8ºC 12 months when stored as per instructions. Shelf life will be reduced to 3 months when stored at 20ºC

Carbofill™ (Part B) 20 litre or 205 litre Plastic Drum Should be stored between 20ºC – 30ºC and away from materials stated in MSDS.


Geofoam (Part A) 20 litre Steel Drum Should be stored at 5ºC – 30ºC 12 months when stored as per instructions

Geofoam (Part B) 20 litre Steel Drum Should be stored at 5ºC – 30ºC 12 months when stored as per instructions

Note: It is recommended that Carbofill™ Part A be stored at a minimum 15ºC for 12 hours before processing.

In addition to the above packaging information, Orica’s full range of Cavity Fill Chemicals can be supplied in 200 litre drums or 1,000 litre IBC’s.

Health and SafetyOrica Strata Injection and Cavity Fill Chemicals contain various substances that can be harmful to individuals. Orica strongly recommends that the individual product MSDS be thoroughly reviewed prior to the handling or use of any Orica products.

DisposalFollow local regulations. We recommend disposing of liquid residues and empty drums in an authorized incineration plant. Cured product can be disposed of in a domestic waste landfill area.

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Orica High Volume Output Grouts are defined by the fact that considerably larger outputs are possible when mixing this range of products, compared to traditional cement grouts.

This is particularly beneficial in underground mining and tunnelling, as significantly less amounts of physical material are required to be transported into the mine or tunnel.

Originally developed in the UK, Orica commenced the domestic development and manufacture of these grouts to suit Australian mining conditions and requirements in 1989. In 2003 through a new company acquisition, Orica inherited an additional suite of grouts, which lead to a subsequent rationalisation of the combined product ranges. Orica’s High Volume Output Grout product range today is the most extensive in the world, offering products for a large range of routine and unique applications.

Orica High Volume Output Grouts have an extremely successful history of applications in Australia, which began with the construction of live tested explosion resistant coal mine ventilation seals. This developed further with the use of these grouts for general underground cavity filling, collapsed roadway recovery, backfilling behind steel sets and sidewall (rib) stabilisation. In 2001 successful applications commenced in Australian metal mines, using Orica grouts for rockfill consolidation and pillar replacement. This involved consolidating old backfilled stopes for the safe and successful removal

of remnant crown and rib pillars and to create false pillars in newly mined stopes. Specific information on these individual applications is available from Orica.

Orica’s product range consists of numerous foaming and non-foaming grouts, ranging in strength from 0.5 MPa to 25.0 MPa. Purpose designed placer pump units are used to continuously place the entire range of High Volume Output Grouts and hire and training in the safe and correct of these units is available from Orica.

All products are supplied pre-blended and pre-packaged requiring only the addition of set amounts of water to produce consistent quality grouts. Orica grouts are available in either 1.2 tonne bulk bags, or 20 kg High Wet Strength (HWS) multi wall plastic lined paper bags. Orica’s 20 kg HWS paper bags have been aggressively evaluated to confirm superior performance to traditional stitched or glued plastic bags in relation to strength, durability and moisture absorption properties. All grouts are supplied on shrink wrapped 2,000 kg rated pallets.

Full training procedures exist for the application of all Orica cement grout products and comprehensive training and assessment by qualified Orica representatives is available to all customers.

High Volume Output Grouts

Advantages• Rapid placement

• Quick strength gain

• Remote pumping

• Reduced formwork requirement

• Rapid gelling quickly seals leakage paths

• Quality controlled application

• Yields to ground pressure thereby reducing stress concentration

• Non shrinking and low alkalinity (safe to handle)

• Long distance pumping, up to 3 km (Hydropak)

It is highly recommended that the individual product training procedure be reviewed prior to the application of any Orica cement grout. In addition, on site quality control programs can be specifically developed and managed to suit individual customer requirements, ensuring the consistent quality of placed grout.

Orica’s comprehensive range of High Volume Output Grouts includes the following:

Tekseal™

Long life foaming grout used for ventilation seals and cavity filling.

FB200™

Low viscosity grout used for rockfill consolidation and ventilation seals.

Geofill™

Fast setting grout used for fall recoveries, sidewall (rib) stabilisation and cavity filling.

Rockfast – HydroblendFast setting low viscosity grout used for fall recoveries.

Rockfast – HydrofoamFast setting low strength grout used for short term cavity filling.

CMT GroutHigh strength grout used for standing supports (chock bags) and backfill applications.

