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By Chee S. Theng

As the 2015 president of the Society for Mining, Metallurgy & Exploration Inc., I am pleased to present the 2015 issue of the Transactions of the Society for Mining, Metallurgy & Exploration Inc., Vol. 338. A significant portion of the contribution that we make as a professional society is the publication of professional and technical papers that accelerate the advancement of scientific knowledge and enable the transfer of technology. Communication within the mining community is the key to a successful society. This technology exchange continues a tradition that dates back to the 1871 meeting of 22 mining engineers in Wilkes-Barre, PA, that resulted in the founding of AIME. Those individuals envisioned that these transaction volumes “would form a most valuable and greatly needed addition to our professional literature.” This volume fulfills that pledge. The 2015 Transactions contains some of the most interesting research and insights from the past year and features an international slate of authors spanning industry, academia and government. Papers include the latest findings from the U.S. National Institute for Occupational Safety and Health (NIOSH) and special-focus articles on gold processing, iron ore processing and coal processing. The 2015 Transactions consists of a total of 67 technical papers, encompassing all 22 papers published in 2015 in the Technical Papers Section of Mining Engineering (Vol. 67) and all 29 papers published in 2015 in Minerals & Metallurgical Processing (Vol. 32). Additionally, this volume contains 15 papers and one discussion that are being published for the first time in this issue. The papers presented in this volume were written by some of the most distinguished professionals in the industry worldwide. All of the technical papers were peer-reviewed. The process of review and publication requires much hard work by authors, reviewers and our publications staff. As the 2015 president of SME and on behalf of all our members, I would like to extend our gratitude to all whose volunteer efforts contributed to the publication of this volume.

Jan 1, 2015

By Timothy J. Matthews, Timothy J. Batchler, Daniel J. McElhinney

The National Institute for Occupational Safety and Health’s (NIOSH) Mine Roof Simulator (MRS) at the Pittsburgh Mining Research Division was commissioned for operation in 1981. The MRS was originally designed for longwall shield research and was the only hydraulic press in the world with the capability to apply biaxial loads to these large structures. The results of this forty-year research program have contributed to improved performance and increased knowledge of longwall shields, mobile roof supports and hydraulic cylinders in the mining industry. Also, considerable research and development have been conducted to develop standing support technologies for the mining industry. The Support Technology Optimization Program (STOP) was developed to evaluate how these various technologies can impact and improve both ground control conditions and mine safety. Additional MRS research has included the performance of ventilation stopping walls including the development of a new testing protocol to evaluate the transverse loading capabilities under arching load conditions and evaluating the performance characteristics of welded wire screen as used in underground mine roof surface control. The NIOSH Mine Roof Simulator has been a reliable and valuable tool for the past forty years for the evaluation of safety structures used in mining, and this research has contributed significantly to the advancement toward safer mines. This paper will summarize those research results and provide a glimpse of planned future activities.

By George R. Powe

If Campbell County, Wyoming were an independent nation, it would rank fifth in the world among countries with known coal reserves. Only the United States, Russia, mainland China and West Germany would have greater volumes available. Not too many years ago that statement would not have seemed important, because oil and natural gas had become our nation's principal fuels. Western coal deposits, particularly those of the Powder River Basin in Montana and Wyoming, and which underlie virtually all of Campbell County, were largely unknown. But recently, in response to the three-pronged stimulus of vanishing gas reserves, rising petroleum prices, and clean environment statutes, these vast deposits have been delineated and have become, in the minds of many, indispensable to our goal of energy independence. Not only does western coal lie in thick seams near the surface where it can be mined in huge quantities at low cost, but also it possesses another coveted attribute in this age of environmentalism: low sulfur content. At Burlington Northern we count ourselves at the forefront of those who believe this coal is essential to any hope for the government's "Project Independence." But to that belief we add another article of faith. We are convinced the economics of unit train delivery of this incredibly immense resource make it the only transportation system that can help us achieve energy self-sufficiency in this country.

