How To Build A Mine Support System
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1 New Ground Support Products For Longwall Gate Roads For 2013 LONGWALL USA Pittsburgh, PA May 9, /20/2013 1
2 New Ground Support Products For Longwall Gate Roads By: Dakota Faulkner 6/20/2013 2
3 New Products Outline 1. Fully Grouted Cable Bolt (FGCB) 2. INSTáL Tensionable Cable Bolt 3. Standing Support Technologies J-Crib - Pumpable Cribs Rapid Installation Props (RIP) J-Sand Props 4. Non-Metallic Bolt and Plates 5. Questions/Open Discussion 6/20/2013 3
4 6/20/ FULLY GROUTED CABLE BOLT
5 What is the FGCB? A cable bolt that can be injected with polyurethane (PUR) to fully encapsulate the cable bolt and drill hole. 6/20/2013 5
6 How Does It Work? Modified drive head to allow injection of PUR. Addition of rubber packer to pressurize drill hole. 6/20/2013 6
7 Typical Uses Long term corrosion protection. Consolidate fractured or laminated strata. Water stoppage. 6/20/2013 7
8 6/20/ FGCB Diagram
9 Fully Grouted Cable Bolt Available in: 0.6 (30 ton) or 0.7 (40 ton) cable. Non-Tensioned or Tensionable (INSTáL CC). Typically: Installed in 1 or 1-3/8 drill hole. Point anchored with 4-5 eq. feet of resin. Standard 1-1/8 drive nut. Standard minimum length of 8. 6/20/2013 9
10 CASE STUDY (Deteriorating Roof Conditions) 6/20/
11 FGCB Used for Deteriorating Roof Conditions Location - Eagle seam Mining method - Longwall Previously mined headgate began to take excessive weight and roof conditions rapidly began to deteriorate. 6/20/
12 JENNMAR Recommended the FGCB JENNMAR s technical engineers made an on-site visit and inspected the area. Recommended the FGCB due to its ability to inject the roof strata with PUR along with the added strength of a cable bolt. 6/20/
13 6/20/ Injected PUR Migrating Through the Cracks in the Strata
14 6/20/ FGCB Successfully Utilized to Halt the Deteriorating Roof Conditions
15 Scoped Drill Hole Before injection. After injection. 6/20/
16 INSTáL TENSIONABLE CABLE BOLT SYSTEMS 6/20/
17 INSTáL TENSIONABLE CABLE BOLT INSTáL CC - 4 tensionable zone. INSTáL CB - tensionable zone below bail shell. *Now available in a Fully Grouted model. 6/20/
18 New Designed Bail Type Expansion Anchor (Shell) New serration design improves anchorage capacity. Improved resin channels to reduce installation pressure. 6/20/
19 INSTáL Cable Bolt Specifications 0.6 (30 ton) or 0.7 (40 ton) cable. Simple and fast installation. Provides immediate support and confinement to roof. Consistent applied tension. Can be implemented as part of primary roof support system. Tension Range 6,000 lbs minimum. *Can be used in conjunction with PUR injection. 6/20/
20 6/20/ FULLY GROUTED INSTáL CC (Tensionable PUR Injectable Cable Bolt)
21 FULLY GROUTED INSTáL CC Now available in 0.6 (30 ton) and 0.7 (40 ton). Tension Range 6,000 lbs minimum. Can be implemented as part of primary roof support system and injected at any time. 6/20/
22 Case Study - INSTáL CC (Longwall Setup Face) 6/20/
23 Longwall Setup Face Eagle Seam Full-width setup face. Laminated sandstone roof susceptible to damage with very little roof deflection. Significant roof movement observed in first half of setup face due to slow installation of posttensioned cables. INSTáL Cables recommended to provide immediate support and reduce roof deflection for second half of setup face. 6/20/
24 Longwall Setup Face Post-Tensioned Cables INSTáL CC Cables Roof location 100 ft after switch from Post Tensioned Cable Bolts to INSTáL CC cable bolts. 6/20/