CMT Grout Hi ThixHigh thixotropic grout used for backfilling and sidewall (rib) stabilisation in broken ground.

Rockfast – HydrosealFibre reinforced grout used for cavity filling and fall recoveries.

HydropakTwo component grout used for long distance pumping applications.

Technical Data

Product Family Name

Water to Powder Ratio

20ºC Gel Time (minutes)

Kg Powder per m3

Fresh Wet Density (kg/m3)

UCS1 Day(MPa)

UCS7 Days(MPa)

UCS28 Days(MPa)

Flexural Strength 28 days (MPa)

Tekseal™ 1:1 3 – 5 200 – 240 400 – 450 0.6 0.8 1.0 0.3

FB200™ 2:1

2.5:1

4 – 8

8 – 11

400 – 440

340 – 360

1200 – 1300

1160 – 1260

0.6

0.5

3.3

1.4

7.5

4.5

1.8

1.5

Geofill™ 2:1

2.5:1

1 – 2

2 – 2.25

420 – 430

340 – 350

1200 – 1300

1160 – 1260

3.4

2.5

3.9

2.8

5.0

4.0

–

–

Rockfast – Hydroblend™ 2.5:1

2:1

1.75:1

5 – 6

3 – 4

2 – 3

340 – 360

400 – 440

470 – 480

1200 – 1300

1220 – 1320

1250 – 1350

3.0

4.0

5.0

4.5

4.7

5.5

4.8

5.0

6.5

–

–

2.1

Rockfast – Hydrofoam™ 2.5:1 2 – 3 100 – 120 300 – 400 0.35 0.50 0.62 –

CMT Grout 2:1

1.5:1

1:1

12 – 15

9 – 11

4 – 7

415 – 425

535 – 545

735 – 745

1260

1340

1470

4.0

6.0

10.0

5.0

8.0

14.0

7.0

12.5

18.0

–

–

–

CMT Grout Hi Thix 2:1

1.5:1

1:1

12 – 15

9 – 11

4 – 7

415 – 425

535 – 545

735 – 745

1260

1340

1470

1.3

3.0

6.0

2.5

5.0

13.0

7.0

13.0

25.0

1.8

2.1

2.8

Rockfast – Hydroseal™ 1.8:1

1.5:1

1.2:1

7 – 8

2.5 – 3.0

2 – 2.5

480 – 500

560 – 590

640 – 680

1300 – 1500 2.8

3.5

5.3

3.1

4.7

6.5

3.7

5.0

7.9

–

Hydropak 2.5:1

2:1

1.75:1

8 – 12

6 – 8

5 – 6

345 – 355

420 – 430

470 – 480

1200 – 1300 5.1

8.0

9.0

6.0

8.5

6.0

6.1

9.1

11.3

–

High Volume Output Grouts Page 2 of 3

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Quality ControlThe superior quality of Orica High Volume Output Grouts is assured through a four-part quality control program:




4. Quality System Management to ISO 9001 AS/NZS ISO:9001

All quality control testing is completed by trained personnel using industry recognised equipment, regularly calibrated by an independent and authorised testing company in accordance with Orica’s Quality Management system.

Water QualityAll Orica High Volume Output Grouts are tested with and should be used with potable water. If water quality is of concern for any proposed application, a 20 litre sample of the intended water should be sent to Orica’s Nowra laboratory for grout comparison testing. This testing will confirm the compatibility for use with the selected Orica grout and ensure that the design specifications of the grout can be achieved.

Storage

Shelf LifeOrica cement grouts have a shelf life of 12 months when stored in dry conditions. High temperature and high humidity may reduce the shelf life.

Storage ConditionsOrica cement grouts should be stored in original packaging under dry warehouse conditions. If grouts are to be stored underground they should be stored in a dry area, free from water ingress.

Health and SafetyOrica cement grouts are non-toxic and non-flammable.








High Volume Output Grouts Page 3 of 3

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The word Orica and the Ring Device are trademarks of Orica Group Companies. Silent Seal is a registered trademark of FOMO USA.

Silent Seal®

Orica is an approved and exclusive Australian supplier of Silent Seal,® a multi purpose two-component expanding resin foam for rapid sealing applications.

Silent Seal® can be used for a large range of applications including sealing around ventilation structures, sealing cable bolts holes prior to grouting, small cavity filling and containment barriers in underground mining and tunnelling excavations.

Silent Seal® is supplied in ready to use packs including delivery hoses, spray gun and nozzles. Silent Seal® can be applied by simply opening the valves of the two separate component canisters, attaching a nozzle to the spray gun, directing the nozzle towards the intended application point and pressing the trigger.