Jan 1, 1975

By K. Mohamed, G. Rashed

A conventional mechanical anchor bolt consists of a smooth bar threaded at the anchor end, with a conical wedge, and a mechanical shell anchor. When the smooth bar is torqued, the conical wedge pushes the shell anchor against the borehole wall. Coal mines use mechanical bolts in addition to other types of bolts to control the deformation and stabilize the yielded coal ribs. Limited research has been conducted to understand how a mechanical anchor performs in a coal rib. Researchers from the National Institute for Occupational Safety and Health (NIOSH) conducted the study described in this paper to define the loading characteristics of mechanical bolts (stiffness and capacity) installed in coal ribs at five underground coal mines. Standard pull-out tests were performed in this study to define the loading characteristics of a mechanical rib bolt. Based on the strength of the coal seam and the conditions of the coal mines, the bolts were installed at different amounts of torque. A typical tri-linear load-deformation response was obtained from these tests. It was found that the anchorage capacity depends on the coal strength, and the anchorage stiffness depends on the installation torque. The outcome of this research provides essential data for rib support design. INTRODUCTION Rib falls are a serious hazard in underground coal mines. In the last 10 years, rib failures have resulted in 17 fatalities, representing 52% of the ground-fall fatalities in underground coal mines in the United States (MSHA, 2018). Although resin bolts has been used increasingly in the last few years to control coal ribs, mechanical bolting (mainly expansion-shell bolts) is still used in many underground coal mines. Recently, NIOSH researchers surveyed 90 sites in 14 underground coal mines in the Eastern United States and found that 79% of the mines determine their rib support requirement based on the depth, mining height, and the loading conditions, of which 35% use the conventional mechanical bolts. Conventional mechanical bolts are preferable for rib support because they do not require the miners to be too close to the rib during rib bolting. Hence, using the conventional mechanical rib bolts can reduce the risk of injuries and fatalities during the installation process. The mechanical bolt or the point-anchored bolt is the oldest type of rock bolt that is still in use today. The point-anchored bolt is a tensioned bolt anchored down the hole with a mechanical expansion shell or a grouted medium (Peng and Tang, 1984). Figure 1 shows the components of the mechanical anchor bolt. The mechanical anchor bolt consists of a plug, a shell anchor, a headed smooth bar with the top end threaded, a bearing plate, a hardened washer, and sometimes a friction-reducing washer. The shell anchor can be either standard or bail type. The shell of the standard type is held in place by a nut, while the bail anchor uses a strap to hold the shell in place (Peng, 2008). The diameter of the smooth bar is generally 5/8 in for the #5 bolt or 6/8 in for the #6 bolt. The diameter of the hole that the bolt is inserted into must be carefully controlled since an oversized hole can result in poor anchorage (Moss, 1971). The anchorage is obtained by applying torque to the bolt head, which in turn pulls the wedge down in the shell and expands the serrated leaves against the sides of the hole-wall. In the resin-grouted anchor, the resin replaces the mechanical expansion shell at the end of the hole. The anchorage is achieved by bonding between the resin, bolt, and the hole-wall.

Jan 1, 2019

By G. W. Cutting

It is well known in both the research field and in commercial flotation processes that the grades and recoveries obtained from flotation plants are heavily influenced by the structure and height of the froths produced in the flotation cells. The development of steady-state mathematical models of flotation processes based upon practical and readily obtained parameters have demanded detailed information about the structure of flotation froths. The important parameters are the distribution of floating values, gangue and water in the froth with respect to froth height, cell pulp density, cell air flow rates and flotation inducing additives. Little work has been conducted in this field although considerable attention has been paid to bubble loading and other factors close to the cell froth/pulp interface. Laboratory batch tests are prefaced for the derivation of the above mentioned parameters for both practical and economic reasons. The standard laboratory flotation tests using a batch cell produces a froth of low height (1 to 3 cms generally) together with a varying cell pulp density as the test progresses due to the addition of top up water and the removal of froth from the cell. This form of test can be considered only as giving information about froth conditions close to the cell froth/pulp interface under conditions of widely varying cell pulp densities. In commercial processes the froth heights are much larger (frequently greater than 10 cms); therefore the laboratory batch test, although useful in many ways, does not directly yield parameters relating the state of the froth flowing over the cell lip to process operating conditions. To investigate flotation conditions, where more realistic froth heights are developed, an equilibrium type of batch cell has been developed at Warren Spring 1 Laboratory . In this a tank with high walls is used to contain the pulp and whole froth and, after a short period of operation, an equilibrium between froth

