Tag Archives: rock bolting

Epiroc makes the ‘impossible possible’ with launch of Boltec ABR

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Epiroc has taken another significant step forward in its rock reinforcement automation journey with the release of the Boltec Auto Bolt Reload (ABR).

Combining the company’s ground support nous with its mechanisation and automation knowledge has resulted in a solution able to remove operators from the front end of the bolter – where personnel are most at risk of rock falls from unsupported ground – and increase bolting productivity, especially in poor ground conditions.

With mining operations steadily going deeper as they develop existing and newly discovered orebodies, the rock stresses associated with mining these orebodies are typically increasing, too. This often results in more challenging rock conditions with fractured rock mass, rock burst and squeezing ground, requiring more regular rehabilitation work. The Boltec ABR, with improved operator safety, flexibility and productivity, is the obvious choice for such conditions, Epiroc says.

Epiroc claims the Boltec ABR is the first ever underground rock reinforcement drill rig designed in such a way that the bolt type and machine work together in synergy to deliver optimal safety, performance and quality. The machine can also be equipped with a mesh delivery system.

This synergy also leads to improved accuracy in bolt installations and a reduced need for re-bolting, according to Peter Bray, Global Product Manager, Rock Reinforcement at Epiroc’s Underground division.

“By using a Boltec ABR, you are better able to install bolts and mesh correctly with high quality, reducing the need for re-bolting, re-meshing…and rehab work in the future,” he told attendees of a webinar announcing the product launch today.

The mechanisation of the bolting process – in tandem with the use of self-drilling anchors (SDAs) and pumpable resin – should provide operations with the comfort to follow recommended bolting patterns, reducing the need for the installation of additional bolts that go above and beyond optimal industry practice.

The main design feature of the Boltec ABR is the fully mechanised bolt reloading system. The system automatically feeds bolts from a large carrier magazine – able to hold 44 bolts in 2.4-m or 3-m lengths – to the feed magazine – able to hold eight bolts – all while the operator remains safe inside the cabin. This innovation removes the need for manually reloading the feed magazine, thereby reducing the associated risk to the operator.

The fast auto reloading sequence speeds up the production cycle, with a total of 52 bolts able to be installed in a heading before manual reloading of the carrier magazine. The carrier magazine is mounted on a swing arm that lowers the magazine to ground level for easy reloading behind the machine’s front support jacks – where ground support should already be in place.

Productivity can be further boosted with the operator carrying out the reloading process when bolting is being carried out in multi-bolt auto mode, according to Bray.

The Boltec ABR opens the door to other safety and productivity-enhancing autonomous functionalities previously not compatible with underground bolting machines, according to Epiroc. Tele-remote control and the aforementioned multi-bolt auto are now available options that can provide bolting potential during shift changes or when conditions preclude having an operator physically on the machine. The machine is also available with a battery-electric driveline.

Bray said the development and integration of SDAs and pumpable resin on conventional Boltec machines have been integral to achieving this new functionality.

“If you think about our face drills and long hole production rigs, they have had automation for many years,” he said. “There hasn’t been a mechanical reason why we couldn’t automate a bolting machine; the stopping point has been the type of legacy rock bolts used.”

SDA bolts, which, according to Epiroc, offer faster bolting times and higher quality installation, are not sensitive to varying conditions and will achieve consistently fast installation. This provides easier scheduling accuracy for mine planning and forecasting.

The pumpable resin, developed to address inconsistent and unreliable bolt installations as mines go deeper and rocks become less competent under added pressure, offers fast setting times and full bolt encapsulation, ensuring speed and quality of installation, the OEM says. An added plus is the resin’s insensitivity to wet ground conditions, which can be a desirable characteristic for many deep underground operations.

“Given that it is much cleaner and easier to use than traditional cement, the pumpable resin reduces hours spent on cleaning the machine,” Bray said. “Hence, it is increasing productivity by providing more bolting time.”

Like other Boltecs in the range, the Boltec ABR comes with a boom-mounted bolting system, providing flexibility in terms of coverage and bolt installation angles, according to Bray.

