A METHOD OF INSTALLING A CABLE BOLT, A SYSTEM AND COMPONENTS OF SAME
20250277449 ยท 2025-09-04
Inventors
Cpc classification
International classification
Abstract
A method of installing a grouted cable bolt, a system for providing same and components which may form part of the method and/or system including a delivery assembly comprising a delivery nozzle at a distal end of the delivery assembly; a mixing chamber in fluid communication with the delivery nozzle; a first line for conveying a first component to the mixing chamber; and, a second line for conveying a second component to the mixing chamber the first line being located within the second line, and wherein the hardenable composition in liquid form is formed from mixing the first component with the second component.
Claims
1. A method of installing a cable bolt within a borehole including an open end and an inner surface leading away from the open end towards a blind end, the method including the following steps: (a) delivering a hardenable composition in liquid form at or near the blind end of the borehole via a delivery assembly and substantially filling the borehole with the hardenable composition from the blind end towards the open end of the borehole wherein the hardenable composition is formed from two components, a first component and a second component which when mixed form the hardenable composition in liquid form, the delivery assembly including a first line for delivering the first component and a second line for delivering the second component the first line being located within the second line; (b) introducing an anchor end of the cable bolt to the open end of the borehole and pushing the anchor end of the cable bolt through the hardenable composition in liquid form until the anchor end of the cable bolt is proximate to the blind end of the borehole; and, (c) allowing the hardenable composition to harden.
2. The method according to claim 1 wherein the delivery assembly is withdrawn from the borehole at one of a same or similar rate as the rate at which the borehole is filled with the hardenable composition.
3. The method according to claim 1 wherein the first component and the second component are mixed in a mixing chamber in the delivery assembly prior to delivering the hardenable composition in the liquid form; the delivery assembly includes a delivery nozzle at a distal end for delivering the hardenable composition to the borehole; and the first line and the second line deliver the first component and the second component to the mixing chamber which is in fluid communication with the delivery nozzle, with the mixing chamber being located immediately before the delivery nozzle on the delivery assembly.
4. (canceled)
5. (canceled)
6. The method according to claim 3 wherein the mixing chamber is located immediately before the delivery nozzle on the delivery assembly, with the mixing chamber includes a static mixer located therein for assisting with the mixing of the first component and the second component, with the static mixer is a helical static mixer.
7. (canceled)
8. (canceled)
9. The method according to claim 3 wherein the mixing chamber and the delivery nozzle are one or more of located within the borehole during step (a) and proximate the blind end of the borehole at a commencement of step (a).
10. (canceled)
11. The method according to claim 1 wherein the first line is located within and substantially coaxial with the second line.
12. The method according to claim 11 wherein the delivery assembly further includes an adaptor with a first port and a second port located at one end, the first port for connecting to a source line of the first component to the adaptor and the second port for connecting a source line of the second component to the adaptor, the adapter configured to deliver the first component to the first line via the first port, and to deliver the second component to the second line via the second port.
13. The method according to claim 1 wherein the hardenable composition hardens at least three minutes after step (a) and preferably at least five minutes after step (a).
14. The method according to claim 1 wherein the blind end is orientated at a higher level than the open end and wherein the hardenable composition includes sufficient anti slump properties whereby the hardenable composition is retained within the borehole after step (a).
15. The method according to claim 1 wherein the hardenable composition is selected from a two component resin consisting of a resin and a hardener, or a two component cementitious grout.
16. The method according to claim 3 wherein the method further includes a flushing step after step (a) wherein at least one of the first component and second component remaining in at least one of the mixing chamber and the delivery nozzle of the delivery assembly are flushed therefrom.
