Krzysztof Zagórski

Reinforcement of Underground Excavation with Expansion Shell Rock Bolt Equipped with Deformable Component

Abstract The basic type of rock mass reinforcement method for both preparatory and operational workings in underground metal ore mines, both in Poland and in different countries across the world, is the expansion shell or adhesive-bonded rock bolt. The article discusses results of static loading test of the expansion shell rock bolts equipped with originally developed deformable component. This component consists of two profiled rock bolt washers, two disk springs, and three guide bars. The disk spring and disk washer material differs in stiffness. The construction materials ensure that at first the springs under loading are partially compressed, and then the rock bolt washer is plastically deformed. The rock bolts tested were installed in blocks simulating a rock mass with rock compressive strength of 80 MPa. The rock bolt was loaded statically until its ultimate loading capacity was exceeded. The study presents the results obtained under laboratory conditions in the test rig allowing testing of the rock bolts at their natural size, as used in underground metal ore mines. The stress-strain/displacement characteristics of the expansion shell rock bolt with the deformable component were determined experimentally. The relationships between the geometric parameters and specific strains or displacements of the bolt rod were described, and the percentage contribution of those values in total displacements, resulting from the deformation of rock bolt support components (washer, thread) and the expansion shell head displacements, were estimated. The stiffness of the yielded and stiff bolts was empirically determined, including stiffness parameters of every individual part (deformable component, steel rod). There were two phases of displacement observed during the static tension of the rock bolt which differed in their intensity.

Comparison of cost, material and time usage in FDM and SLS 3D printing methods

Additive manufacturing (AM) is the process of joining materials to make objects from Computer Aided Design (CAD) model data, usually layer upon layer, as opposed to using subtractive manufacturing methods. The use of rapid prototyping technologies has increased significantly in recent years. This paper represents an attempt to answer the questions of when 3D printing can be used efficiently and of choosing the appropriate technology on the basis of batch size, element size, complexity, and time requirements.

Application of Long Expansion Rock Bolt Support in the Underground Mines of Legnica–Głogów Copper District

Abstract In the underground mines of the Legnica–Głogów Copper District (LGOM) the main way to protect the room excavation is the use of a rock bolt support. For many years, it has proven to be an efficient security measure in excavations which met all safety standards and requirements. The article presents the consumption of the rock bolt support in the Mining Department “Polkowice–Sieroszowice” in the years 2010–2015 as well as the number of bolt supports that were used to secure the excavations. In addition, it shows the percentage of bolt supports that were used to conduct rebuilding work and cover the surface of exposed roofs. One of the factors contributing to the loss of the functionality of bolt supports is corrosion whose occurrence may lead directly to a reduction in the diameter of rock bolt support parts, in particular rods, bearing plates and nuts. The phenomenon of the corrosion of the bolt support and its elements in underground mining is an extremely common phenomenon due to the favorable conditions for its development in mines, namely high temperature and humidity, as well as the presence of highly aggressive water. This involves primarily a decrease in the capacity of bolt support construction, which entails the need for its strengthening, and often the need to perform the reconstruction of the excavation. The article presents an alternative for steel bearing plates, namely plates made using the spatial 3D printing technology. Prototype bearing plates were printed on a 3D printer Formiga P100 using the “Precymit” material. The used printing technology was SLS (Selective Laser Sintering), which is one of the most widely used technologies among all the methods of 3D printing for the short series production of the technical parts of the final product. The article presents the stress–strain characteristic of the long expansion connected rock bolt support OB25 with a length of 3.65 m. A rock bolt support longer than 2.6 m is an additional bolt support in excavations, and it is increasingly frequently used to reinforce roofs and in rebuilding the underground mines of KGHM Polish Copper S.A. In order to conduct the laboratory tests that are most suitable for the mine conditions, and yet are carried out on a laboratory test facility, the Authors used a steel cylinder with an external diameter of 102 mm and a length of 600 mm, which was filled with a core of rock (dolomite) from the roofs of the mine workings. In addition the maximum load that took over the bolt support made of rods and connected with sleeves was determined. For the initial tension, the elastic and plastic range of the maximal displacements, which were measured by the rope encoder, were determined. The statical tests of the expansion rock bolt support were carried out at the laboratory of the Department of Underground Mining in simulated mine conditions. The test facility enables the study of the long bolt rods on a geometric scale of 1:1 for the different ways of fixing. The aim of the laboratory research was to obtain the stress–strain characteristics, of the long expansion rock bolt support with a steel bearing plate and a plate printed on a 3D printer.