A Review of Application and Benefits of

Thin Spray-On Liners for Underground

Rock Support in South African Mines
8th South African Young Geotechnical
Engineers Conference
Cultivating the Future of Geotechnics
Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

Introduction
Budget

Planned
return on
investment

Safety
Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

Business
aim of
mining
operations

(Stacey, 2001; 2009)

(Webber-Youngman & Van Wyk, 2009)

Introduction
- continued
Explosives
3%
Electricity
2%
Other
7%
Fall of
Ground
35%

Machinery
4%
Rallbound
S/W
Equipment
Installation
10%
5%
Trackless
Mobile
Machinery
16%

Mining roof top

General
18%

Potvin et 90% of rockfall injuries involve rocks smaller than one metric tonne.
al., 2001
In USA metal mines in 1996, small rocks weighing 11-kg or less were
Lacerda, responsible for 65% of all reported injuries and fatalities.
2004
Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

Introduction - continued

http://www.tensarcorp.com/Applicati http://miningandconstruction.com/construct
ons/Mining/mining-roof-and-wallion/behind-the-gray-walls-the-art-ofsupport#
shotcreting-2485/

Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

TSLs - Definition
(Ferreira, 2012)

Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

(Sudbury Mining Solutions Journal, July 2012)

TSLs History and Background

Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

TSLs Composition, Properties & Type

Polymer base and Mixture type
Reactive or
Non-reactive
Polymer
based

Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

Water based

Polyurethane/
Polyurea

Support Mechanism/Analysis of TSLs

Adhesion

a)

Tension

Adhesion
failure

b)

Shear failure

contributory area

contributory area
tendon spacing

(Kuijpers et al., 2004)

Extent of debonding

fracture
zone
depth
fabric forces
Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

tendon forces
8

Application of TSLs in Mines

Tentative application guidelines for TSLs

Development drift (walls)

Development drift (roof or

back)
Production headings (lower
wall)

Rock Mass Rating

(%)
45 - 65
>65
45 - 65
>65
45 - 65

2-3
3-4

2-3

>65
45 - 65
>65

Production headings (roof

and back)

TSL Thickness
(mm)

3-4

Bolting pattern1
1.8 m x 1.5 m2
1.8 m x 1.5 m3
1.8 m x 1.1 m4
1.8 m x 1.3 m4
1.8 m x 1.5 m5

Boltless or spot bolting5

1.8 m or 2.4 m x 1.1 m4

(Espley et al, 1999)

Description

Note:
1Mechanical

bolts.
2Bolting after every two rounds of advance.
3Indefinitely delayed with bi-annual audits.
4Install before or immediately after liner.
5Installation can be delayed.
Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

Benefits from use of TSLs in SA Mines

Reduced
Material
Handling

Rapid
Curing
Times

Increased
Productivity

Flexible
and
Elastic

Effective
Cover against
Weathering

Reduction
in Fatalities

Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

10

Benefits Product Comparisons (cost, application and time)

Approximate ex
factory product
cost per m2
Approximate
dedicated labour
cost per m2
*Approximate
Total cost per m2

Rebound
Bags per m2
Kg per m2
Ease of Application
**Time to cover 45
m2 (conventional
application)
Equipment
Interference with
development cycle

Shotcrete

KT 2C

( 25mm)

( 5mm) 3m2

R85

R95

R85

R65

R85

R125

R55

R55

R55

R55

R210

R150

R140

R120

R140

Hardly any

Hardly any

Hardly any

Hardly any

0.33

0.33

0.33

0.33

88
Cumbersome

8.35
Easy

8.35
Easy

8.35
Easy

8.35
Easy

150 Minutes

55 Minutes

55 Minutes

55 Minutes

55 Minutes

Large

Small

Small

Small

Small

High

Minimal

Minimal

Minimal

Minimal

Poor (lots of
material)
3.5

Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

KT White

KT Grey

KT Fast

( 5mm) 3m2 ( 5mm) 3m2 ( 5mm) 3m2

(Ferreira, 2012)

Description

11

Benefits Early Age Properties Comparison

1 : 15 hr : min
2 : 30 hr : min
3 : 45 hr : min
5 : 00 hr : min
6 : 00 hr : min
8 : 00 hr : min
12 : 00 hr : min
24 : 00 hr : min
25 : 00 hr : min
40 : 00 hr : min
7 days
28 days
5 hours
8 hours
24 hours
7 days
28 days
6 weeks
Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

Non-Reactive TSL
MPa
PSI
Bond Strength
0.30
44
0.40
58
0.50
73
0.55
80
0.60
87

1.20
1.50
2.00

1.5

Fiber Reinforced Shotcrete

MPa
PSI

0.2
0.3
0.5

29
42
71

1.7

239

1.0
1.7
2.2
2.3

145
247
312
328

174
218
290
Tensile Strength
218

2.0

290

4.0

580

(Lacerda, 2004)

Elapsed Time

12

Benefits Reduction in Fatalities

Relation between injuries and TSLs usage in South African
Mines (1998 2002)

400

200

0
0

20

Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

40
60
TSL usage (Percentage)

80

100

(Adams, 2002)

Injuries (Total counts)

600

13

Conclusion
Five attributes of Innovation

Complexity
Compatibility

Relative
Advantage
Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

Trialibility

Uptake

Observability

(Rogers, 2003)

14

Conclusion
Five stages of innovation process

Confirmation
Implementation
Decision
Persuasion
Knowledge
(Rogers, 2003)

Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

15

THANKS

Jjuuko Samuel
Department of Civil Engineering
University of Cape Town
smljju001@myuct.ac.za

16