“It’s very rare that you have perfect straight drive profiles in underground mining,” he said. “The boom-mounted bolting system offers the flexibility to address this.”

LKAB, along with the European Institute of Innovation & Technology, have been key partners in the development of this machine, with the prototype tested out at both the Kiruna and Malmberget mines in northern Sweden.

Kiruna suffered a significant seismic event during May 2020 where several areas underground were adversely affected, providing a good test case for the new machine.

These affected areas required rehabilitation with bolts and mesh to make them safe for production again, according to Bray – a process the iron ore miner is continuing to carry out at Kiruna with the prototype Boltec ABR unit.

“The Boltec ABR was the perfect machine for the challenge; it has proven to allow safer operation and significant productivity increases when compared to LKAB’s conventional bolting fleet,” he added.

Epiroc said that up to double productivity gains were achieved in a trial with the Boltec ABR in LKAB’s Malmberget mine when compared with the miner’s conventional bolting fleet.

Bray concluded: “This solution has made the impossible possible. We can now install bolts where it used to be extremely difficult. Giving some relief to the bottleneck that rock reinforcement had become.”

Epiroc looks to set underground rock reinforcement standard with Boltec M10, E10

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Epiroc is showcasing the latest additions to its rock reinforcement line at MINExpo 2021 in Las Vegas, with the new Boltec M10 and Boltec E10.

The Boltec M10 (pictured) and the larger Boltec E10 are fully mechanised rock bolting rigs for medium- and large-sized tunnels, designed to increase productivity and bolt installation quality thanks to intelligent options and compatibility with different bolt types, according to the company.

Peter Bray, Global Product Manager, Rock Reinforcement Equipment with Epiroc’s Underground division, said: “As mining operations move ever deeper underground, the difficulty in bolting and securing increasingly fragmented rock is rising. The Boltec M10 and Boltec E10 introduce previously unavailable autonomous functionality: this is the benchmark in underground rock reinforcement.”

With self-drilling anchor bolts (SDA) in combination with pumpable resin, the Boltec M10 and Boltec E10 can perform single bolt and multi-bolt installation automatically, according to Epiroc. These new functions work hand-in-hand with teleremote bolting and offer bolting potential during shift changes or other situations where off-board control during bolting is needed, the company says.

With in-built flexibility, the Boltec M10 and E10 have the ability to handle several different types of bolts, mesh and installation methods as well as radial, face bolting and extension drilling capability, Epiroc says. The boom bolter concept ensures the operator stays at a safe distance from the working area of the machine during the bolting process.

The new Boltec rigs come with an optional battery-electric driveline, which brings additional advancements for operator health, maintenance, ventilation and cooling.

The Boltec M10 and Boltec E10 also come with a completely redesigned operator station. The optional ROPS- and FOPS-certified cabin sets new standards for operator safety and comfort thanks to significantly reduced noise levels down to only (65 dB(A)), HEPA air filtration and better visibility, according to Epiroc. The air-conditioning system also features automatic temperature adjustment, further boosting operator comfort.

Sandvik to unveil new battery-powered bolter, simulator and app at MINExpo

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Sandvik Mining and Rock Solutions is set to unveil three new underground drilling solutions at MINExpo 2021 in Las Vegas, based around a common theme of electrification, sustainability and digitalisation.

The new products to be unveiled at the show, taking place from September 13-15, include a new battery-powered bolting rig, an accompanying portable training simulator and a new mobile application for enhanced drilling.

The new Sandvik DS412iE (pictured) is a highly automated, productive, battery-electric powered rock bolter for underground mining and tunnelling applications. It is equipped with an electric driveline system and battery package with electric motor for zero emissions while tramming and drilling, thereby reducing thermal load and underground ventilation requirements, Sandvik says.

The rig’s iSeries platform offers various levels of automation for rock support drilling as well as providing component commonality through the 400i drill range. The introduction of Sandvik DS412iE rounds out Sandvik’s first range of battery-electric vehicles for all underground drilling applications, according to the company.

