Solutions for. Hard Rock Mining. Expanding Horizons Underground

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1 Solutions for Hard Rock Mining Expanding Horizons Underground

2 Introduction Improved Productivity MEYCO Global Underground Construction, (MEYCO) is a world leader in the provision of reliable, customer-oriented product solutions focused on your needs in the mining sector. We are part of BASF, The Chemical Company, a well established multinational company with extensive support frameworks and are resources that you would expect from a leading worldwide construction chemical supplier. MEYCO recognises that your success is founded on delivering solutions that meet or exceed your customers critical needs. By being there from the start and understanding the issues that are important to you, we can contribute to your success. Enhanced Safety As many underground projects attract international contractors and design teams, our global presence allows the seamless transfer of technology and services to any of your projects, anywhere in the world. MEYCO knows that creating a safe mining environment for efficient production is an absolute necessity for any mine operator. With today s vast array of increasingly sophisticated equipment, ground control techniques and materials, MEYCO continues to support mining partnerships by developing many technological advancements, both in products and equipment, that can directly enhance safety and improve productivity in the mining environment. Our mining experience is Global, covering North and South Americas, Europe, Africa, Asia and Australia, hence we are familiar with the requirements of most underground mining systems. 2

3 Solutions The Total Package for Ground Support Simplicity is the Key Rock Solid Support Through MEYCO s total system s approach, we offer the mining sector a number of key product solutions in the general field of ground support: Admixtures - for sprayed concrete, pre cast concrete and in situ linings of roadways and shafts, as well as accelerators, stabilisers, water reducers, fibres and curing systems. MEYCO Equipment the world renowned sprayed concrete pumps and robotic manipulators, with robust construction, are able to operate in confined spaces, such as MEYCO Cobra. We can also offer special equipment such as MEYCO Altera sprayed concrete unit and the GP 2000 grout pump. Looking to the future, the automated Logica sprayed concrete technology system is being transferred from the civil tunnelling sector to the mining market. Our MEYCO Thin Spray-On Liners, (TSLs) for rapid surface support, rock weathering protection and ventilation sealing. Backfill products to improve the efficiency of mine backfill operations, whether with paste, hydraulic or cemented rock / aggregate fill. Rock and cable bolt grouting products which include cement grout additives and pre bagged products. A complete range of products for your bolting requirements. Other ground control systems using cementitious foaming grouts for ventilation seals, side support and cavity filling. Water control systems, including the widest range of ground injection products both cementitious and chemical. Corrosion and abrasion control systems suitable for metallurgical processing plants, workshops and high wear areas in the mine, above and below ground. Polyurethane and urea silicate injection systems for superior ground consolidation and low-risk cavity filling. Complete System Approach with all mining products supplied by MEYCO, we complement them with the correct equipment, advice and support from experienced mining personnel in your region. 3

4 Applications 1 Pre-Injection 2 Injection/Rock Bolting 3 TSL/Dry Sprayed Concrete/MEYCO Piccola 4 Wet Mix Sprayed Concrete/MEYCO Cobra 5 Mine Backfill 6 Wet Mix Sprayed Concrete/MEYCO Altera 7 Admixture for Shaft Concrete 8 Admixture for Roadway Concrete

5 Injection: Ground Consolidation and Cavity Filling MEYCO has a complete range of water-sealing and ground consolidation products. Rock Bolting: Advanced Technology Our specially formulated additives and pre-bagged grouts offer practical solutions. Thin Spray-on Liners (TSL): Fast Acting Our unique sprayable membrane for surface protection. Backfill: Flow Optimization Customized solution for rheology control and binder optimization Shaft and Roadway Concrete: Our advanced concrete technology provides endless options when it comes to placing concrete underground. Sprayed Concrete: Total System Approach MEYCO s unique range of dry and wet mix solution gives you safety, flexibility and economy for this important support activity. Abrasion Resistant Lining: We have proven abrasion-resistant flooring and lining products for processing plants. Ventilation: Effective Surface Protection and Sealing Our unique sprayable membrane reduces air slaking and weathering. Service-Technical Support and Training: We support all products with extensive on-site training and trouble shooting. We have a worldwide team in excess of 250 specialists so help is only a call away. Products RHEOCEM Microfine Cements MEYCO MP 350, 355, 357, 358 SC (PU) MEYCO MP 364, MP 367 (PUS) MEYCO MP 320 Colloidal Silica MEYCO Minegrout with Corrosion Protection MEYCO Cablegrout Flowcable with Corrosion Protection Equipment One and two component PU injection pump Packers, lances etc. Grout pump MEYCO TSL 865 MEYCO Piccola MEYCO Oruga MEYCO Minefill Solutions GLENIUM Hyperplasticizers RHEOBUILD Range of Plasticizers DELVO CRETE Stabiliser GLENIUM ACE for Self-Compacting Concrete GLENIUM Hyperplasticisers MEYCO TCC 735 Concrete Improver MEYCO SA Alkali-Free Accelerators DELVO CRETE Stabiliser Hydration Control MEYCO FIB Steel & Structural Plastic Fibers MEYCO Cobra, MEYCO Oruga MEYCO Suprema Pump MEYCO Altera Pump MEYCO Piccola, MEYCO GM MEYCO Anvilmine / MASTERTOP 230 MEYCO Piccola, MEYCO GM MEYCO Altera, MEYCO Suprema, MEYCO Cobra MEYCO TSL 865 MEYCO Piccola MEYCO expertise is always available to you underground. Our highly trained and experienced team will be there whenever needed. 5

