The present application claims priority from Australian Provisional Patent Application No 2019900457 filed on 13 Feb. 2019, the contents of which are incorporated herein by reference in their entirety.
This invention relates to a dolly for use in installing rock bolts and to an associated method of installing rock bolts, particularly self-drilling rock bolts, using resins and catalysts to secure the rock bolts in mine walls and roofs.
Rock bolts are used in soft and hard underground mines to provide ground support for mined excavations, and in particular are used to support mine walls and roofs.
Installation of conventional rock bolts involves drilling a borehole into the strata to a desired depth using an elongate drilling tool (“the drill steel”), with a drill bit attached to the distal end of the drill steel. Once the hole has been drilled, the drill steel and drill bit are removed from the borehole. In a second step, two component plastic resin cartridges/capsules having one component containing a curable resin composition and another component containing a curing agent (catalyst) are inserted into the borehole either mechanically or by hand. In a third step, a rock bolt with a resin mixing device and nut secured to the rock bolt is loaded onto a rock bolting apparatus in the form of a drilling/bolting machine with the drive dolly of the machine engaging the nut. The machine is aligned with the borehole that contains the resin cartridge. The machine is operated to spin the rock bolt, and the distal free end of the rotating rock bolt is slowly inserted into the borehole, which shreds the resin capsule and mixes the two parts of the resin cartridge together. The mixed resin components cure and solidify and bind/encapsulate the rock bolt in the borehole.
This conventional installation process has a number of drawbacks. First, in poor ground conditions, or where there is low quality rock mass, the bore holes often collapse when the drill steel is removed from the bore hole. When this happens, inserting a resin capsule and rock bolt into the collapsed borehole is difficult and sometimes impossible, so conventional rock bolt installation methods cannot be used in such poor ground conditions.
Another commonly used method of installing rock bolts involves using a self-drilling rock bolt which uses a sacrificial drill bit attached to a hollow rock bolt. This allows rock bolts to be used in poor ground conditions where the self-drilling rock bolt acts as the drill steel and remains in the borehole after drilling. Using this method, there are often difficulties in uncoupling the installation dolly used to install the rock bolt from the self-drilling rock bolt, if the rock bolt is not properly engaged with or locked into the borehole. A secondary related issue arises where the boreholes are vertical or greater than horizontal, where the rock bolts have a tendency to drop out of the borehole when they are disconnected from the dolly, if they are not properly engaged with or locked into the borehole.
Self-drilling rock bolts are cement grouted or resin injected to lock them into the borehole and this involves a further step of connecting adaptors and setting up additional pumping equipment to inject the self-drilling rock bolt with resin or cement to lock it into the bore hole.
The present invention seeks to at least address some of the deficiencies of existing methods and provide for efficient and reliable rock bolt installation.
Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each of the appended claims.
According to a first broad aspect the present invention provides a method of installing a rock bolt comprising:
drilling a borehole in strata or rock using a self-drilling rock bolt connected to a bolter boom or the like via a dolly;
while the self-drilling rock bolt remains in the borehole, and preferably remains engaged with the self drilling rock bolt, injecting grout into the borehole via the dolly and the self drilling rock bolt; and disconnecting the self-drilling rock bolt from the dolly.
Typically, the grout comprises resin and a catalyst and the method further comprises:
supplying the resin via a resin pathway in the dolly; and
supplying the catalyst via a catalyst pathway in the dolly, separate from the resin pathway.
It is preferred that the resin passageway in the dolly has a diameter of at least about 10 mm and the resin has a viscosity of between 100,000 and 400,000 centipoise and preferably 125,000 to 225,000 centipoise.
It is preferred that the resin is a polyester resin, preferably including from 10 to 25% by weight of an inert filler, such as limestone.
The method may further include the step of disconnecting the rock bolt from the dolly after the resin has cured and flushing the dolly with water via a passageway in the dolly.