Jan 1, 1975

By J. R. Allan

Loki Gold Corporation of Vancouver, B.C. is developing the Brewery Creek Mine, an open pit heap leach gold mine, 55 km East of Dawson City in Yukon, Canada. Mineable reserves are 17.1 million tonnes of ore grading 1.45 grams/tonne, containing 24.8 tonnes (797 000 oz) of gold. Ore processing will employ a cyanide heap leach using run of mine ore. Permitting this mine has drawn significant attention because the heap leach technology, while proven in other jurisdictions, has not been used in Yukon. Engineering design of the heap leach was similar to that for heaps in more temperate climates, with the added issues of permafrost and cold weather operations. Solution balance with seasonal placement of ore and year -round leaching requires very large pond capacity for spring thaw conditions.

Jan 1, 1996

By Christos Roumpos, Philip‑Mark Spanidis, Francis Pavloudakis

Coal mining operations are large-scale, long-term frameworks of high complexity. Mining organizations accumulate, develop, and leverage knowledge from diverse scientific and technological fields as a result of these operations. Both practical experience and existing literature indicate that knowledge management (KM) methods within the mining industry primarily target solving immediate technical challenges and operational requirements. However, they are not commonly regarded as strategic tools to enhance the performance and competitiveness of mining companies. Empirical evidence from the Greek mining industry suggests that the management of available knowledge is intricate, less effective, and dysfunctional. This paper presents a methodology based on the principles of quantitative research (QNR), collaboratively conducted with a group of mining experts, to assess the KM landscape in the Greek mining industry. The methodology involves a structured data collection framework using questionnaires, subsequent statistical analysis, a discussion on critical methodological aspects, and an interpretation of results focusing on key aspects useful for planners and designers of KM systems in the mining industry. Finally, the paper concludes by summarizing the methodology’s outcomes and proposing further perspectives for research.

Mar 16, 2024

By D. Nebbia, R. Aliberti, F. Solesin

The launch of a Tunnel Boring Machine (TBM) is one of the most challenging activity parts of the construction of a tunnel. Challenges are coming from limited space available, learning curve, concurrence of other activities and in some cases from the geological conditions. Launching a TBM is an extraordinary and complicated operation requiring a great level of planning. The Earth Pressure Balance (EPB) TBM named “Chris” was successfully launched for the Northeast Boundary Tunnel, the largest component of the Clean Rivers Project in Washington, DC. Due to space and time constraints, the 8-meter diameter TBM was launched from a single 20-meter diameter shaft, with a 30-meter-long tail tunnel by means of umbilical connections. This paper presents the steps followed during the TBM assembly and launching to complete the excavation of the initial drive of the tunnel maintaining high level of efficiency and quality despite the space constraints. Specifically, it focuses on the methods and phases used to extract the excavated material (muck) from the TBM and from the tunnel, to supply consumables, precast rings and backfill grout. The paper presents results in terms of productivity, lesson learned and possible alternatives to be considered in similar conditions.

Jun 13, 2021

By Thomas D. Kaufmann

The 1982 recession set the US mining and metals industries reeling. Will the oncoming recession of 1991 hit as hard? Probably not, thanks to a shallower downturn, a weaker dollar and remarkable lower costs. Effects of the last recession That the 1982 recession was traumatic to the American mining and metals industry is an understatement. Quantities of metals consumed dropped. Metals prices fell despite continuing general inflation. The resulting real gross revenues of producers of each of the major metals plunged, in the trough of 1982, to levels one-fourth to two-thirds of those of the peak of 1979 (Table 1). By contrast, most industries in the United States were not hit anywhere nearly as hard. Real GNP, the aggregate of all production, slipped only 1 % from 1979 to 1982. Metals are most sensitive to the business cycle because of their applications. All metals but gold are raw materials to downstream industries. Raw materials are victims of strong fluctuations. This is because buying industries try to hold high inventories in boom periods when goods are in short supply. They reduce inventory levels in buyers markets when suppliers have idle capacity and raw materials are in ample supply.