Sandvik Digital Driller™ training simulators provide a compact and flexible solution to safely train underground drill rig operators or maintenance teams, the company says. The latest Digital Driller module is specifically designed to support the new Sandvik DS412iE battery-electric rig, with the new version retaining the key features of being low weight and highly portable, enabling it to be used where it is most needed – on site.

Use of the simulator is estimated to increase annual productivity by 5% due to increased rig availability alone, Sandvik claims. In addition, training costs are reduced by up to 35% through less energy and consumables costs and reduced rig damage.

The new Sandvik DrillConnect mobile application transfers drilling plans – including those created in iSURE® – drilling reports and MySandvik machine data in environments where network coverage is inadequate or not available. Sandvik DrillConnect removes paper-based processes and automates the data transfer between the office and drill rig via a customer’s preferred mobile device. The app also provides easy access to the machine’s troubleshooting and manuals and is designed to be scalable for future development, according to Sandvik. The first version will be compatible with iOS devices, with plans to introduce Android compatibility in future iterations.

Patrick Murphy, President of Underground Drilling at Sandvik Mining and Rock Solutions, said: “Our latest developments are based on the feedback we have received from customers. We have listened to their challenges and are developing solutions that ensure we will continue to lead the industry shift toward a more digitalised and electrified future.”

In addition to the new underground drilling solutions being introduced at MINExpo, a Sandvik DL432i tele-remote operator chair will be on display. Sandvik will also showcase the latest updates to its underground drilling product offering.

Sandvik to add rock bolter to battery-powered mining line up

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Sandvik Mining and Rock Technology plans to launch its first and one of the the mining industry’s first battery-powered rock bolters next year, as it continues to roll out new solutions to electrify the underground mining space.

The Sandvik DS412iE extends the zero emissions concept to the underground rock bolter class and opens a wide range of possibilities for mines driven to boost their productivity and safety with data-based analytics, according to the company.

In its core mission of delivering productive, secure and versatile rock support solutions, Sandvik rock bolters have a clear track record, according to the company.

“Still, these tools’ automation and data acquisition capabilities have not been as advanced as their production and development drill rig counterparts,” the company said. “Scheduled for launch during 2021, the new Sandvik DS412iE rock bolter will complement the intelligent family of next-generation battery-powered underground drill rigs.”

Anssi Kouhia, Product Manager, Rock Support Drills, said the DS412iE is basically an upgrade on its existing Sandvik DS411.

“We have received positive feedback about that model,” Kouhia said. “We made an accomplished model even better with more advanced automation capabilities, improved data acquisition and upgraded ergonomics.”

Like the battery-powered DD422iE  jumbo drill, the rig trams on battery and carries out drilling and bolting when connected to the mains power.

Along with its direct predecessor, the new intelligent bolter also has much in common with the larger Sandvik DS512i in the 5 x 5 m drift size. One example is their similar versatility in terms of bolting systems: Sandvik DS512i and Sandvik DS412iE can handle a wide range of bolt types and lengths, including a combination of automatic cement mixer and automatic resin injection on the same bolter.

The new Sandvik DS412iE will effectively complete Sandvik Mining and Rock Technology’s rock support drill range for the 4 x 4 m class, updating its entire product range to the latest i-standard of connectivity and automation capabilities, the company said. Additionally, the Sandvik DS412iE will be the supplier’s first battery-powered rock bolter.

“In other words, the zero underground emissions approach will now include all stages of the underground mining process: rock support drilling as well as development and production drilling and loading and hauling,” Sandvik said. “The ability to virtually eliminate underground particulate matter, NOx, CO2 and heat emissions is first and foremost a major health and safety benefit, but also offers cost savings by reducing mine ventilation power requirements.”

The new rig responds to major industry trends that customers have identified in feedback sessions, Sandvik said.

In addition to reducing underground emissions and improving working conditions, the safety and environmental improvements also make economic sense by reducing time lost to injuries and costs. The advanced automation capabilities will increase the speed and safety of the bolting cycles as well as open a range of possibilities for process optimisation, the OEM said. “This will translate into more reliable rock supporting and safer working environments.”