6 Sprayed Concrete Workers Safety Continuous Strength Development High Durability The demand for high quality, durable sprayed concrete which poses negligible health risks and fewer negative impacts to the environment is ever increasing. Worldwide, there has been an important shift from dry to wet mix applications in underground construction. This change, together with the latest technology in equipment and alkali-free accelerators providing low dust and rebound levels, has significantly improved the working environment and lowered health risks. In order to achieve early and long-term strength to meet the demands of the underground construction market, MEYCO offers the following key systems that allow durable sprayed concrete structures to be constructed successfully and safely: MEYCO SA range of alkali-free liquid accelerators, a family of products developed to suit your site conditions, offering compatibility to local cements and excellent long-term durability. At the same time it ensures rapid and safe progress through its early strength and continuous strength development. This is a very important factor as early strength can be overlooked for long term strength and durability. GLENIUM state-of-the-art superplasticizers give you a very low w/c ratio coupled with high and extended workability. DELVO CRETE hydration control admixtures are designed to prolong the workability of your concrete mix to allow flexible site logistics. A range of other additives such as silica fume, colloidal silica, steel and polypropylene fibers. 6

7 Spraying Equipment Tradition of Innovation Advanced Equipment Systems Quality and Service Equipment with Added Value MEYCO Equipment invented the first gunite dry powder machine operating according to the rotor principle - the MEYCO GM - in This started a tradition of innovation which has continued through to the present day, providing further breakthroughs and new benchmarks in the industry. Equipment design is focused on optimizing the application of sprayable products underground. It provides the most accurate dosing systems, low pulsation pumping and specialized spraying manipulators, some incorporating laser guidance and various levels of automation, for every type of profile. MEYCO Equipment is certified to meet the highest current industrial and environmental standards. This is reflected in the Customer Service philosophy: available around the globe, wherever and whenever you need us. MEYCO Logica for safe, easy and extremely accurate application through automatic and semi-automatic modes, combined with quality management tools such as profile measurement and data analysis. This technology presently used in the civil industry is being transferred to the field of mining. Wet-spraying machines using MEYCO Suprema pumps, have site-proven reliability and unsurpassed dosing accuracy to produce the highest possible quality end product. MEYCO Cobra, compact and extremely robust mobiles for tighter profiles in mining. MEYCO Cobra 7

8 Injection Higher Productivity and Safety with Pre-injection Controlled Setting Ecologically Friendly Water ingress during underground construction usually escalates project and production costs, inevitably causes significant delays. To counteract these risks, pre-injection of the ground ahead of the advancing roadway face with microcements and mineral based grouts is an economical approach. Of course, some circumstances call for post-injection, stabilization of soils and even structural repairs using high-performance chemical injection products. MEYCO offers a complete range of products and technical support to suit any problem you encounter. The RHEOCEM range of microcements represents a significant technological advancement in cementitious injection. Its unique feature is rapid and controlled setting, minimizing delays to the mining cycle of drill and blast. MEYCO s polyurethane (PU): MEYCO MP 350, 355, 357, 358 SC and polyurea-silicates (PUS): MEYCO MP 364, 367, are used for waterproofing, strata stabilization and void filling in mining applications. We offer a range of high performance acrylic gels for durable, structural concrete crack injection and water seepage reduction. A unique addition to the MEYCO injection family is MEYCO MP 320, a mineral-based grout. MEYCO MP 320 is stable and only consists of natural ingredients, making it non-hazardous and ecologically very friendly. Thanks to its very low viscosity, MEYCO MP 320 penetrates finer fissures than any cement based product and ensures unrivalled penetration and permanent stabilization of fine, silty sands. Colloidal Silica, MEYCO MP 320 0,015 µm RHEOCEM µm RHEOCEM µm RHEOCEM µm Ordinary Portland Cement CEM I µm 8