Jan 1, 1990

By R. L. Miller

"Why should we care about diesel quality amidst the complexity of mining for minerals? Mining companies use a large amount of diesel fuel in their worldwide operations, both for moving ore from the mine to the processing mills or transportation hubs, and to generate power for onsite processing. This creates a large carbon footprint and poses both environmental risk with the production of emissions, and public perception of how those companies do their business as stewards of the environment while incurring a huge fuel expenditure. To improve diesel quality and create incremental value and greater environmental stewardship, the opportunity is broken down into several segments: 1. Mining industry diesel consumption 2. Fuel quality issues 3. Impacts on operations, economics, and emissions 4. Potential solutions 5. How improved fuel quality saves fuel expenditures 6. Economics of improved fuel quality 7. Recommended testing process 8. Fuel quality analysis checklist MINING INDUSTRY DIESEL CONSUMPTION The average grade of mined Australian ore bodies has halved, while the waste removed to access the minerals has more than doubled over the last 30 years, thus increasing energy consumption by 70%, (http://eex.gov.au/industry-sectors/mining/). Energy consumption and intensity in mining and mineral processing is rising at around 6% per annum. The mining industry is a huge consumer of diesel fuel worldwide, and the SRS Rocco Report of 4 August 2014 gives a better picture of recent trends. To better understand the reasons to reduce both fuel costs and consumption, we need to compare metrics on the amount of diesel consumed per each ounce of gold produced over the last decade. The rate of diesel consumption in gallons per each ounce of gold produced for the top five worldwide gold producers has doubled in the last 8 years from 12.7 gallons per ounce in 2005 to 25.8 in 2013 as shown in Figure 1 below.This is caused by 1) lower ore grades requiring more hauls to get same amount of finished gold product, and 2) haul trucks moving ore from deeper sources in open pit and underground mines. For one large multi-national gold mining company, the 2005 waste rock / production ratio was 52 metric tons/gold ounce; by 2013 that ratio had grown to 113 metric tons/gold ounce per the same SRSrocco 4 August 2014 report. Using the metrics above, the top 5 gold miners used over 591 million gallons of diesel fuel in 2013. The cost of diesel in dollars per ounce of gold has increased from $30.48 in 2005 to $101.14 in 2013, an annual appreciation of 16.2% as shown in Figure 2 below."

Jan 1, 2017

By T. S. McGahey

The southeastern region of the United States has long been a major market area for coarse and medium particle size natural ground calcium carbonate fillers. The primary market for calcium carbonate in the southeast traditionally has been as fillers in building materials such as carpeting, joint cement and roof shingles. In these applications the economic value of the calcium carbonate in the final product is weighted more toward lessening the cost of the final product, as opposed to contributing any desirable physical characteristics. For example, in carpet backing applications the calcium carbonate filler does little more from a physical standpoint than add weight and body to the backing adhesive. The important factor in the use of calcium carbonate in carpet backing is that it can be used at high loading levels to replace the more expensive latex binder, thus lessening the cost of the final product. It is estimated that calcium carbonate producers in the southeast sell in excess of 200,000 tons (181,436,000 kg) annually for use in latex compounds for carpet backing applications.

Jan 1, 1986

By M. R. Peterson

The U.S. Bureau of Mines (USBM) is investigating alternative methods to strip metal-loaded solvent extractants. Hydrolytic, precipitation, and hydrogen pressure stripping all recover metal or metal salts directly from the organic solvent extractant. Pure metals, metallic oxides, or metal salts can be formed, allowing direct production of value-added products. Aspects affecting commercial application are emphasized, including metal recovery from actual ore leach solutions, particle size control, organic modifier and diluent effects on stripping and metal recovery efficiencies, metal grade, seed addition, mixing intensity, recycling efficiency, and reactor plating. Metal separations from copper ore leach solutions and complex waste leach solutions were examined.