In related aspect, there is provided a rock bolt dolly arranged to connect a self-drilling rock bolt including a elongate hollow rod defining at least one externally threaded end, to a rock bolting apparatus and arranged to transfer percussive energy applied to the dolly by the rock bolting apparatus to the rock bolt during installation of the rock bolt in strata and rock, the dolly comprising:
coupling means for coupling the dolly to the output shaft of the rock bolting apparatus;
a percussion plate comprising an end plate and integral side walls defining an internally threaded recess for receiving the threaded end of the rock bolt, for applying percussive loading to the elongate hollow rod of the rock bolt via the end plate and threaded side walls;
a body portion extending between the coupling means and the percussion plate transmitting forces from the output shaft to the percussion plate; wherein the body portion defines at least one passageway for the passage of grout from a reservoir through the rock bolt dolly and into the rock bolt.
Preferably, the body portion defines at least two passageways, one passageway for supplying catalyst and one passage way for supplying resin to the rock bolt.
The diameter of the passageway for supplying resin is preferably at least about 10 to 20 mm diameter, most preferably at least 10 to 15 mm diameter.
The body portion may further define a passageway for supply of water to the percussion plate.
Grout may be supplied to the passageway in the body portion via a rotary housing which extends around the body portion and is rotatable relative to the body portion and which is prevented from rotating relative to the output shaft to provide a non-rotating connection point for one or more hoses for supplying grout to the dolly.
Typically, the rotary housing defines an annular passageway which is in constant fluid connection with a radial inlet in the body portion of the dolly.
Where the body portion defines at least two passageways, one passageway for supplying catalyst and one passageway for supplying resin to the rock bolt, the resin and catalyst may be supplied to the passageways in the body portion via a rotary housing which extends around the body portion and is rotatable relative to the body portion and which is prevented from rotating relative to the output shaft to provide a non-rotating connection point for a hose for supplying grout to the dolly.
In this embodiment, the rotary housing defines a first annular passageway which is in constant fluid connection with a first radial inlet to the catalyst passageway in the body portion of the dolly and a second annular passageway which is in constant fluid connection with a second radial inlet to the resin passageway in the body portion of the dolly.
Advantageously, the present invention may allow an operator to use percussive energy to drill rock bolts into strata and rock and directly inject grout such as a two part resin (resin and catalyst) directly into the rock bolt and borehole to encapsulate the rock bolt within the borehole without having to disengage the rock bolt from the installing dolly until the end of the installation process, using a single pass installation method. This method is not only more reliable as it avoids the issues of collapsing boreholes and disengaging rock bolts from known prior art installation methods it is also more efficient and quicker as there are fewer installation steps and the rock bolt is only attached and detached from the dolly/bolting machine once.
The percussive plate allows percussive forces to be transferred directly to the elongate rod of the self-drilling rock bolt for efficient and effective drilling.
The resin pathway allows for the passage of polyester resins which have a greater viscosity than polyurethane resins.
A related aspect of the invention provides a method of using a dolly to install a self-drilling rock bolt in strata and/or rock, the self drilling rock bolt including a elongate hollow rod defining at least one externally threaded end, the method using the dolly to transfer percussive energy applied to the dolly by the rock bolting apparatus to the rock bolt during installation of the rock bolt in strata and rock, wherein the dolly comprises:
coupling means coupling the dolly to the output shaft of the rock bolting apparatus;
a percussion plate comprising an end plate and integral side walls defining an internally threaded recess for receiving the threaded end of the rock bolt, for applying percussive loading to the elongate hollow rod of the rock bolt via the end plate and threaded side walls;
a body portion extending between the coupling means and the percussion plate transmitting forces from the output shaft to the percussion plate; wherein
the body portion defines a first passageway having a diameter of for the passage of resin through the rock bolt dolly and into the rock bolt, and a second passageway for the passage of catalyst through the rock bolt dolly and into the rock bolt, wherein the diameter of the first passageway is at least about 10 mm, the method including the steps of:
drilling a borehole in strata and/or rock using the self-drilling rock bolt connected to the rock bolting apparatus via the dolly;
while the self-drilling rock bolt remains in the borehole, injecting resin into the borehole and rock bolt via the first passage passageway in the dolly and injecting catalyst into the borehole and rock bolt via the second passage passageway in the dolly wherein the resin comprises a polyester resin having a viscosity of from 100,000 to 400,000 centipoise; and
disconnecting the self-drilling rock bolt from the dolly.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
Specific embodiments of the present invention will now be described, by way of example only, and with reference to the accompanying drawings, in which: —
Referring to the drawings
The percussion plate including the internally threaded interior bore for receiving the R32 externally threaded end of the rock bolt allows percussive force, in addition to rotational forces, to be effectively transferred to the rock bolt. This allows the installation process to be quicker and more efficient.