Like one-hole automation that has been a standard feature in Sandvik mining and tunnelling jumbos, the one-bolt automation feature of Sandvik DS412iE now extends this capability to rock bolters, Sandvik said.

“The rig can carry out a single bolting cycle unassisted, so that in optimal conditions the operator only needs to manually relocate the boom from one bolt location to another,” the company said.

The battery-powered unit will come with two automation levels: the standard Silver package from the outset and, in the near future, the optional extended Gold level. The main difference between the two packages is in the remote monitoring and operating capabilities and in the measurement-while-drilling functionality.

The automation packages seamlessly mesh with Sandvik iSure software, according to the company. Available as a standard tool for designing drift drilling plans and blasting plans, iSure now increasingly extends to bolting operations and comes in three levels: iSure Basic and iSure Plus for the standard Silver automation package, and iSure Premium for the optional Gold level automation. The advanced automation solutions can offer a significant productivity and quality boost, Sandvik said.

“With iSure, you can design a bolting pattern in the office, transfer it to the rig over Wi-Fi or on a USB flash drive, carry out the bolting according to the pattern, and, on top of that, you can retrieve a report that compares the plan and the realised bolting pattern,” Kouhia says.

iSure compatibility, in particular, enables more extensive data acquisition and reporting, Sandvik said.

In addition to the bolting pattern, the retrieved data will also include various parameters that characterise the quality of the bolting process, such as grouting concrete consumption and bolt tightening torques. This can serve to document the bolting process in much greater detail than it did previously, which enables more accurate quality control of the rock supporting measures.

The verifiable track record of the rock support measures taken provides systematic safety documentation and, should a failure still occur, the bolting process reports can help to determine the cause of it, down to the level of an individual bolt – when it was installed, how it was installed and whether it complied with set specifications.

Full compatibility with the My Sandvik fleet management portal and the OptiMine suite of digital mine automation and analytics solutions further enhances the connectivity of Sandvik DS412iE, providing all-round data-based control for rock support operations, the company said.

While the main areas of focus for Sandvik DS412iE surround automation, connectivity and data acquisition capabilities, productivity has not been neglected, Sandvik said.

The new boom control system, advanced boom manipulator mode and optimised bolting head movements help the operator to achieve a smooth and efficient process by keeping the bolting head automatically aligned with the correct bolt fan positions and angles, the company explained.

In terms of sheer mechanical power, much of the new bolter’s high productivity derives from the new control system of the Sandvik RD314 rock drill, which substantially increases the output and penetration rate. Overall, the productivity upgrade is roughly 25% from previous models, according to Sandvik.

The Sandvik DS412iE includes many safety and ergonomic features.

The bolter is designed to be compliant with the EN16228 standard for drilling and foundation equipment, which is harmonised with the requirements of the European Machinery Directive. One of the EN16228 requirements is an access detection system (ADS). In the Sandvik DS412iE, the ADS automatically scans the surroundings of the bolter and alerts the operator should a person enter the work area, which effectively reduces potential accidents. The safety improvements also include a fully covered steel strand reel.

The Sandvik DS412iE continues the bolter class’ legacy of secure and effective cabin design, Sandvik says, with a 55% percent improvement in visibility, better effective vibration control and significant noise reduction adding up to a safer and more comfortable workplace for the operator.

Future launches will also include a diesel-powered version, Sandvik DS412i, which will be compliant with the latest engine emission specifications, Sanvik said.

This is an edited version of a story that first appeared on Sandvik’s Solid Ground platform here.

Sandvik narrows down market for new class of underground drills

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Sandvik Mining and Rock Technology has launched a new class of narrow size drills specifically aimed at the requirements of specialist mining companies as well as drill and blast contractors requiring safe, productive, mobile rigs for use in narrow vein and other confined areas.

The new 2711 class of drills are simple and safe to operate, with robust components, and provide an excellent performance to ownership cost ratio, according to the company.

