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Hilti Mining Australia “Industry Success with Hilti Innovation”. 1. www.hilti.com.au. Mining I 2010 I RIM. Hilti Mining Australia. Agenda Hilti Introduction Product Overview Hilti OneStep Bolt Innovation/ Technical Specs OneStep Field Test Data Ground Support Customer Portfolio
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Hilti Mining Australia “Industry Success with Hilti Innovation” 1 www.hilti.com.au Mining I 2010 I RIM
Hilti Mining Australia • Agenda • Hilti Introduction • Product Overview • Hilti OneStep Bolt Innovation/ Technical Specs • OneStep Field Test Data • Ground Support Customer Portfolio • Project Update • New Products Launched 2011
Hilti Mining is established in major markets and quickly expanding dark red: Established Hilti Mining Key Markets; orange: Current Business build-up
Hilti ground control systems HTTHilti Cable Bolts HFD Thrust Dowels HFD-T Torque-Tension Dowels HMS Hilti MiningScrews HOS Hilti One Step resin bolt(steel) HTT Hilti Cable Bolts complement the full Hilti ground support offer
Pretension OneStep– Technical Specification • Yield Strength > 270 KN • Ultimate strength > 320 KN • Elongation at failure >10% Tube length 1200 – 2500mm Tube diameter 38.5mm Drill bit diameter 40.5mm Shear Strength 250 – 300KN
Drive & Pretension system • Drilling • Clockwise drilling with water flushing • Setting • Dispense resin and hold 5-10 sec to allow fast resin (red above) to cure • Tensioning • Anti clockwise rotation
Drill tip Two piece nut right hand rotation drilling left hand rotation pre tension Static resin mixer ensures correct mixing of resin components Two speed Resin cartridge in steel inner tube for optimum transport and storage Channel for flushing water Pretension OneStep – Features
QLD Newlands Northern Broadmeadow Carborough Downs Moranbah North Coal NSW Metropolitan Angus Place Beltana West Wallsend Spring Vale Ravensworth Dendrobium Myuna Tahmoor Mannering NRE Austar Newstan Ground Support Customer Portfolio
Newlands • Newlands Northern underground operates 3 development panels with CM005 currently utilising the OneStep system in the roof • Newlands have been bolting with the OneStep on different machines and different areas since 2009 and have installed app 50,000+ ISL and Pretension bolts • Brian Vorster has completed an internal assessment of the OneStep at Newlands in 2010. Review of the Hilti Bolt Trial 04 02 2010 • Abstract from report • Intensive reviews by SCT of the technical characteristics of the Hilti One Step Bolt (OSB), numerous short encapsulation pull tests, over coring, in loco trials of in excess of 22 000 bolts in what is considered “normal” NUG conditions and in a heavily faulted area in the Newlands Underground Extension mains development has indicated that the Hilti OSB is a suitable support system to use at this mine site. • Hilti operation and geotechnical auditing shows excellent average encapsulation rates with 96%+ bolts showing resin at the collar
Broadmeadow Mine • Broadmeadow operates two development panels with Joy 12CM12 continuous miners currently with COM2002 utilising the OneStep system in the roof with plans for the second miner to be on line by the end of the year. • Broadmeadow has installed approximately 1000 bolts since the start up in October with excellent encapsulation rates and installation quality. • Broadmeadow have previously installed 9,000 ISL bolts 2007-08 and were Hilti Mining’s first large scale project in Australia. • Hilti have also submitted a report on the longwall retreat past the bolts 07/08 including input from Site Senior Geotec Robert Coutts. • Abstract from report • “I have not observed or measured any material change in roof behaviour during longwall retreat. There was no measured movement in any of the tell-tales installed in the MG 4 area were Hilti OneStep bolts were installed”
Moranbah North Coal • Moranbah North Coal operate two longwalls with the new Joy 1750t LW108 being the largest capacity shields in in the world. • Moranbah North Coal decided to utilise the Hilti OneStep pretension (HOSPT) bolt to complete their LW108 bolt up, with the main driver being the bolt’s ability to deliver superior operator safety, and installed performance potential compared with the standard solid bar bolts previously used by MNC. • Moranbah North Coal installed approx. 2,000 2.1m bolts in the roof and face during the 108L/W take-off in July, supplemented with 8m cable bolts. • Discussions regarding a large scale Development project utilising HOSPT were initiated due to the success experienced on the longwall bolt-up.
Moranbah North Coal – LW108 bolt up Pull test location Boltup
Moranbah North Coal • Testimonial from Richard Campbell- Consultant Geotechnical Engineer • The LW108 bolt-up and salvage was to occur in heavily structured ground, where concerns were raised regarding the loss of encapsulation and the risk for operators when required to spend time out on the RFB’s inserting chemicals, bolts & changing drill steels. A proposal was put forward for the use of the HOSPT bolts. • At the last moment the mine approved the use of the OneStep bolt (9 days to bolt-up). The response from the Hilti team was very professional, from doing pull tests through to risk assessments, delivering training and modifications to the RFB’s all with in the tight time frame required. • During bolt up Hilti provided MNC with 24hr product and technical support, ensuring a smooth process. • The result was the most controlled shield salvage the mine had experienced, the bolted ground stayed intact as the e-frame advanced with the shields being salvaged, the face remained stable and the ventilation circuit was maintained MG to TG for the entirety of the salvage process. • None of the typical strata issued at MNC was experienced for this salvage, and indeed the face stood up until the last 60 chocks, at which time the roof simply folded onto the floor, in a low energy manner. • No injuries were recorded, and the operators involved have asked that we use the same bolts on the next salvage – which we are intending to do. • Of the 2000 odd bolts installed we had 1 failure, where the operator pushed the wrong lever.
Longwall Customers QLD Carborough Downs x 1 Moranbah North Coal x 2 Broadmeadow x 1 + Jan ‘13 Newlands x 1 + Apr ‘13 NSW Springvale X 3 West Wallsend x 4 Ravensworth x 3 Beltana x3 Metropolitan x 4 Angus Place x 5 Integra x 1 Ashton x 1 West cliff x 1 Dendrobium Booked Dec
NSW Projects Mine Application • Development Trial – 1.5m PT Bolts • Gate road drivage • 980 panel – CM01 Joy 12cm30 Sandvik RFB with Hilti system mounted Current Status • Trial started 12th September • 2700+ bolts installed to date • Average consumption of 1,200-1,400 bolts p/m • 10,000 bolt trial extension • Second miner committed for trial and awaiting parts
NSW Projects Mine Application • QDS Bolter – Rib repair • 2.5m long HOS bolts • Rib breakout >2m in extreme • cases • Current mechanical anchor system not providing adequate support Sandvik RFB with Hilti system mounted Current Status • HOS system purchased & rig converted and bolting commenced • Average consumption of 500 bolts & plates /month • 10,000 bolt trial being considered in development panel
NSW Projects Mine Metropolitan Application • 5000 1.5m cuttable HOS bolts for both the block and pillar side • 20T tensile with a 12T nut pull off required • Assessment of suitability based on following criteria: • Drillability vs failure rate • Can the miner and longwall cut them out • Outbye belt issues Sandvik RFB with Hilti system mounted Current Status • 2500 installed • All criteria successfully achieved • Gen 2 HOS-C fabricated now
Hilti Mining Screws Mining screws – Work like a resin bolt without resin!