Full training procedures exist for the application of Silent Seal® and comprehensive training and assessment by qualified Orica representatives is available to all customers. It is highly recommended that the individual product training procedure be reviewed prior to the application of any Orica product.

Silent Seal® is a multiple purpose expanding sealant designed as a quick and efficient air tight sealant used to insulate, fill and seal gaps and voids. Silent Seal® is a polyisocyanurate two-component foam, approved for

underground mine use (information available on request) and has an extremely low flame spread index of less than 25, based on independent ASTM E-162-87 test results.

Typical mine uses for Silent Seal® include ventilation sealing and borehole sealing.

• supplied as a ready to use pack, simply open the valves to begin

• can be sprayed onto any surface in any direction

• fully expands and tack free within seconds, cures in 1 hour

• expansion ratio (approximately) 8 to 1

• excellent coverage

• cured sealant is chemically inert, non-toxic and non-reactive in approved applications

• UV exposed surfaces must be coated to prevent degradation

• requires no power source to apply

• empty containers are fully disposable

• thoroughly shake containers before use

• theoretical yield 0.42 m3 per pack

Storage

Shelf LifeSilent Seal® has a shelf life of 12 months when stored in ideal conditions. Excessive heat can cause premature aging or components resulting in a shorter shelf life. Once opened Silent Seal® should be continuously used to avoid reaction of components within spray lines that may cause spray nozzle blockages.

Storage ConditionsSilent Seal® should be stored in a cool dry area. Do not expose to open flame or temperatures above 49ºC.

Health and Safety• Silent Seal® must be used in a well ventilated

area and according to NSW DPI conditions of use for NSW coal mines

• Necessary PPE includes approved eye protection, dust mask and full length protective clothing


• It is highly recommended that personnel be trained in the safe and correct use of Silent Seal® prior to undertaking any application. Full application procedures and training is available from Orica.

Tekpak™ Pumpable CribThe Advanced Pumpable Crib System

Niosh Research Laboratory Pumpable Crib Bag using 5 mm steel wire.

Orica’s Pumpable Crib System has been specifically developed to provide enhanced standing and roof support in underground coal mining.

Typically cribs are used for Gateroad support. The system provides a more productive means to install roof support in longwall mining operations, providing reduced safety exposure for operational personnel and more cost effective mine production.

The system uses Orica’s patented Tekpak™ P technology to deliver high early strength and support to help resist bed separation and convergence. The crib bag system has been specifically designed and developed for Australian underground mining conditions and safety requirements (FRAS Rated). The unique design of the crib bag enables over 400 tonne load bearing capability to be installed with this yielding system. The system has the flexibility to be pumped over long distances enabling ready application to many sites & mining applications from the one surface location.

The Tekpak™ Pumpable Crib System is a product and service incorporating:

• Tekpak™ P patented technology comprising a two part chemical system consisting of Tekcem and Tekbent which are prepared separately on site

• Mixing and pumping equipment to prepare the Tekpak™ components, mix the components and deliver them to the underground installation area

• Crib bags which have been specifically designed for Australian application i.e. FRAS rated

• Trained operational labour to supervise and operate equipment and manage crib installations underground

• Quality control system to ensure consistent performance is delivered

of 3Tekpak™ Pumpable Crib

To implement this system, the following aspects are required at the mine site:

• The surface operation area needs to be accessible by bulk tankers with firm level base area large enough for trucks to turn around

• Clear access to the borehole location

• A level compacted area for the storage of bulk tanks and pumping equipment for the Tekpak™ component preparation

Prior to implementation of this system representatives from both the Customer and Orica will participate in a joint product and service familiarisation and conduct a joint risk assessment prior to commencement of the service. For more details about the Tekpak™ product used in the Pumpable Crib System, please see the specific Tekpak™ Product Data Sheet.

For more details about Orica’s Pumpable Crib System, please contact your local Orica Ground Support Representative.

Advantages• Speed of installation – installation

time is significantly reduced over other existing methods, meaning labour and equipment can be more productively used on other duties and producing coal.

• Quick Tekpak™ Gel Time – reduced hydraulic pressure in the crib bag when filling allowing 3 metre high PCB’s to be filled in a single pumping operation in about 12 to15 minutes.

• Simplicity of use – a simpler system to set up for underground operation reduces requirements for diesel transport equipment.

• Improved safety – reduced safety risk exposure for operators in carrying loads to the work area and installing cribs.