Jan 1, 1995

By M. Javier

In business mining, dilution is the result of the operating parameters that occur too often and cause serious consequences to mine performance, questioning TO WHOM BENEFITS DILUTION. Mining persists in changing perception of real meaning of dilution. The lack of interrelation between mineral processes and nature compromises the understanding of dilution; this absence of interrelation occurs due to the misinterpretation of nature, otherwise, Geomimic could be helpful to filling the gap of misinformation. NATURE provides LIMITED metals in low content deposits; it is a challenge to obtain them. Nature never considers dilution. Furthermore, though dilution is a human concept, dilution is accepted and promoted. Reality of dilution is in its errors accumulation that translates into technology level or status applied in nature. It is doubtful that dilution can continue surviving if it is ?meaningless?. It will discourse: Is dilution illegal? If the change occurs in the prediction of mining will prevail a different destiny, it is important to touch the cores of the business; otherwise, it would represent repetition of the same ?negative? effects, as usual. Mining defines many losses during the disturbance of nature, from NPV elaboration to the metal recovery to commerce, demanding BETTER DESIGN. This paper introduces and applies MANAGEMENT BY LOSS, as first steps, to limit risks and uncertainties in mining. As result, the management of dilution will be obtainable under mining practices which promotes its character of SUSTAINABILITY.

Feb 23, 2014

By R. K. Singhal

In an underground coal mining environment, a frictional ignition may be defined as the ignition of an explosive air/ methane/coal dust mixture by mining machinery. As the use of power loading equipment has become more widespread, frictional ignition incidents have increased. There have been many fatalities and injuries from this cause including the death of eleven miners in Sydney coalfield of Nova Scotia, Canada in 1979. This paper reports on the findings of a preliminary study carried out under the auspices of the Coal Research Laboratories, Department of Energy, Mines and Resources Canada. The objective of this study has been to identify a Longwall face cutting system that is inherently safer than the conventional shearer loaders used in Nova Scotia.

Jan 1, 1985

By G. R. Luster

In most current practice, the methods that are employed in technical evaluations of cement raw materials are deterministic; i.e., decisions among alternative raw mixes and alternative plant designs are reached with the aid of only "average" compositions and "representative" samples of the available raw materials. Nevertheless, cement plants are sensitive to raw-material variability, and uniformly high-quality raw materials are not so abundant as they once were. Some simple examples will illustrate how geological techniques can be combined with geostatistical and operations-research approaches to customize mining and processing systems to deal with variable raw-material compositions.

Jan 1, 1987

By W. G. Pariseau

Reliable stress measurement using hollow inclusion gauges and monitoring stress change using borehole stress meters and borehole deformation gauges in anisotropic rock remains a challenge for the rock mechanics community. In this regard, the complex variable method advanced in 1983 for deducing stress in anisotropic rock is flawed and software is privileged. Fortunately, advances in computer hardware and software now enable fast, reliable reduction of hollow inclusion stress measurement data for determining stress in anisotropic rock. Monitoring stress change in anisotropic rock poses a different challenge but is also subject to numerical analysis. Stress measurement using a hollow inclusion (HI) gauge such as the triaxial Australian HI is done in four steps: 1) drilling a measurement hole, 2) installation of an HI, 3) stress relief of the HI by overcoring, and 4) data reduction. The last step, data reduction, is the focus of this work. The process is well-known in linearly elastic, isotropic rock (Worotniki and Walton 1976, Duncan Fama and Pender 1980). However, in case of linearly elastic, anisotropic rock the requisite technology is not readily available. This situation is somewhat surprising because anisotropy is more often the rule rather than the exception, especially in the neighborhood of ore bodies. Rahn (1984) has pointed out the potential for significant errors with neglect of anisotropy and the adverse consequences for engineering design. Amadei (1984) has also pointed out the potential for errors with neglect of anisotropic rock properties in stress measurement. Worotniki (1993) cites other studies that indicate potential for serious errors when doing measurements in anisotropic rock. In both theoretical cases (isotropy and anisotropy), data reduction is essentially a composite of solutions to boundary value problems in linear elasticity. In the finite element approach, the analysis is a simulation of gauge hole drilling, installation and overcoring. Two important advantages with the finite element approach are a more faithful representation of the conditions of HI stress measurement than approximated in theory and the capability for handling rock whether isotropic, transversely isotropic or fully anisotropic