The 2711 class drills have been developed to cater to the needs of certain mining and tunnelling operations.

Sandvik explained: “Selective mining methods and small tunnel developments have proved to be a good way to extract ore economically, and control the dilution when ore is distributed in narrow veins typically less than 2-3 m in width. Sandvik’s narrow size underground drills are thus designed specifically with the requirements of drilling narrow vein drifts and that of small tunnels projects in mind.”

The drills are also equipped with Sandvik’s Fleet Data Monitoring systems, enabling mines and tunnelling contractors to improve fleet performance and management.

The 2711 class is an ideal solution for specialist mines and drilling contractors looking for smarter control of ore dilution and increasing selective process in mining, according to Sandvik. The series consists of three drill types using a common platform covering different applications: namely development drilling DD2711, rock support bolting DS2711 and long hole production drilling DL2711 and DL2721.

The DD2711 (pictured) is a compact and flexible single boom electro-hydraulic jumbo for mining development and construction in small and medium size tunnels with a minimum cross section of 2.7 m x 2.7 m. The versatile boom delivers large coverage and fully automatic parallelism for fast and accurate face drilling, while 20 kW of drilling percussion power is provided through Sandvik’s HXL5 rock drill.

The rig is designed for underground hard-rock applications that require high capacity and reliability in development blast holes ranging from 3.7 m to 4.3 m in length.

The DS2711, meanwhile, is a one-man operated electro-hydraulic, fully mechanised bolter for rock reinforcement in underground hard-rock mines. The operator works from supported ground while protected under a FOPS-certified canopy structure. “Mechanisation of the bolting process ensures efficient, constant and durable rock bolts integrity,” Sandvik said.

The DS2711 provides “excellent” bolting performance to cost ratio for small and medium size tunnels with minimum cross section of 2.7 m (width) x 3 m (height), according to Sandvik.

“Designed with proven and reliable components, the DS2711 provides high reach, and is able to install all types of mechanised rock bolts ranging in length from 1.5 m to 2.4 m. It is in effect a small premium bolter, compact, mobile and designed for global needs.

The next addition to the range will happen in 2020 with Sandvik DL2711 & DL2721 long hole drills.

Sandvik concluded: “The new 2711 drill family provides, in one modular platform, accurate drilling with high performance, large coverage and drill capacity, with enhanced product safety and excellent mobility, tramming smoothly into small mining drifts and tunnels.

“The selected reliable components and simple electro-hydraulic systems are designed to be used in conjunction with Sandvik’s comprehensive range of underground drills, loaders and trucks, all being supported worldwide by the Sandvik network.”

Sandvik improves rock bolting safety and efficiency with DS512i

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Sandvik Mining and Rock Technology says it has launched its new bolter for 5 m x 5 m size headings, combining a safe, ergonomic working environment with high levels of performance.

Equipped with a completely new carrier, high frequency rock drill, control system and ergonomic cabin, the Sandvik DS512i offers high levels of safety and efficiency, providing peace of mind for all rock reinforcement operations, the OEM says.

“The safe and efficient new Sandvik DS512i is equipped with the new FOPS/ROPS cabin as standard, providing a safe, comfortable working environment for the operator,” Sandvik said. “This reduces noise, vibration and dust levels and improves visibility while drilling and tramming.”

Furthermore, the operating environment has an interactive graphic user interface enabling all bolting operations to be performed by a single operator in safety and comfort, according to Sandvik.

Intelligent control systems assist during drilling, grouting and bolt tightening for high levels of automation, while machine efficiency is further maximised through easy to access service points from ground level, Sandvik says. The latter provides rapid maintenance and trouble shooting.

The new DS512i also comes ready for the AutoMine® fleet and information management system and has multiple levels of automation, enabling the correct choice of rig for the specific application.

“High levels of drilling performance are ensured, thanks to the use of the Sandvik RD314 high frequency rock drill and the drilling control system which optimises drilling penetration rates,” the company said.

The one bolt automation function of the DS512i, meanwhile, provides improved drilling productivity and extends operating lifetime of the drilling tools.