• Consistent performance – the crib bag concept delivers a more consistent quality of ground support loading and installation, due to full contact with the roof no point loading like alternative systems.

• High strength – the specially designed system delivers a superior support loading which yields controllably to ground pressure.

• Cost effective – this system delivers more cost effective support infrastructure.

0.30.250.20.150.10.05

1000

2000

3000

4000

5000

0

Test B – 0.76 meter diameter – 2.06 meter tall – 1280 kgs – Australian Bag

Test C – 0.76 meter diameter – 1.92 meter tall – 1276 kgs – Australian Bag

Test F – 1 meter diameter – 3.43 meter tall – 3837 kgs – Australian Bag

Test G – 1 meter diameter – 3.3 meter tall – 3769 kgs – Australian Bag

Niosh Research Laboratory Minova – Australian Pumpable Crib Bag 5/23/2012 using 5mm steel wire

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The word Orica, the Ring Device and Tekpak are trademarks of Orica Group Companies.

Page 3 of 3Tekpak™ Pumpable Crib

Tekpak™ PTekpak™ P is a patented pumpable crib material having substantial benefits in terms of roof control, speed and ease of installation.

Tekpak™ P has a high early strength allowing the crib to resist bed separation and convergence.

The fully cured strength is over 400 tons of load bearing capacity depending on PCB size see Tekpak™ Pumpable Crib Technical Data Sheet.

Advantages• Simplicity of use – a symmetrical

two component system utilizing basic equipment.

• High yield – a pack of 80% by volume water, reducing the material requirement.

• Long distance pumping – from over 4 km out bye through low cost small diameter pipe, thus easing transport and enabling more than one site to be serviced from a single pumping station.

• Cost effective

• Long pumping life – reduces flushing out and giving material savings and time saving with the added advantages of longer pumping distances and reduction in the probability of blockages due to equipment failure.

• Superior suspension agents – allows the slurries to stay in the batch mixers longer which improves efficiency and reduces waste.

• Consistent performance – compared to timber cribs.

• High strength – yet yields controllably to ground pressure.

• Quick Tekpak™ Gel Time – reduces hydraulic pressure in bag when filling allowing 3 meter high PCB’s to be filled in a single pumping operation in about 12 to 15 minutes.

DescriptionTekpak™ P is a two part system consisting of Tekcem P and Tekbent which when mixed together rapidly react to produce a load bearing crib.

Tekcem P is a non-combustible brown blended cement powder which forms an easy to pump slurry with water.

SG = 1.46 at 20°C

Tekbent is a non-combustible low viscosity non setting liquid.SG = 1.22 at 20°C

Tekbent has a 12 month pumping life when stored between 5 to 35°C and Tekcem P is pumpable for at least 24 hours.

PackagingTekcem P, 20kg Bags, 60 bags per stretch wrapped pallet.

Tekbent, bulk tankers or 1000L IBC.

Shelf-lifeTwelve months if you keep liquid above 5°C and powder cool and dry.

Instructions for useThe slurries of Tekcem P and Tekbent can be prepared in any standard batch or continuous mixer. Approximately 3 minutes mixing under medium shear (i.e. paddle type mixer) is adequate for either product. The slurries are then pumped separately to the crib where they are mixed just prior to entering the crib bag. Equal volumes of Tekcem P and Tekbent slurries are employed. Do not allow Tekcem P and Tekbent to mix until just before entering the crib bag; the combined mix sets in a few seconds.

The reaction between Tekcem P and Tekbent slurries is very rapid and strength development is typically as follows:

Tekpak 100mm Cube UCS

Cure Time (Days)

UC

S (M

pa)

05

7

8

9

10

11

12

6

5 10 15 20 25 30

Consult with manufacturer for specific recommendations regarding mix proportions and crib installation.

Tekpak 100 mm Cube UCS

Orica is the world’s leading design, manufacture and supplier of steel and chemical strata support components for the underground mining, tunnelling and civil construction industries.

In addition to a complete range of steel and chemical components, Orica can also provide an extensive and complimentary range of accessories for steel strata support requirements.

