how megabolts installed as primary support assist in safely improving development rates acarp...
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How megabolts installed as primary support assist in
safely improving development rates
ACARP Roadway Development Operators Workshops - October 2011
IntroductionIntroduction
Three types of megabolts installed from continuous miner
● Post grouted megastrands – MW9● Resin anchored, torque-tensioned megaflex bolts - TTX● Resin anchored, post groutable fibreglass rib bolts
ACARP Roadway Development Operators Workshops - October 2011 2
MW9 MegaboltMW9 Megabolt
● Most commonly installed megabolt is the barrel & wedge version – MW9
● Fully bulbed using spiral rib wire for max load transfer
● Up to 11 m long cables installed from miner in LW installation roads
ACARP Roadway Development Operators Workshops - October 2011 3
MW9 – Nth Goonyella face roadMW9 – Nth Goonyella face road
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MW9 advantagesMW9 advantages
● 42 mm hole – no reaming● Single 1,000 mm resin capsule
with resin retainer● Resin pushed up hole with bolt
– no conduit● Collar fittings attached after
bolt installed● No bearing plate or bolt head to
catch on walkway
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MW9 advantagesMW9 advantages
● Tension within 5 mins of installation
● Tension using system hydraulics or intensifier
● 9 to 20 t pre-tension can be achieved depending whether system hydraulics or intensifier used
● No air needed on miner● Provides immediate point
anchor support of 57 t
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Important considerationsImportant considerations
● Bolt is point anchored until grouted
● Anchor length designed to take capacity of bolt – depends on rock type at anchor horizon
● Pull tests must be done to determine if anchor can take full capacity of bolt
● This ungrouted bolt is loaded to 45-50 tonnes
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MW9 groutingMW9 grouting
● Top down grouted using grout lance – quickest grouting method
● Grouting done within designated time or distance advanced – depends on conditions
● Heavy conditions may require grouting within 24 hrs
● Good conditions (intersections) can be left for more than a week
ACARP Roadway Development Operators Workshop 2011 8
MW9 groutingMW9 grouting
● Grout generally reaches sufficient strength (30 to 40 MPa) within 24 hrs
● Readily & easily audited● Regular auditing has greatly
improved quality of installation
● Grouting non-compliance now less than 5%
● Good installation reduces likelihood of remedial roof support
ACARP Roadway Development Operators Workshop 2011 9
MW9 developmentsMW9 developments
Mechanised insertion ●Lobster from Conway Engineering●Being used at Angus Place●Favourable reports so far
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MW9 developmentsMW9 developments
Resin grouting using Minova Carbothix●Immediate roof support●Remote pumping●Quicker grouting
ACARP Roadway Development Operators Workshop 2011 11
Megaflex TTXMegaflex TTX
● Torque-tensioned● TT bolt becoming more in
demand● 56 t and 48 t versions● 56 t generally requires 28
mm hole● 48 t a 27 mm hole
ACARP Roadway Development Operators Workshop 2011 12
TTX – advantagesTTX – advantages
● No exposure to high pressure tensioner hydraulics
● Reduced injuries from handling tensioners
● Quicker installation than hydraulically tensioned cables
● Combo dolly
13ACARP Roadway Development Operators Workshops - October 2011
Combo dolly – no changing dolliesCombo dolly – no changing dollies
MixingInner socket engages hex drive
14ACARP Roadway Development Operators Workshops - October 2011
TighteningOuter socket engages nut
TTX – advantagesTTX – advantages
● Roller race between nut & washer reduces friction
● Race is shrouded to keep bearing free of dirt or mud
● 7 t bolt tension from 320 Nm drill torque
● Minimal protrusion from roof – important in low seams
● Removing hex drive reduces protrusion further – as little as 115 mm
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TTX – advantagesTTX – advantages
● Wires are anchored in the bolt head using button heads forged on end of each wire – maintains max collar strength
● B&W anchor typically reduces cable collar capacity by approx 10%
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TTX – advantagesTTX – advantages
● Increased load transfer from spiral wire
● Groutable version being developed – will require 42 mm dia. hole
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Limitations of torque-tensioned cablesLimitations of torque-tensioned cables
● Reduced bolt pre-tension compared to hydraulic tensioning
● Possible use of torque multipliers
‐ Slows down installation
‐ Failure of torque multiplier can delay production
‐ Possible safety issues● May need modifications to head-plate of drill mast to
accommodate bolt and/or dolly ● Full resin encapsulation difficult for cables > 4 m● Load transfer lower than for bulbed cables● If bulbed then larger hole dia. & bigger resin capsule
ACARP Roadway Development Operators Workshop 2011 18
Groutable FG rib boltGroutable FG rib bolt
● 42 t capacity● Cuttable● 42-45 mm drill hole● Point anchored initially● Breakout nut● High torsion strength –
stalls rib bolting rigs● 17 t collar capacity● Shear strength of 14 t● SG of 1.9 to 2.1 – separates
in washery
19ACARP Roadway Development Operators Workshops - October 2011
Groutable FG rib dowel - advantagesGroutable FG rib dowel - advantages
● Immediate rib support● Hollow centre - post groutable
with thixotropic grout● Full encapsulation vital in
heavy rib conditions ● Easily audited● No secondary rib support
required – maximises development rates
20ACARP Roadway Development Operators Workshops - October 2011
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