17. (canceled)
18. The method according to claim 1 wherein the borehole has a cross sectional diameter of less than 45 mm.
19. (canceled)
20. (canceled)
21. A delivery assembly for introducing a hardenable composition in liquid form to a borehole, the delivery assembly including: a delivery nozzle at a distal end of the delivery assembly; a mixing chamber in fluid communication with the delivery nozzle; a first line for conveying a first component to the mixing chamber; and a second line for conveying a second component to the mixing chamber the first line being located within the second line, and wherein the hardenable composition in liquid form is formed from mixing the first component with the second component.
22. The delivery assembly according to claim 21 wherein the first line is located within and substantially coaxial with the second line.
23. The delivery assembly according to claim 21 wherein the mixing chamber comprises a static mixer located therein for assisting with the mixing of the first component and the second component, with the static mixer being a helical static mixer.
24. (canceled)
25. The delivery assembly according to claim 21 further including an adaptor with a first port and a second port located at one end, the first port for connecting to a source line of the first component to the adaptor and the second port for connecting a source line of the second component to the adaptor, the adaptor configured to deliver the first component to the first line via the first port, and to deliver the second component to the second line via the second port.
26. The delivery assembly according to claim 21 further including a connector in fluid communication with the first line and the second line, the connector configured to deliver the first component and the second component to the mixing chamber.
27. The delivery assembly according to claim 21 wherein the delivery assembly has a cross sectional diameter of less than 40 mm.
28. (canceled)
29. A system for installing a cable bolt within a borehole including an open end and an inner surface leading away from the open end towards a blind end, the system including the following: i. a delivery assembly for introducing a hardenable composition in liquid form to a borehole, the delivery assembly including a delivery nozzle at a distal end of the delivery assembly; a mixing chamber in fluid communication with the delivery nozzle; a first line for conveying a first component to the mixing chamber; a second line for conveying a second component to the mixing chamber the first line being located within the second line, and wherein the hardenable composition in liquid form is formed from mixing the first component with the second component including a liner open end and a liner blind end; ii. a source of the first component for delivery to the first line; and iii. a source of the second component for delivery to the second line.
30. A system according to claim 29 wherein the first line of the delivery assembly is located within and coaxial with the second line of the delivery assembly.
31. The system according to claim 29 wherein the mixing chamber of the delivery assembly includes a static mixer located therein for assisting with the mixing of the first component and the second component, with the static mixer being a helical static mixer.
32. (canceled)
33. The system according to claim 29 wherein the delivery assembly further includes an adaptor with a first port and a second port located at one end, the first port for connecting to the source of the first component to the adaptor and the second port for connecting the source of the second component to the adaptor, the adaptor configured to deliver the first component to the first line via the first port, and to deliver the second component to the second line via the second port.
34. The system according to claim 29 wherein the delivery assembly further includes a connector in fluid communication with the first line and the second line, the connector configured to deliver the first component and the second component to the mixing chamber.
35. The system according to claim 29 wherein the delivery assembly has a cross sectional diameter of less than 40 mm.
36. (canceled)
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] Notwithstanding any other forms which may fall within the scope of the method and apparatus as set forth in the Summary, specific embodiments of the method and apparatus will now be described, by way of example, and with reference to the accompanying drawings in which:
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DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS
[0060] The present disclosure provides a method of installing a cable bolt within a borehole which enables the method to be carried out during the process of providing primary support. That is the method as herein described may be undertaken at the same time or shortly after the rock excavation process.
[0061] The method involves installing a cable bolt in a borehole which includes a circular open end, an inner surface leading away from the open end towards a blind end. Typically, the borehole would be drilled into a rock substrate with the orientation of the holes being from vertical-up to about 30 off the vertical although sometimes the borehole orientation is near to horizontal. The length of the borehole may be up 20 meters in length but typically borehole lengths are 2 to 6 metres. Typical diameters of the borehole may be from 33 to about 42 mm in length and the cross section is substantially cylindrical providing an inner surface including cylindrical side walls which run the length of the borehole to the blind end. Drilling the borehole may be undertaken by conventional technology and methods.