Orica’s range of steel product accessories includes:

Strata Strap• W shaped steel mining strap available

in various lengths

Mechanical Anchors• Expansion shell anchors available for a

range of rock bolt and hole diameters

Mine Nuts• Rock bolt nuts available for a range of

bolt sizes and threads

Hanger Nuts• A rock bolt nut and hanger loop

assembly to enable hanging of services

Dome Ball Washers• Domed washers used to assist in the

alignment of rock bolts with plates

Couplings• Round or hexagonal steel tubes to join

double ended rock bolts

Eye Bolts• Rock bolts with a loop formed

and welded on one end

Service Hangers• Multiple hook configurations available

L Pins• L shaped rock bolts available with

threaded ends

Pull Collars• A round collar for use with Strata Bolts

to enable pull testing

Steel Accessories

General Information

Product General Description General Features

Strata Strap W shaped steel strap used to provide additional surface support between rock bolts, custom sizes available

280 mm wide, supplied in various lengths with multiple holes, available black or galvanised

Mechanical Anchors

Mechanical anchors are used to provide immediate point anchored load bearing support to installed rock bolts. Anchors are attached to the inserted end of rock bolts and are set in place by rotating the bolt to draw the anchor through the wedges. Mechanical anchors are available to suit various thread forms. Typical hole sizes used with mechanical anchors are 32 mm and 45 mm diameter. Anchors are tested to MUL and MNSL as per applicable ASTM F4A32 standards.

Load bearing capacity can be dependent on ground type. Anchors are designed to be installed in specific hole diameters. Oversized holes diameters can result in lower than acceptable anchorage. Undersized holes can result in anchor damage during installation resulting in unacceptable or no load. Mechanical anchor bolts will generally lose load over time and should not be considered long term support. Can be supplied black or galvanised.

Mine Nuts Plain rock bolt nuts can be supplied separately to enable additional plating of the bolts and other uses.

Various nut size and thread form combinations can be supplied to suit any Orica rock bolt available. Can be supplied black or galvanised.

Hanger Nuts A rock bolt nut and hanger loop assembly to enable hanging of services from previously installed rock bolts.

Various nut size and thread form combinations can be supplied to suit any Orica rock bolt available. Can be supplied black or galvanised.

Dome Ball Washers

Domed washers are used to assist in the alignment of rock bolts with rock bolt plates during installation on irregular surfaces or at angles of up to 18º. Used to transfer load from the bolt to the plate, and assist during installation by reducing the probability of the bolt thread catching on the inside edge of the plates hole.

Most suitable for use with dome shaped plates. Can be supplied separately, and are typically supplied on most rock bolts. Available black, galvanised or coloured to indicate bolt length.

Couplings Round or hexagonal steel tubes used to join double ended rock bolts to enable longer length bolting in confined spaces.

Couplings are available with a range of thread forms to suit any Orica rock bolt. Can be supplied black or galvanised.

Eye Bolts Rock bolts with a loop formed and welded on one end, and a thread rolled onto the other end. Typically used with a mechanical anchor to enable instant use.

Available in various diameter bars and thread forms. Can also be slotted if required. Inside diameter of eye loop is 75 mm. Can be supplied black or galvanised.

Service Hangers

Hangers incorporating multiple hook configurations that are typically attached to mesh or rock bolts to enable hanging of multiple service lines including water and compressed air.

Can be supplied black or galvanised.

L Pins L shaped rock bolts available with threaded ends. Available in various diameter bars and thread forms. Can be supplied black or galvanised.

Pull Collars A round collar for use with Strata Bolts to enable pull testing.

Available to suit all diameter Strata Bolts and can be supplied separately or included on specific number of bolts per pack. Available black or galvanised.

Steel Accessories Page 2 of 3

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Technical Data

DescriptionSteel Grade

Dimensions (mm) Strength

Unit Weight (kg’s)

Units per Pack

Strata Strap 280 mm x 3000 mm Black HA1 280 x 3000 x 1.9 N/A 13.0 50

Strata Strap 280 mm x 3000 mm Gal G2Z275 280 x 3000 x 1.9 N/A 13.5 50







Description

Typical Hole Diameter (mm)

Anchor / Wedge Length (mm)

Unit Weight (kg’s)

Units per Box

Typical Load

MNSL* MUL*

Mechanical Anchor M16x32 RHT Black 32 9.36 MT 14.8 MT 85 / 57 0.22 50

Mechanical Anchor M24x43 RHT Black 45 18.2 MT 33.7 MT 85 / 57 0.46 20

Mechanical Anchor R24 x 43 LHT Black 45 18.2 MT 33.7 MT 85 / 57 0.46 20

DescriptionSteel Grade

Height (mm) Width (mm)

