Self Drilling Rock Bolt System for the Coal Industry Ground Support Services Pty Ltd & Alminco Pty Ltd March 2008

© 2008 GSS Pty Ltd & Alminco Pty Ltd 2 Advanced SDRB System  Installation System  New Alminco Crawler Rig  Integrated Bolting & Resin Pumping System  Standard Steel SDRB  New Telescopic SDRB  New Fibreglass SDRB  Future Directions  Installation System  New Alminco Crawler Rig  Integrated Bolting & Resin Pumping System  Standard Steel SDRB  New Telescopic SDRB  New Fibreglass SDRB  Future Directions

© 2008 GSS Pty Ltd & Alminco Pty Ltd 3 Objectives of the SDRB project:  Pumpable Resin Bolting System  Fit existing machines  Resin tanks, resin pumps, delivery system etc  Roof and Rib support  Minimise manual handling  Maximise rock support  Improve Productivity  Pumpable Resin Bolting System  Fit existing machines  Resin tanks, resin pumps, delivery system etc  Roof and Rib support  Minimise manual handling  Maximise rock support  Improve Productivity

© 2008 GSS Pty Ltd & Alminco Pty Ltd 4 Installation System Standard Crawler Rig with new engineering features:  Integrated & self contained  Operator seated remote from drilling & resin injection operation  Standard drill mast – vertical & horizontal drilling  New innovative Drilling Chuck Standard Crawler Rig with new engineering features:  Integrated & self contained  Operator seated remote from drilling & resin injection operation  Standard drill mast – vertical & horizontal drilling  New innovative Drilling Chuck

© 2008 GSS Pty Ltd & Alminco Pty Ltd 5 Installation System New Drilling Chuck features:  lightweight with RH & LH mounting  offset drive motor with quick detach injection head  2 speed with RH & LH rotation  through drive socket tension to roof New Drilling Chuck features:  lightweight with RH & LH mounting  offset drive motor with quick detach injection head  2 speed with RH & LH rotation  through drive socket tension to roof

© 2008 GSS Pty Ltd & Alminco Pty Ltd 6 Resin System Resin Delivery System:  Two separate systems with resin pressure control  Twin 120 litre tanks (easily increased)  New Injection Head:  seamless water & resin injection & flushing  quick change over & replacement Resin Delivery System:  Two separate systems with resin pressure control  Twin 120 litre tanks (easily increased)  New Injection Head:  seamless water & resin injection & flushing  quick change over & replacement

© 2008 GSS Pty Ltd & Alminco Pty Ltd 7 Why Pumpable Resin SDRB? resin fills bearing plate & also locks mesh in place full encapsulation both inside and outside bolt  Full bolt encapsulation maximises roof support  Resin fills cracks & cavities  No gloving, no plastic film  Perfect resin mixing every time  Resin fills bearing plate & locks mesh in place  Minimises water inflow & bolt corrosion  Full bolt encapsulation maximises roof support  Resin fills cracks & cavities  No gloving, no plastic film  Perfect resin mixing every time  Resin fills bearing plate & locks mesh in place  Minimises water inflow & bolt corrosion visible resin at collar proves full encapsulation

© 2008 GSS Pty Ltd & Alminco Pty Ltd 8 Plate Design  Round design – stackable with no orientation required  “soft” footprint won’t damage mesh  Large plate “footprint”  Resin can fill bearing plate & lock mesh in place & provide intimate surface contact  Once full of resin, becomes very strong in compression  Round design – stackable with no orientation required  “soft” footprint won’t damage mesh  Large plate “footprint”  Resin can fill bearing plate & lock mesh in place & provide intimate surface contact  Once full of resin, becomes very strong in compression

© 2008 GSS Pty Ltd & Alminco Pty Ltd 9 Standard Steel SDRB  One piece  No drive dollies, no drill rods, no resin cartridges  fast penetration with high thrust  High Capacity ~ 36 tonnes  High load transfer capacity >1.4 tonnes/cm  Custom bearing plates with “soft” footprint  One piece  No drive dollies, no drill rods, no resin cartridges  fast penetration with high thrust  High Capacity ~ 36 tonnes  High load transfer capacity >1.4 tonnes/cm  Custom bearing plates with “soft” footprint