[0062] The method has herein described includes the step of: (a) delivering a hardenable composition in liquid form at or near the blind end of the borehole and substantially filling the borehole with the hardenable composition from the blind end towards the open end of the borehole. This step may be undertaken via a delivery assembly in the absence of the cable bolt within the borehole. Otherwise, stated, the borehole is filled with hardenable composition without the cable bolt located within the borehole.
[0063] Once step (a) is completed and the borehole is filled with the hardenable composition, the method moves to step (b) where an anchor end of the cable bolt is introduced to the open end of the borehole. During this step, the cable bolt may be pushed through the hardenable composition which is still in liquid form contained within the borehole until the anchor end of the cable bolt is proximate to the blind end of the borehole. Once the anchor end of the cable bolt is in place proximate to the blind end of the borehole, the method proceeds to step (c) where the hardenable composition is allowed to harden whereby the cable bolt is secured in place.
[0064] During step (a) the hardenable composition in liquid form may be delivered at or near the blind end of the borehole via a delivery assembly. The delivery assembly may be withdrawn from the borehole during step (a) at the same, or similar rate as the rate at which the borehole is filled with the hardenable composition. This provides that the hardenable composition does not surround the delivery assembly as the borehole is filled with the hardenable composition.
[0065] In certain embodiments, the hardenable composition hardens after at least three minutes after step (a) is completed. In a preferred form, the hardenable composition hardens after at least five minutes after step (a) is completed. In a further preferred form, the hardenable composition hardens within 20 minutes after step (a) is completed. In yet a further preferred form, the hardenable composition hardens within 15 minutes after step (a) is completed.
[0066] The hardenable composition may be cementitious or resin and it may be a single component grout or have two or multiple components that react together to initiate hardening.
[0067] As herein described, the hardenable composition will generally comprise a mixture of two or more classes of substances, that is at least a first component and a second component, which solidify (harden, or cure) upon mixing. It is preferred that the first component and the second component are also stable in liquid form and are able to be pumped, i.e. pumpable.
[0068] The mixing step of the first component and the second component will typically occur during step (a) of the method as herein described such that the hardenable composition is in liquid form for a sufficient time to allow the hardenable composition to harden (cure) during step (c) once the cable bolt is in place within the borehole and surrounded by the hardenable composition. In a preferred form, at least a first component and a second component of the hardenable composition are mixed in a mixing chamber in the delivery assembly prior to delivering the hardenable composition in liquid form.
[0069] The hardenable composition may be selected from any one of the following: silicate resins, polyurethane resins, polyester resins, epoxy resins, urea formaldehyde resins, polyurea resins, melamine formaldehyde resins, vinyl ester resins, furan resins, acrylates, methacrylates, thermosetting resins and/or cement based materials and mortars.
[0070] In certain embodiments, additional components such as fillers may be included in the hardenable composition.
[0071] It is preferred that the hardening time of the hardenable composition must be delayed for at least 3 minutes, and preferably at least 5 minutes from the time of completion of step (a). This enables enough time for installation of the cable bolt by thrusting though the grout emplaced in the boreholes.
[0072] It is preferable that the hardenable composition builds strength rapidly after it has hardened, so that the hardenable composition may form a critical bond length of less than 1 metre within 2 hours, and preferably within 1 hour of completing step (a).
[0073] It is preferable that the hardenable composition in liquid form and in particular the first component and the second component have low viscosity of less than 10,000 mPa.Math.s (centipoise) and more preferably, less than 1000 mPa.Math.s, and yet more preferably less than 500 mPa.Math.s. The low viscosity provides benefits as this reduces the pressures needing to be developed to pump the first and second components by their associated pumps. Lower pumping pressures also allows the use of thinner-wall conduits, increasing cross-sectional area available for flow, especially in the confined cross-section of the borehole. Flow of low-viscosity fluids more readily transitions from laminar to turbulent. Turbulent flow enhances mixing, potentially supplementing the effect of the mixing chamber to better form the hardenable composition from mixing the first and second components.