Unit Weight (kg’s) Units per Pack

Nut Plain R24 LHT Black Grade 8 32 36 0.20 N/A

Nut Plain R24 LHT Gal Grade 8 32 36 0.20 N/A

Nut Plain M24 RHT Black Grade 8 32 36 0.20 N/A

Nut Plain R27 Domed LHT Black Grade 8 40 46 0.29 N/A

Nut Plain R27 Domed LHT Gal Grade 8 40 46 0.29 N/A

Nut Hanger R27 RHT Black Grade 8 105 55 0.35 N/A

Nut Hanger R27 RHT Gal Grade 8 105 55 0.35 N/A

Dome Ball 24 Black – 25 mm dia hole N/A 22 47 dia 0.17 N/A

Dome Ball 24 Gal – 25 mm dia hole N/A 22 47 dia 0.17 N/A

Eye Bolt M16 x 600 RHT Black 1045 N/A

Eye Bolt M24 x 600 RHT Black 1045 N/A

Eye Bolt R24 x 600 RHT Black 1045 N/A

Pull Collar 47 Gal SG Cast N/A

Pull Collar 34 Gal SG Cast N/A

* MUL – Minimum ultimate load

* MNSL – Minimum non-seizure load

Steel Accessories Page 3 of 3

Orica has manufactured a range of cementitious and chemical based products and systems used in the design and construction of underground mine ventilation structures and bulkheads for more than 20 years.

In 1999 Orica Australia diversified into contract design and installation of Ventilation Control Devices (VCD’s) and since that time has considerably expanded the range of products, devices and services available to the underground coal and metal mining industries globally.

Orica Australia boasts the largest range of live tested explosion rated VCD’s available, with test work on numerous devices undertaken at world renowned facilities

including Lake Lynn test explosion mine in the United States and the Londonderry explosion test chamber in Australia. In addition Orica also has a large range of engineer rated devices designed specifically for underground coal mining and metal mining requirements.

Orica can provide VCD’s certified by a registered professional Queensland engineer (RPEQ) according to coal industry guidelines.

Orica’s vast experience and capability in engineering, design, product manufacture, fabrication and contract installation of VCD’s has enabled the successful development and implementation of many specific devices for individual customer requirements. Orica’s extensive range of VCD’s includes:

• Explosion resistant plug seals – 20 psi, 50 psi (Tekseal,™ FB200™)*

• Explosion resistant concrete seals – 20 psi, 50 psi (Meshblock,™ Sprayplast)*

• Explosion resistant ventilation stoppings – 2 psi, 5 psi (Sprayplast,** Flexistop,™* shotcrete)

• Explosion resistant fabricated man doors and vehicle doors***

• Explosion resistant fabricated overcasts***

• Water Bulkheads – 5,10,15, 20, 30 metre (wetmix)

• Steel fabricated vehicle access doors, air-locks, man doors and coffin seals – 5 psi

• Fabricated louvre regulators

• Blastflow™ fabricated louvre regulators

• QBC ventilation blinds

• Fleximesh stopping systems*

• Plastic regulator drop boards

• Fan flaps

* Live explosion tested at Lake Lynn Experimental Mine, Pennsylvania USA

** Live explosion tested at Londonderry Explosion Galler, NSW Australia

*** Engineer rated

# Live explosion tested at customer site

Ventilation Control Devices

Plug Seals – Tekseal,™ FB200™

Orica Plug Seals can be individually designed to suit the strata conditions and roadway dimensions of most underground mines, and have been installed throughout coal mines globally for more than 20 years. Plug seals are typically constructed using Orica’s “High Volume Output Grouts” including Tekseal™ and FB200™. Specifications for these grouts can be obtained from the relevant Orica product data sheet.

Explosion rated Tekseal™ plug seals have been extensively tested to withstand blast pressures of 20 psi and 50 psi at the Lake Lynn test mine in the United States.

Orica Australia can offer a full underground roadway evaluation, and the subsequent design and contract installation of explosion rated Plug Seals. Orica contract installed structures are fully rated and quality control tested to ensure construction is completed according to full design specifications.

Concrete Seals – Meshblock™

Orica Concrete Seals can be individually designed to suit the strata conditions and roadway dimensions of most underground mines, and have been installed throughout Australian coal mines for more than 15 years. Orica Concrete Seals are typically constructed using Orica’s Meshblock™ system, reinforced by a series of steel rebars anchored into the surrounding strata. The Meshblocks are subsequently filled with a specifically designed concrete mix to form an effective explosion resistant coal mine ventilation, water and gas barrier.

Explosion rated Meshblock™ concrete seals have been extensively tested to withstand blast pressures of 20 psi and 50 psi at the Lake Lynn test mine in the United States.