25 B-RIGID TRUSS SYSTEM with INSTáL CC 6/20/
26 B-Rigid Truss System Overview Jennmar T-Channel used in conjunction with Jennmar Cable Bolts. Outside bolts are angled over ribs into undisturbed strata. Replaces conventional truss systems. 6/20/
27 Advantages of B-Rigid Truss Simple Installation uses standard roof support materials with no special installation tools needed. Conforms to roof no gaps between channel and roof line. Provides confinement to immediate roof for better roof support. Allows individual cables to interact. Can be used with all cable bolting systems. 6/20/
28 6/20/ Example of B-Rigid Truss in Use
29 6/20/ Example of B-Rigid Truss in Use
30 6/20/ Example of B-Rigid Truss in Use
31 6/20/ New Standing Support Technologies
32 6/20/ J-CRIB Pumpable Crib
33 J-CRIB Pumpable Crib J-CRIB is a specialized pumpable cement and containment bag which replaces conventional timber cribs in longwall tailgates and bleeder headings. Two part system consisting of Part A and Part B, which when mixed together rapidly react to produce a load bearing mine roof support. Typical diameters and peak capacities- 24 (610mm) tons (135 tonne) 27 (686mm) tons (181 tonne) 30 (762mm) tons (209 tonne) 6/20/
34 J-CRIB Advantages High efficiency mixing and pumping equipment. High yield, approximately 90% by volume water. Long distance pumping, up to 18,000 ft (5486 m). Long pumping life, at least 12 hours. Yields controllably to ground pressure. 6/20/
35 Conforms and Pressurizes Against the Roof & Floor Consistent performance, pressurization of bags ensures good contact with the mine roof and even load bearing capacity. Rapid gelling allows bags to be filled completely without additional form work. 6/20/
36 Conforms and Pressurizes Against the Roof & Floor Consistent performance, pressurization of bags ensures good contact with the mine roof and even load bearing capacity. Rapid gelling allows bags to be filled completely without additional form work. 6/20/
37 27 Diameter Standard J-CRIB Results 6/20/
38 27 Diameter High Deformation J-CRIB Result 6/20/
39 6/20/ Rapid Installation Prop (RIP)
40 Rapid Installation Prop Designs: Available in 50 & 100 ton (45 & 91 tonne) capacities. Applications: Tailgate and bleeder support. Cross-cut and intersection stabilization. Belt line and headgate entry support. Longwall shield recovery. Longwall center entry. CM pillar extraction. Violation prevention. 6/20/
41 RIP 50 & RIP 100 Technical Data - RIP SUPPORT, tons (metric tons) TRAVEL, in(mm) PIPE, in (mm) EXTENSION THREAD, in (mm) RIP 50 (45) 12 (305) 3 (76) 2.0 (51) RIP 100 (91) 18 (457) 4 (102) 3.5 (89) ADVANTAGES: Available in 50 or 100 ton (45 or 91 metric tons) capacities. Single pipe, height can be modified if necessary. Easy screw height adjustment. Piranha top plate engages roof to prevent rotation when tightening. 6/20/
42 6/20/ J-SAND PROP
43 J-SAND PROP Designs: Available in 30, 60 & 100 ton (27, 54 & 91 tonne) capacities. Yieldable or Non-Yieldable. Applications: Tailgate and bleeder support. Cross-cut and intersection stabilization. Belt line and heagate entry support. Longwall shield recovery. Longwall center entry. CM pillar extraction. Violation prevention. 6/20/
44 Standard J-SAND PROP Advantages 24 inches of height adjustment. Light, quick and easy to install. No equipment or tools required to install. Cannot be over extended. Available with a variety of head plates. Yieldable versions developed provide additional displacement. 6/20/