© 2008 GSS Pty Ltd & Alminco Pty Ltd 10 Rock Drilling Rock Drilling with SDRBs:  Possible to drill 80 MPa concrete with blue metal  Tungsten carbide ensures maximum penetration rate  Tungsten carbide equates to about 4 seconds in time cost Rock Drilling with SDRBs:  Possible to drill 80 MPa concrete with blue metal  Tungsten carbide ensures maximum penetration rate  Tungsten carbide equates to about 4 seconds in time cost

© 2008 GSS Pty Ltd & Alminco Pty Ltd 11 Principle of the Telescopic SDRB

© 2008 GSS Pty Ltd & Alminco Pty Ltd ~3.4m Principle of the Telescopic SDRB

© 2008 GSS Pty Ltd & Alminco Pty Ltd 13 New Telescopic SDRB 1.9m 3.4m  One piece  Automatically extendable  No couplers, no drive dollies, no drill rods, no resin cartridges  High Capacity ~ 36 tonnes  High load transfer capacity ~2.0 tonnes/cm  Fast, simple  One piece  Automatically extendable  No couplers, no drive dollies, no drill rods, no resin cartridges  High Capacity ~ 36 tonnes  High load transfer capacity ~2.0 tonnes/cm  Fast, simple

© 2008 GSS Pty Ltd & Alminco Pty Ltd 14 New Fibreglass SDRB nut & thread >10 tonnes Simple, high speed, high capacity Hollow Fibreglass Rod >30 tonnes Fits same Drill Chuck as steel SDRBs

© 2008 GSS Pty Ltd & Alminco Pty Ltd 15 New Fibreglass SDRB Spiral wound surface provides undulations Grit coated surface Surface provides very high load transfer capacity ~ 1 tonne/cm

© 2008 GSS Pty Ltd & Alminco Pty Ltd 16 New Fibreglass SDRB Injection moulded thread Hollow Fibreglass Rod Hardened Steel Drill Bit Small borehole annulus

© 2008 GSS Pty Ltd & Alminco Pty Ltd 17 New Fibreglass SDRB Coal Drilling in Ribs:  hardened steel drill bits okay for coal ribs  patented Drill Bit design enables small borehole annulus  minimises resin volume  maximises load transfer capacity Coal Drilling in Ribs:  hardened steel drill bits okay for coal ribs  patented Drill Bit design enables small borehole annulus  minimises resin volume  maximises load transfer capacity

© 2008 GSS Pty Ltd & Alminco Pty Ltd 18 Bolt Performance

© 2008 GSS Pty Ltd & Alminco Pty Ltd 19 SDRB Drilling in 80 MPa concrete  Drilling in 80 MPa concrete with blue metal  Penetration rate reasonable  Rotary drilling only – no percussive  Note water being displaced by resin  Full resin encapsulation of bolt and plate Points to Note:

© 2008 GSS Pty Ltd & Alminco Pty Ltd 20 Full Resin Encapsulation Resin filling “cavities” The pumpable resin system synergistically enhances the SDRB & the bearing plate

© 2008 GSS Pty Ltd & Alminco Pty Ltd 21 Future Directions:  Refine & test Crawler mounted System  Large scale secondary bolting demonstration  Quantify field support performance:  mechanical & geotechnical & cycle times  Engineering design for a production face system  Future Continuous Miner mounted system  Refine & test Crawler mounted System  Large scale secondary bolting demonstration  Quantify field support performance:  mechanical & geotechnical & cycle times  Engineering design for a production face system  Future Continuous Miner mounted system

© 2008 GSS Pty Ltd & Alminco Pty Ltd 22 Thanks:AcarpXstrataAlminco Thanks:AcarpXstrataAlminco