Orica Australia can offer a full underground roadway evaluation, and the subsequent design and contract installation of explosion rated Concrete Meshblock™ Seals. Orica contract installed structures are fully rated, quality control tested and audited to ensure construction is completed according to design specifications.

Ventilation Stoppings

Orica can provide a range of rated and non rated stoppings for any underground mine ventilation requirements. Devices available include Flexistop, a rapidly installed flexible ventilation stopping, and various sprayed structures using Orica’s Sprayplast, Rappass GD, Fastshot™ or Tekflex™ products for non rated stoppings. Individual product specifications on these sprayed products can be obtained from the relevant Orica product data sheet.

Explosion rated Flexistop™ stoppings have been extensively tested to withstand blast pressures of 2 psi and 5 psi at the Lake Lynn test mine in the United States. Explosion rated Sprayplast™ structures have been extensively tested to withstand blast pressures of 2 psi and 5 psi at the Londonderry test chamber in Australia. A second test program in 2012 provided live test data for the design of 20 and 50 psi seals using Sprayplast.

Orica Australia can offer a full underground roadway evaluation, and the subsequent design and contract installation of rated and non rated stoppings. Orica contract installed structures are fully rated and quality control tested to ensure construction is completed according to full design specifications. Rated man-doors designs can be provided to suit customer requirements.

Flexistop Advantages• Patented stopping system enables

rapid installation with 2 stoppings installed per shift

• Overpressure designed and live tested to rating that is achieved immediately on completion of installation

• Easily installed in high ventilation areas

• Flexible structure and sealing system allows stopping to take significant convergence without affecting stopping integrity

• No dust of fumes generated during installation process

• Superior cloth strength of over 100 kN/m tensile strength ensures resilience to projectile damage

• Significant reduction in underground transport requirements

• Unique fixing system allows easy detachment for vehicle access if required

• Optional integrated rated door design supported by cables

Blastflow™ Regulators – Set and Forget Solution

In 2005 Orica developed a revolutionary new automatic airflow regulator for metalliferous mines. Blastflow™ regulators have been designed to enable simple retrofitting to existing regulator sites by simply lifting and locking the modules into place. Regulator modules can be preset to any position from fully open to fully closed by one person using a wheel adjustment mechanism. The louvre blades will automatically open during stope firings releasing large volumes of air, with a constant force gas strut controlling the opening of the louvre blades.

Once the air pressure has dissipated the louvre blades adjust to their original airflow setting.

Ventilation Control Devices Page 2 of 5

Blastflow™ has been live tested in a working underground metalliferous mine through a series of stope firings of increasing size cumulated in a 380kT blast. High speed cameras recorded the operation of the Blastflow™ modules during blasting. No damage was sustained to the regulator modules or components and settings were maintained. A double module installation can regulate up to 50 m3 per second of air, and is suitable for most mine requirements. Orica can also provide the components to automate the Blastflow™ modules using actuators. Linak actuators are used for remote control regulators for ventilation on demand applications.

Blastflow™ Advantages• Modules can be fabricated to suit any

dimensions

• One person can adjust and set, simply set and leave

• Eliminates the manual removal and replacement of timber boards

• Does not need to be adjusted prior to stope firing

• Immediate control of primary ventilation airflow after stope firing

• Eliminates damage caused to drop-board regulators

• Can be easily lifted into place using an I.T.

• Simple to use locking pins for installation into existing regulator frames

• Can be automated and controlled by remote telemetric monitoring

• Available in galvanised or 3 coat paint protection system

• All frames can be fitted with plastic drop-boards

Ventilation on Demand (VOD) Ventilation on Demand allows an underground mine’s ventilation circuit to be electronically controlled, enabling instantaneous remote adjustments to maximize ventilation efficiency. VOD combines secondary fans with automated Blastflow™ regulators, allowing the mine to control where and when air is placed. In addition to airflow efficiency benefits there are considerable savings available through the reduced electricity required to power fans and more rapid adjustment for air flow providing rapid access to production areas.

QBC – Easy Access Ventilation Device

The Orica QBC for secondary air control, is an easy to install ventilation blind that allows for the stopping of air flow to or from underground mining areas that may require complete access at a later stage. QBC’s are used to control ventilation flow at stope accesses and draw points, ore passes, and for the general direction of ventilation throughout other mine areas. Devices are quickly opened and closed using a manual winch and pulley system, and can be clearly and individually numbered to assist with communication by mine personnel during travel throughout the mine ventilation circuit. Orica QBC’s are designed for arduous conditions with high tear resistant FRAS cloth and fibreglass dowels that will bend and not permanently deform.