Sandvik says: “The new DS512i provides the ultimate peace of mind in rock support. With up to 55% increased operator visibility and 35% higher penetration rates for greater productivity, performance and safety are seamlessly combined.”

An upgraded bolting head comes with different bolt lengths providing an extensive bolt selection, while the eight-rock bolt carousel ensures the DS512i is capable of installing different types of rock bolts ranging from 1.6 m (5’) to 6 m (20’) in length.

An automatic resin shooting and cement mixing system further guarantees a high quality rock reinforcement process.

Able to carry a 1200 kg cement silo, the DS512i delivers increased meshing as well as hole angle measurement and an advanced boom manipulator, the company said. Bolting head movement is further optimised with new assistive and automatic features.

“Designed specifically for tunneling and mining, the DS512i has been developed based on a modularised concept leading to high levels of parts commonality with the Sandvik DT922i, enabling lower levels of total cost of ownership,” Sandvik said. “The bolter has been designed for the integration of subsequent actions involved in the drill & blast.”

As well as being the ideal bolter for tunneling, the new DS512i comes complete with features to make it the perfect choice for mining bolting operations, according to the company.

“It possesses several types of bolt length and varieties within the same machine and an automatic cement mixer in parallel with automatic resin injection,” Sandvik says.

”Ideal for small and large headings, it enables high bolting and meshing coverage, with efficient operations being ensured through sharing high commonality of parts with other members of the 400i carrier series.”

Automation

As well as the above performance features, the new DS512i is equipped with high levels of automation. These have been developed to suit the specific needs of the customers and come in two packages: Silver and Gold.

The Silver package comprises of ‘one bolt’ automation (collaring, drilling, grouting, bolt handling, tensioning) and hole angle measurement. The boom is fully instrumented with indicators for hole angles, tilt and rotation, as well as an advanced boom manipulator, automatic cement mixing and basic remote monitoring, among other features.

The Gold package has full instrumentation and fan bolt locations to show one or more bolt fans to the specific mine or tunnel coordinates. iSURE comes as standard along with MWD, Total Station Navigation, Tele-Remote bolting, ‘planned versus actual’ bolting (which can be transferred to the control system) and full remote monitoring.

 

Epiroc pumps up rock reinforcement offering

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Epiroc, together with LKAB, has developed a new solution for installing long-term rock bolts in poor rock conditions.

The pumpable resin system for underground rock bolting, designed for the mechanised bolting machines Boltec M and Boltec E models, is a result of the mining OEM and mining company’s collaboration within the EU-led Sustainable Intelligent Mining Systems (SIMS) project.

Epiroc says: “One of the more difficult rock reinforcement tasks in underground mining and tunnelling operations is how to install long-term rock bolts in poor rock conditions. Rock bolting, as a result, is often the bottleneck within the drill and blast cycle, leading to difficulties to predict work task scheduling.”

Blocky or friable ground often leaves drilled bolt holes blocked or partially blocked. This slows down, or in the worst case, prevents the introduction of bonding agents such as cement grout or resin cartridges into the bolt hole.

“The Epiroc and LKAB solution will allow a faster, more reliable and cost effective bolting alternative for long term rock reinforcement in difficult ground conditions,” Epiroc said.

Peter Bray, Global Product Manager, Epiroc, said: “An important factor to achieve a workable rock reinforcement solution is to have a system where the bolt design, bonding agent and bolting rig all work together to provide a robust and reliable bolt installation. To this end, Epiroc has worked hand in hand with a leading bolt and chemical supplier to create a bolting system that addressed the issues faced with long-term bolting in poor ground conditions.”

The result of this work is an integrated pumpable two-component resin system that can be used with a Self-Drilling Anchor style bolt in tougher ground conditions or, alternately, with a two-step hollow bolt in more moderate ground conditions.

“Having the ability to choose a long-term rock bolt that suits the ground conditions means that customers are able to achieve an optimal rock reinforcement regime in terms of function and budget,” concluded Bray.