[0074] It is also preferable that the hardenable composition rapidly begins thickening (i.e. rise in viscosity) where the hardenable composition develops strong anti-slump properties upon the mixing of the first component and the second component, so that the grout emplaced in the borehole does not flow out of the hole under its own weight. In a preferred form, the hardenable composition begins thickening within 20 seconds upon mixing of the first component and the second component. In a more preferred form, the hardenable composition begins thickening within 10 seconds upon mixing of the first component and the second component, and in a further preferred time within 5 seconds upon mixing of the first component and the second component.
[0075] The thickening of the hardenable composition occurs once the first component and the second component are mixed during step (a). The thickening of the hardenable composition occurs prior to the hardening of the hardenable composition.
[0076] More scientifically, the hardenable composition when thickening is preferably a Bingham Liquid. Bingham liquids require a minimum shear stress before they yield or start to flow. In this case the hardenable composition has a shear stress threshold higher than the stress stresses set up by the weight of the hardenable composition from gravity. Whilst the Bingham characteristic remains desirable, the threshold shear stress should not be so high that the anchor end of the cable bolt cannot be pushed through the hardenable composition when located within a borehole. However, it should be high enough that the cable is retained in the hardenable composition and does not slide out under its own weight.
[0077] It is preferred that the rheological properties of the hardenable composition are independent of the hardening of the hardenable composition, which preferably begins after approximately 3 minutes after step (a) and more preferably after 5 minutes after step (a).
[0078] It is preferable the hardenable composition has sufficient longevity once cured which provides that the properties of the hardened composition last for at least as long as the design service life of the cable bolt support element. In addition, it is preferable the hardenable composition has a pH that is safe to use, includes corrosion-inhibiting properties, slight expansivity as well as low cost.
[0079] In another embodiment, the present disclosure provides a delivery assembly for introducing a hardenable composition in liquid form to a borehole, the delivery assembly including a delivery nozzle at a distal end of the delivery assembly; a mixing chamber in fluid communication and located adjacent the delivery nozzle along the length of the delivery assembly; a first line or conduit for conveying a first component in liquid form of the hardenable composition to the mixing chamber; and, a second line for conveying a second component of the hardenable composition in liquid form to the mixing chamber. The hardenable composition in an initial liquid form may then be prepared within the mixing chamber by mixing the first component with the second component which is then delivered via the delivery nozzle.
[0080] The first line may be located within the second line. This provides that the first and second line are contained within a single outside surface. Otherwise stated, the first line is located within the bore of the second line. The first line may be located entirely within the bore of the second line whereby the first line and the second line are in the form of elongate conduits where an outside cylindrical surface of the first line is entirely contained within and separate to an inner circumferential surface of the second line. In an alternative form, the first line may be located within the bore of the second line where at least a part of the inner circumferential surface of the first line is formed from the second line.
[0081] The first line may be located substantially in line with the axis of the second line such that the first line may be within and substantially coaxial with the second line. Alternatively, the first line may be located within the second line and where the first and second line do not share the same axis.
[0082] By providing a structure where the first line is located within the second line the first and second line have a more streamlined outer surface (i.e. the surface of the second line) which assists in inserting and withdrawing the delivery assembly within the borehole in line with the method as herein described. In this embodiment, the first line may be a cylindrical elongate conduit with an outer surface. The first line may be contained within the second line which is also in the form of a cylindrical elongate conduit. This means that the outside surface of the first line is contained within the interior surface of the second line. This structure also provides that the second component flowing through the second line is in contact with the outside surface of the first line, but not in contact with the first component flowing through the first line.
[0083] An advantage of the first line being located within the second line is that this structure makes better use of the available cross-sectional area within the borehole, allowing more of the cross-sectional area to be utilised for flow of the liquid components through the first and second lines. This reduces the pumping pressures required and/or enables higher flow rates of the first and second component. In addition, the structure provides that the pressure difference across the wall of the first line is less than the pressure difference experienced if the first line was external from the second line. This is because the outer surface of the first tube is subject to the pressure of the fluid flowing in the surrounding second line, which may be close to or substantially similar to the pressure of the fluid in the first line. This allows that the wall thickness of the first line may be reduced.
