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Corrosion of Rock Reinforcement in Underground Excavations

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Corrosion of Rock Reinforcement in Underground Excavations Western Australian School of Mines Department of Mining Engineering and Surveying Corrosion of Rock Reinforcement in Underground Excavations Rhett Colin Hassell This thesis is presented for the Degree of Doctor of Philosophy of Curtin University of Technology February 2008 DECLARATION To the best of my knowledge and belief this thesis contains no material previously published by any other person except where due acknowledgement has been made. This thesis contains no material which has been accepted for the award of any other degree or diploma in any university. Signed: ……………………………………….. Date: ………………………. -i- ABSTRACT The effect of corrosion on the performance of rock support and reinforcement in Australian underground mines has not been widely researched and is generally not well understood. This is despite the number of safety concerns and operational difficulties created by corrosion in reducing the capacity and life expectancy of ground support. This thesis aims to investigate corrosion and relate how the environmental conditions in Australian underground hard rock mines impact on the service life of rock support and primarily rock reinforcement. Environmental characterisation of underground environments was completed at a number of mine sites located across Australia. This provided an improved understanding of the environmental conditions in Australian underground hard rock mines. Long-term testing on the impact of corrosion on the load bearing capacity of reinforcement and support under controlled experimental conditions was conducted in simulated underground environments. Rock reinforcement elements were examined in-situ by means of overcoring of the installed reinforcement and surrounding rock mass. Laboratory testing of the core determined changes in load transfer properties due to corrosion damage. These investigations provided an excellent understanding of the corrosion processes and mechanisms at work. Corrosion rates for a range of underground environments were established through the direct exposure and evaluation of metallic coupons in underground in-situ and simulated environments. It was found that the study of corrosion is challenging due to the time required to gather meaningful data. In particular, the wide range of materials that comprise ground support systems means that it is impossible to examine all the possible combinations of variables and their potential influence on the observed levels of corrosion and measured corrosion rates. Despite these challenges, the systematic investigation has resulted in new corrosivity classifications for both groundwater and atmospheric driven corrosion processes for various reinforcement and support systems used in the Australian underground mining industry. Previous corrosivity classifications were not found applicable. Furthermore, these new corrosivity classifications are simpler than previous classifications and corrosion rates may be predicted from readily obtained measurements of ground water dissolved oxygen and atmospheric relative humidity. Different types of reinforcement and surface support systems have been rated with respect to their corrosion resistance and estimates have been made for the expected service life for various rates of corrosion. -ii- ACKNOWLEDGEMENTS Many people have contributed to the completion of this thesis. Foremost, has been my supervisor Professor Ernesto Villaescusa whose enthusiasm for research combined with his attention to particulars provided for motivation and focus throughout the project. Dr Alan Thompson, associate supervisor, whose input never failed to amaze with its significance. Thank you to you both for your guidance and support. The financial support of the following sponsoring companies and institutes is gratefully acknowledged: Mineral and Energy Research Institute of Western Australia (MERIWA), BHP Billiton, Goldfields Australia, Barrick Gold, Xstrata, Strata Control Systems, 360 Drilling, Cooperative Research Centre for Mining Technology and Equipment (CRC Mining) and the Western Australian School of Mines (WASM). Scholarships from the Australian Postgraduate Award Scheme and MERIWA have been greatly appreciated. My sincerest appreciation also goes to: • The numerous site based personnel who provided for much during the site visits from information, insight, corroded ground support specimens, water samples or just a lift underground. • Mr Brett Scott and Mr Lance Fraser for their many hours spent helping with the technical issues that arose with the corrosion chambers and the overcoring rig. • Staff members of the Department of Mining Engineering and WASM administration for their help throughout the project, in particular Dr Jianping Li and Mr Chris Windsor. Finally to my family and beautiful partner Michelle, whose love, support and understanding was greatly appreciated. -iii- TABLE OF CONTENTS DECLARATION.................................................................................................................................................. I ABSTRACT ....................................................................................................................................................... II ACKNOWLEDGEMENTS...................................................................................................................................III TABLE OF CONTENTS..................................................................................................................................... IV LIST OF FIGURES...........................................................................................................................................VII LIST OF TABLES ...........................................................................................................................................XIV CHAPTER 1 INTRODUCTION ...............................................................................................................................................1 1.1 OUTLINE OF INVESTIGATIONS INTO CORROSION OF SUPPORT AND REINFORCEMENT IN AUSTRALIAN UNDERGROUND MINES.........................................................................................................................4 CHAPTER 2 CORROSION FUNDAMENTALS AND GROUND SUPPORT USED IN AUSTRALIAN UNDERGROUND MINES .................................................................................................................................7 2.1 INTRODUCTION....................................................................................................................................7 2.2 MECHANICS OF CORROSION ................................................................................................................7 2.3 THE UNDERGROUND MINING ENVIRONMENT .....................................................................................13 2.4 PROTECTION OF STEEL FROM CORROSION..........................................................................................20 2.5 ROCK SUPPORT AND REINFORCEMENT PRINCIPLES ............................................................................23 2.6 INVESTIGATED ROCK SUPPORT AND REINFORCEMENT USED IN AUSTRALIAN UNDERGROUND MINES 27 2.7 DISCUSSION AND CONCLUSIONS .......................................................................................................39 CHAPTER 3 ENVIRONMENTAL CONDITIONS IN AUSTRALIAN METALLIFEROUS UNDERGROUND MINES................................................................................................................................................................40 3.1 INTRODUCTION..................................................................................................................................40 3.2 CORROSION ASSESSMENT SYSTEM FOR UNDERGROUND MINES .......................................................40 3.3 ENVIRONMENTAL CONDITIONS AT SELECTED AUSTRALIAN MINES ..................................................47 3.4 ATMOSPHERIC CONDITIONS IN AUSTRALIAN METALLIFEROUS UNDERGROUND MINES ......................78 3.5 GROUNDWATER CONDITIONS IN AUSTRALIAN METALLIFEROUS UNDERGROUND MINES....................80 3.6 DISCUSSION AND CONCLUSIONS .......................................................................................................88 -iv- CHAPTER 4 REINFORCEMENT AND SUPPORT TESTING USING A SIMULATED UNDERGROUND ENVIRONMENT ..............................................................................................................................................90 4.1 INTRODUCTION..................................................................................................................................90 4.2 DEVELOPMENT OF THE SIMULATED UNDERGROUND ENVIRONMENT..................................................90 4.3 TESTING OF CEMENT GROUTED CABLE STRAND AND REBAR REINFORCEMENT ELEMENTS .................96 4.4 TESTING OF THE SWELLEX BOLT .....................................................................................................126 4.5 TESTING OF CABLE BOLT BARREL AND WEDGE ANCHORS................................................................131 4.6 DISCUSSION AND CONCLUSIONS .....................................................................................................144 CHAPTER 5 OVERCORING OF ROCK REINFORCEMENT IN UNDERGROUND MINES...................................146 5.1 INTRODUCTION................................................................................................................................146 5.2 DEVELOPMENT OF THE WASM OVERCORING RIG ..........................................................................147
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