The Orica QBC is fully tested and designed, and is manufactured in Australia to suit specific mine ventilation pressures and requirements. Orica QBC’s are available in two standard sizes, 5.7 m(w) x 5.3 m(h) (Large) and 4.6 m(w) x 5 m(h) (Type 3) however other sizes maybe available upon request.

Orica QBC Advantages• Easily installed using existing

mine services

• Can be opened and closed within minutes by one person to allow vehicle, truck or loader access

• Can be designed to suit specific size opening and ventilation requirements

• Durable and high tensile cloth eliminates wear and impact damage

• Flexible support ribs eliminate damage from excessive pressures

• Easily relocated for re-use if required

• Can be numbered for location identification purposes

Fleximesh Brattice Stoppings

Fleximesh is a lightweight mesh stopping used to replace the use of steel reinforcing mesh sheets for rapidly installed low cost ventilation structures. Fleximesh is a high strength webbing (80 kN tensile capacity per m2 of cloth) that is attached to the periphery of a mine opening using eye bolts and knocker line. Once in place light-weight vent bag fabric is attached to form a rapid and low cost ventilation barrier. Fleximesh is faster, considerably lighter and much safer to use than steel mesh, and due to its high strength can be reused repeatedly.

Key Blastflow™ Design Features

Standard module size 1,280 mm x 1,690 mm 1,280 mm x 2,720 mm

Locking pins 8 per module 8 per module

Module weight 280 kg (280 kg with door) 350 kg (390 kg with door)

Louvre blades 4 per module (370 mm x 1,120 mm)

7 per module (370 mm x 1,120 mm)

Opening mechanism mechanical wheel mechanical wheel/actuation

Self closing single gas strut double gas strut


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Plastic Regulator Drop BoardsOrica can supply a range of plastic drop boards for use in typical underground mine regulators. The use of recycled plastic drop-boards is the same as for the timber they are intended to replace for controlling air quantities in an underground ventilation circuit. The standard board size is 1,400 mm long x 150 mm wide x 40 mm thick, however boards can be provided up to 1,800 mm long. Plastic drop boards are lightweight (typical 1,400 mm long board weight is 9.5 kg), are easily removed and replaced, and do not swell or break as is often the case with timber boards. Plastic boards can be machined and formed using the same techniques that are used for timber. Orica plastic regulator drop boards are available in grey and can be incorporated as an addition to Blastflow™ regulator frames.

Advantages• Environmentally friendly, made from

recycled, post-consumer waste plastic.

• Do not swell or splinter (no sharp edges)

• Light-weight and durable

• 40 year life possible

Material Specifications and Technical DataTest results for reinforced material used in plastic boards:

Test Test Method Result

Flexural Modulus (MPa) ASTM D 790M 696

Compressive Strength (MPa) ASTM D 695M 23.00

Tensile Strength (MPa) ASTM D 638 9.95

Coefficient of Thermal Expansion (.C-1) ASTM D 696 1.1 x 10-4

Health and SafetyFull-scale fire studies indicate that polyethylene when under combustion is less hazardous from the standpoint of toxicity than cellulosic material, i.e. burning wood. A joint study by the Dow Chemical Company and the Fire and Safety Research Institute in Chicago showed there is: “no substantial difference in toxicity between burning cellulosic materials and burning polyethylene materials“. However, it would be expected that users of recycled-plastic materials will employ the same personal safety items that are used when working with timber.

When comparisons are made on a volume basis, the smoke from wood is the more toxic material. A study found that the main hazards in a large-scale fire situation involving polyethylene or wood are carbon monoxide and temperature.

Steel Fabricated VCDsOrica has provided the mining industry with steel fabricated VCDs for the last 15 years. Vehicle access doors can be designed for 4.5 x 4.5 metre openings and heavy duty for pneumatic or hydraulic control. Coffin seals, air-locks, conventional regulators, overcasts, fan flaps and man-doors can be designed to an over pressure rating. Fabrications can be designed and tailored to a mines specific needs. Pneumatic or pneumatic/hydraulic controls can be designed and tailor made to suit the installation of vehicle access doors.

Heavy Duty Vehicle Access Door

Additional InformationFor additional information relating to Orica’s Ventilation Control Devices contact your nearest Orica Australia office or representative. Complete contact details are available at: www.orica.com.au


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20140916 ground support australia product and services brochure

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