9 Polyurethane and Urea Silicates Product Reaction time Foam factor Applications Equipment MEYCO MP 355 A3 THIX Highly reactive 2 component PU Accelerator ~ 60s to 15 This fast reacting, thixotropic PU resin is used for very demanding water stopping conditions and dilution of PU is likely. The resin provides immediate structural strength. 2 component pump and static mixer MEYCO MP 364 Flex 2 component solvent free urea silicate, fire resistant resin PUS MEYCO MP 367 Foam 2 component solvent free urea silicate, fire resistant resin PUS 90 ~ 120s 1 Dense glue-like resin, with good penetration properties for very effective ground consolidation of fractured rock and gravels. No foaming in contact with water. Can be used for injection under water. 10 ~ 60s 20 to 30 Cavity filling in tunnelling and mining with beneficial fire resistant properties. Expands without water. 2 component pump and static mixer 2 component pump and static mixer Tailor Made Solutions for Underground Mining Some features and benefits of MEYCO injection resins: All polyurethane and urea silicate products are solvent free and the specific water control products build closed cell foams, to prevent water seepage. Many of the products for preventing water ingress into the underground structures can be adjusted on site using different accelerators to give varying set time performance properties to suit the specific conditions. The urea silicate range of ground consolidation products has been developed to provide improved fire resistance properties for increased safety underground with better performance, notably the strata bonding is unaffected by water. The technical properties and health and safety aspects of all MEYCO polyurethanes and polyurea-silicate resins have been tested and certified by external bodies. 9

10 TSLs Thin Spray-on Liners Effective Surface Protection In hard rock mining, oxidation can affect weak strata, causing rock slabbing and side wall degradation. Effective surface support and the protection of rock and strata against weathering are critical to the safety, efficiency and longevity of any mining operation. MEYCO Thin Spray-On Liners (TSLs) contain fast-setting polymers offering progressively increasing tensile strength development. They provide an excellent bond with almost any substrate, including concrete and rock. In hard rock mining, MEYCO TSLs can be used for: Stabilization of rock through substrate sealing Preliminary slope protection Preliminary and temporary in-cycle support Protection against rock weathering Waterproofing Tensile and Bond Strength MEYCO TSLs are applied in a single 3-5 mm layer. They set to a tack-free surface within 5-10 minutes and gain tensile and bond strength over the subsequent hours, days and weeks. This provides supplementary surface support to strategic areas of the mine where people and critical infrastructure are often present, bringing important safety benefits. The characteristics of the system is that TSLs are not rigid but elastic. The elastic membrane can also assist in preventing the passage of radon and methane gas. 10

11 Mine Backfill Chemical Solution with Potential Cost Reductions Flow Optimization Backfill, the process of back filling material into the underground voids created by mining, is essential in many underground operations for the holistic extraction process. Backfill material types and processes are numerous but normally utilize the tailings from the mill with binder and fillers to provide the required restraint, which enables massive strategic support for the underground extraction sequence of the ore. Mine backfill is becoming more and more important because of the trends in mining to: mine deeper, optimize ore recovery, optimize water recovery, improve backfill material properties, decrease environmental impact and reduce overall cost. There is a more scientific approach to this challenge that can help mining companies understand and run backfill operations at lower risks and lower costs. Advanced admixtures can solve various problems associated with backfill processes. These range from paste to cement aggregate (CAF) types of backfill. Chemical solutions are available to increase solid content, reduce friction and segregation, modify rheology, flow and reduce binder content, as well as costs. We push back the physical limits with our existing technologies - such as retarders, water reducers, superplasticizers, viscosity modifying admixtures (VMAs) etc. We are working hard to go even further in all areas of backfilling operations. Depending on our customers requests, we can control and achieve: retardation, acceleration, rheology control, modified viscosity, reduced yield, stress and pumping pressures. Furthermore, we can stabilize fines in the fill matrix and reduce slime run off, segregation and porosity, and also increase strength development and optimize binder content. MEYCO s industry-leading technologies should be considered for new mining projects as well as existing operations as they create opportunities for the mine owner to operate systems that are safer, more environmentally friendly and more cost effective. 11

12 Headquarters BASF Construction Chemicals Europe AG MEYCO Global Underground Construction Vulkanstrasse Zurich, Switzerland Phone BASF Construction Chemicals Europe AG MEYCO Equipment Hegmattenstrasse Winterthur, Switzerland Phone Canada USA Mexico Bolivia Brazil Chile Peru Germany Russia Sweden Turkey UK-Ireland South Africa Kazakhstan Asia Pacific China Hong Kong India Indonesia New Zealand Australia +61 Adelaide (08) Brisbane (07) Canberra (02) Darwin (08) Kalgoorlie (0408) Mackay (0418) Melbourne (03) Newcastle (02) Perth (08) Sydney (02) Townsville (07) Brochures on our underground construction solutions are available at and for Mineral Processing: The information given in this BASF publication is based upon the present state of our scientific and practical knowledge. As the information herein is of a generic nature, no assumption can be made as to a product s suitability for a particular use or application and no guarantee or warranty as to it s accuracy, reliability or completeness either expressed or implied is given. MEYCO : 02/12/AB Crea