[0084] A further advantage that is provided when the first line is located within the second line is that this arrangement reduces the outside circumference of the first and second line which provides that the delivery assembly has a reduced cross sectional area. By having a reduced cross-sectional area, it is possible to insert the delivery assembly in boreholes with diameters less than 45 mm in diameter and less than 33 mm in diameter.
[0085] An example of the first line 25 located within the second line 30 is depicted in
[0086] The mixing chamber of the delivery assembly may also include a static mixer located therein for assisting with the mixing of the first component and the second component. The static mixer may be in the form of a helical static mixer.
[0087] The delivery assembly may also include an adaptor with a first port and a second port located at one end, the first port may be able to connect to a source line of the first component which may in the form of a fluid conduit leading to a tank or reservoir containing the first component. The second port of the adapter may be able to connect to a source line of the second component which may be in the form of a fluid conduit leading to a tank or reservoir containing the second component. A pump may be attached to the source line of the first component and another pump may be attached to the source line of the second component to assist in delivering the fluids to the first and second ports of the adapter. The adapter is structured to then deliver the first component to the first line via the first port, and to deliver the second component to the second line via the second port.
[0088] The delivery assembly may also include a connector which is in fluid communication with the first line and the second line and located immediately before the mixing chamber along the length of the delivery assembly. The connector may include an inlet at one end of the connector which is in fluid communication with the first line and the second line and a deliver port at the other end of the connector which is in fluid communication with the mixing chamber. The connector functions to deliver the first component and the second component from the first line and the second line to the mixing chamber.
[0089] In another embodiment, the present disclosure provides a system for installing a cable bolt, the system including the following: a delivery assembly as herein described for introducing a hardenable composition in liquid form to a borehole, a source of the first component for delivery to the first line; and a source of the second component for delivery to the second line.
[0090] The system may also include a mechanised rig for drilling of holes in rock, the pumping of hardenable composition into the holes and the thrusting of cable anchors through the already-pumped hardenable composition, to span substantially the entire length of the borehole. The rig (and similar rigs) develops the force to thrust the cable into the boreholes by passing the cable between two powered rollers that rotate in unison, engaging frictionally with the cable to advance it. To develop high thrust, the rollers exert a strong compressive force on the cable as it passes between them.
[0091] The method and system as described herein will now be described with reference to an example embodiment depicted in
[0092] Referring to
[0093] Referring to
[0094] Referring to
[0095] Referring to
[0096] At this stage and in reference to
[0097] Referring to
[0098] Referring to
[0099] The mixing chamber 20 and delivery nozzle 15 are shown in more detail in
[0100] Referring to
[0101] The adaptor 40 is shown in further detail in
[0102] In the foregoing description of preferred embodiments, specific terminology has been resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as top and bottom, front and rear, inner and outer, above, below, upper and lower and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.
[0103] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.
[0104] In this specification, the word comprising is to be understood in its open sense, that is, in the sense of including, and thus not limited to its closed sense, that is the sense of consisting only of. A corresponding meaning is to be attributed to the corresponding words comprise, comprised and comprises where they appear.
[0105] In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.
[0106] Furthermore, invention(s) have been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s). Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.
TABLE-US-00001 Table of Parts Delivery assembly 10 Delivery nozzle 15 Mixing chamber 20 First line 25 Second line 30 Static Mixer 35 First component 31 Second component 32 Adapter 40 First port 50 Second port 55 Connector 60 Inlet port 65 Delivery port 70 First opening 71 Second opening 72 Borehole 100 Opening 105 Blind end 110 Side walls 115 Rock strata 120 Hardenable composition 130 Cable bolt 140 Anchor end 145