Mar 2, 2022

By P. James

"INTRODUCTION Control of target stream acidity is widely used in MIW (mining influenced water). Tailoring pH (a measure of acidity) finds application for controlling key chemistry in both process and waste streams. Traditional lime addition for neutralization and precipitation is most often used but has high reagent costs and results in large amounts of mixed metal sludge requiring costly disposal. A new adaptation of BPS’s patented DEMET™ technology (Dynamic Electrolytic Metal Effluent Treatment) platform offers a potentially improved and “reagentless” alternative to traditional chemical addition for pH adjustment. Electricity rather than chemical addition utilized in BPS’s proprietary approach controllably tailors target stream pH. The method offers a simple, low-cost processing technique yielding cleaner treatment chemistry. BPS’s “green” approach may yield lower operating (OPEX) and life cycle costs and significant reductions (up to 50%) in sludge generation compared to conventional lime treatment. It can also allow new opportunities to generate revenue via selective recovery of valuable processing byproducts. Specific savings and revenues depend on the target site chemistries, details, and processing goals. A more detailed discussion of the process and its operational principles may be found in Reference One.[1] Here application of the BPS treatment to POx (Pressure Oxidation) leaching as an alternative to traditional chemical addition is examined. An example operation process flow for gold mining is considered.[2] Promising processing points for potentially replacing conventional processes with DEMET are noted. The possibilities for lowering OPEX costs, lessening sludge creation, and capturing various valuable byproducts and residuals are examined. Financial life cycle benefit estimates of the principal gains provided by DEMET application to the example operation are noted. Extension and generalization of the analyses to a wider range of scenarios is explored."

Jan 1, 2016

By Lester G. Rollins

Coal today enjoys a dominant position, serving the energy and metallurgical marketed The measure of success in the market place is, and will continue to be, the price per million BTUs or price per ton delivered to the user. The Coal Industry's remarkable record of price stability since World War II is well known. The next twenty years promise to be equally as challenging. This challenge will be met our president, Mr. Drain, has often stated that, ?The Joy Manufacturing Company is betting that coal will meet the challenge.? To this end, the resources of Joy have been committed to doing its part. Joy's efforts are directed toward a target which has been defined as: 1. Deliver coal to the user at a price of $.15/MBTU or less. or; 2. Deliver coal to the mine portal at a cost of $1.00 or less.

Jan 1, 1966

By F. J. Sotillo

Mining in Peru is mainly concentrated on metallic and polymetallic ores of gold, copper, lead, zinc, silver, tin, iron, etc. However, little has been done to develop extensive and rich non-metallic or Industrial Minerals deposits with the exception of some silica and phosphate deposits. This paper presents the characterization and metallurgical studies for the development of a feldspar deposit. These studies showed that the special characteristics of the ore, such as high porosity, high Al2O3 content, low clays content, and sized material allowed us to obtain commercial products applying relatively simple and low cost concentrating unit operations. The characterization studies showed that the feldspar products contained no quartz and about 90% of albite (NaAlSi3O8). The 14x40-mesh size fraction product analyzed 5.91% Na2O, 22.56% Al2O3, 65.73% SiO2, 0.65% K2O, 6.50% CaO, and 0.40% Fe2O3; whereas, the 40x150-mesh size fraction product analyzed 6.22% Na2O, 24.30% Al2O3, 60.80% SiO2, 0.91% K2O, 7.06% CaO, and 0.54% Fe2O3. These products could be used for manufacturing glass, ceramics, refractory, and filters in different applications. In addition, Middlings, could be used as insulation material due to its porosity (bulk density of 0.828 Kg/dm3), analyzing 4.46% Na2O, 15.7% Al2O3, 67.2% SiO2, 2.57% K2O, 3.94% CaO, and 4.24% Fe2O3. The material showed a sphericity of 0.77, a roundness of 0.68, and acid solubility of 13.3025% on only washed and 2.72% effective for clean material suitable for use in these applications. No selective accumulation of the valuable mineral was observed at any specific size fraction. However, iron and titanium bearing impurities trended to concentrate in fine fractions (minus 70 mesh -212 µm-). Metallurgical studies demonstrated that this feldspar ore required sizing at 14x40 mesh and 40x150 mesh to render commercial products. In the case of the 14x40-mesh size fraction, the process involved magnetic separation, gravity separation, and flotation for feldspar (direct flotation) using a blend of primary and condensate amines. However, the reverse flotation for mica-biotite and iron bearing minerals was also possible using petroleum sulfonate. The metallurgical process for the 40x150-mesh size fraction required magnetic separation and reverse flotation of iron and titanium bearing minerals, the feldspar being reported in the sink material. Commercial products from this feldspar deposit for glass, ceramics, refractory, and filtration; and for the manufacturing of insulation material were obtained.