45 TECHNICAL DATA J-SAND 30 SIZE HEIGHT, ft (m) COLLAPSED EXTENDED WEIGHT, lb (kg) J-SAND (1.2) 6 (1.8) 53 (24) J-SAND (1.5) 7 (2.1) 57 (26) J-SAND (1.8) 8 (2.4) 61 (28) J-SAND (2.1) 9 (2.7) 65 (29) SIZE COLLAPSED J-SAND 60 HEIGHT, ft (m) EXTENDED WEIGHT, lb (kg) J-SAND (1.2) 6 (1.8) 76 (35) J-SAND (1.5) 7 (2.1) 82 (37) J-SAND (1.8) 8 (2.4) 91 (41) J-SAND (2.1) 9 (2.7) 97 (44) SIZE COLLAPSED J-SAND 100 HEIGHT, ft (m) EXTENDED WEIGHT, lb (kg) J-SAND (1.2) 6 (1.8) 91 (35) J-SAND (1.5) 7 (2.1) 102 (46) J-SAND (1.8) 8 (2.4) 112 (51) J-SAND (2.1) 9 (2.7) 123 (56) J-SAND 30 Light weight Up to 32 pounds lighter than a comparable 60 ton J-SAND Prop. Can be easily carried by one man. J-SAND 60 Light weight Up to 9 pounds lighter than competing 60 ton props. Over 4 of displacement on yieldable versions. J-SAND 100 High capacity to minimize roof movement and keep the entry open. Used when the ultimate load bearing support is required. *Custom sizes are available 6/20/
46 VERTICAL FORCE, Tons Yieldable J-SAND Props 80 NIOSH RESEARCH LABORATORY J-SAND - YIELDABLE PROP - 04/18/ Ton Yieldable Prop - 5 inch 30 Ton Yieldable Prop - 5 inch 30 Ton Non-Yieldable Prop 60 Ton Yieldable Prop inch 60 Ton Yieldable Prop inch 60 Ton Non-YieldableProp VERTICAL DISPLACEMENT, Inches 6/20/
47 6/20/ J-PAK
48 J-PAK Advantages: Replaces conventional timber cribs in longwall tailgates and bleeders. Sustains peak capacity during yielding. Stable and high yield performance. Withstands lateral displacement. Typical diameters and capacities: 18 (457 mm) ; tons (64-73 tonne). 24 (610 mm) ; tons (82-91 tonne). 6/20/
49 VERTICAL LOAD, kips 24 J-PAK Results 250 NIOSH RESEARCH LABORATORY JENNMAR - J-PAK - 6/12/2012 Test A - J-Pak - 24 inch diameter inches tall - 1,381 lbs Test B - J-Pak - 24 inch diameter inches tall - 1,310 lbs Test C - J-Pak - 24 inch diameter inches tall - 1,427 lbs Test D - J-Pak - 24 inch diameter inches tall - 1,320 lbs VERTICAL DISPLACEMENT, inches 6/20/
50 VERTICAL LOAD, kips J-PAK Test Results NIOSH RESEARCH LABORATORY JENNMAR - J-PAK - 6/12/ inch diameter J-PAK inches tall lbs VERTICAL DISPLACEMENT, inches 6/20/
51 6/20/ Non-Metallic Bolts and Plates
52 NON-METALLIC CUTTABLE PRODUCTS Products made from composite materials to resist corrosion in harsh mine environments. Provide rib support in longwall gate roads. Minimum load capacity of system (Bolt and Plate or Pan) 5 tons. 6/20/
53 NON-METALLIC CUTTABLE PRODUCTS Sinkable Plate Made of Glass Reinforced Nylon (GRN) for high density to sink when going through cleaning plant. Plate center allows bolt to be installed at an angle. Hangers molded into plate design. 6/20/
54 NON-METALLIC CUTTABLE PRODUCTS 18 Fiberglass Pan Center section designed so that additional plates are not required. 18 Square pan provides more surface support. Constructed of fiberglass with a high density to sink when going through cleaning plant. 6/20/
55 NON-METALLIC CUTTABLE PRODUCTS Fiberglass Bolt GRN coating injected onto top of bolt to aid in mixing resin. The nut uses a standard 36mm hex wrench. Available in 3 & 4 lengths. 6/20/
56 JENNMAR & KMS WOULD LIKE TO THANK YOU FOR OPPORTUNITY TO BE HERE TODAY. 6/20/
57 Contact Information JENNMAR CORPORATION 258 KAPPA Dr. P.O. BOX PITTSBURGH, PA (412) Dakota Faulkner (412) /20/
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