The threaded end of the rock bolt simply screws into the percussion plate creating an effective connection which does not require seals or the like, when the resin and catalyst are being injected in the later stage of the installation process.
With reference to
As can be seen from
It is noted that the passageways have to be sized to allow the catalyst and resin fluids to flow through them under the pressure supplied by the pumps and depending on the viscosity of the fluids. In this respect it is noted that two pending PCT applications filed by J-LOK Co under numbers WO 2016/141008 and WO 2018/045277, and US patent publication number US 2020/0018165, the entire contents of which are incorporated by reference describe systems for pumping two component resins. In the described embodiment the diameter of the resin/mastic passageway 136-124 should be at least 10 mm, and may preferably be wider. The passageway 124 may be from 10 mm to 20 mm wide, more preferably between 10 and 15 mm wide to ensure that the passageway is wide enough to allow the resin to flow but not so wide as to weaken the structural integrity of the dolly. The dolly is designed for use with a polyester resin, rather than the less viscous polyurethane resin which is also used in mining applications.
With reference to US 2020/0018165, this describes a filled resin having 10-25% inert filler, such as limestone. The resin may have a viscosity of about 100,000 to 400,000 centipoise, most typically 125,000 to 225,000 cps which compares with polyurethane resin which has a viscosity of less than 10,000 centipoise.
The catalyst has a much lower viscosity of about 10,000 to 25,000 cps, so can be pumped through a much narrower bore.
Turning to
Engagement with the drive shaft is by means of a direct left hand drive connection. When the resin injection process is complete (explained in more detail below) right hand rotation is required to disengage the dolly from the drive shaft. The clamps 22a and 22b allow the dolly to clamp onto the drive shaft while allowing for disengagement of the dolly from the rock bolt when using right hand rotation. Hence, the clamps allow both drilling and disengagement of the bolt with the dolly by using left and right rotations respectively.
In use the dolly 10 is attached to a bolter arm such as is shown in
When the rock bolt 300 has been fully installed to the correct depth, the dolly remains coupled to the rock bolt 300 for resin injection. Resin and catalyst are then injected though the passageways in the dolly into the bore 202 of the rock bolt and pass into the borehole, where they mix and harden. The bolt 300 remains stationary at this time and a static mixer located inside the rock bolt mixes the resin and catalyst together. The threaded engagement of the percussion plate and bolt 300 inhibits the leakage of the resin and catalyst being pumped through the dolly to the rock bolt 300. Once the resin has cured after resin injection, the dolly is disengaged from the rock bolt 300 and flushed with water using the water passageway. The rock bolt 300 remains bonded to the bore hole with cured resin. The process is then repeated with the next self-drilling rock bolt.
Advantageously, the present invention may allow an operator to use percussive energy to drill rock bolts into strata and rock and directly inject grout such as a two part resin directly into the rock bolt and borehole to encapsulate the rock bolt within the borehole without having to disengage the rock bolt form the installing dolly until the end of the installation process, using a single pass installation method.
More particularly, the system avoids the step or need to uncouple the rock bolt prior to injecting resin into the rock bolt/borehole. As a consequence, installation is faster and more efficient. The system is more reliable and may provide improved quality control and installation. Water flushing occurs directly at the bolt connection point.
The system may be used on both Bolting and Jumbo drill rigs and can be provided to suit various OEM drill brands.
Advantageously the dolly design is relatively uncomplicated, requiring only one port for resin/mastic and one port for the catalyst as the water is flushed down the centre of the dolly as is normal in installing rock bolts. The dolly also does not require any internal control valves, and is compatible with standard bolting machine drive shafts.
It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.
Number | Date | Country | Kind |
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2019904397 | Feb 2019 | AU | national |
Filing Document | Filing Date | Country | Kind |
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PCT/AU2020/050123 | 2/13/2020 | WO | 00 |