Feb 23, 2014

By S. C. Tadolini, P. Mills

"INTRODUCTION This research produced a shotcrete formulation that extends beyond stabilization and can be used to restore the structural integrity of damaged infrastructure. The primary challenge was to develop a shotcrete or gunite with structural strength within a few minutes to prevent parasitic loading and allow ingress into damaged structures within a few minutes of the mix formulation being applied. This also applies to mining conditions where rapid support of progressive failures can minimize failure. An additional benefit was the discovery that the product had extremely high adhesion properties in addition to high flexural strengths. The approach to product design was the development of “single bag” dry mixes that are entirely self-contained, can be rapidly transported anywhere in the field or underground, and be deployed using simple equipment. Dry mix eliminates issues relevant to high shear water mixing, as water is added in the form of a mist at the point of delivery; thus low W/C can be achieved. However, as there is no onsite powder mixing, the product must have a high degree of inherent homogeneity. A commercial version of this material is currently offered as Minova’s Tekcrete Fast® product which has been successfully deployed in the mining industry and is currently being used in civil, construction and tunneling operations. The material can rapidly stabilize unstable ground in metal/nonmetal and coal mines. This paper described the technology development, product testing results and applications in mining and civil applications. BACKGROUND The original development of this product was to complete rapid stabilization of shock damaged structures, which falls outside the purview of normal construction and mining practices, due to the critical time issue and the nature of the damaged structure. The stabilization of damaged structures requires materials and equipment that can be rapidly deployed to place materials that have very rapid strength development. These materials need to be placeable at a distance to provide some degree of safety to the responders. In addition, the materials must be able to adhere to structural surfaces that have not been specially prepared and conditioned, and may also be highly fractured, dusty, wet, and quite possibly hot or extremely cold. The technology for the rapid delivery of large volumes of cementitious materials to vertical or even overhead surfaces currently exists. Pneumatic delivery (shotcreting) has been used in construction for over 100 years (American Shotcrete Association, 2014). Shotcreting has played a major role in structures like the Washington D.C. Metro subway system and been used in underground mining applications routinely to serve as part of the primary and secondary support system when used in conjunction with traditional roof bolts. Numerous rapid setting cements are commercially available. They are used for rapid repair of surfaces such as bridge decks, pavements, and commercial floors, as well as structural repairs of vertical and overhead surfaces. Few of these products are specifically marketed for use in shotcrete applications. The majority of rapid setting cements are based on, or at least contain, Portland cement as a principle component. Other components are added that help provide early strength, such as high alumina cement (HAC), organic polymers, chemical accelerators (which can also be added during concrete batching), and calcium sulfate hemihydrate (e.g. gypsum plaster) (Lea, 1971). Cementitious mortars prepared with some of these cements can achieve compressive strengths of 6.8 – 13.8 MPa (1,000-2,000 psi) within 1 hour. However, Portland cement mortar and concrete typically require many weeks of proper curing to reach significant levels of their ultimate strengths, even when used with set accelerators. Also, high early strengths require the use of large proportions of Portland cement in the concrete mix, which can lead to high heat evolutio"

Jan 1, 2017