Title: Suitable composition for Resin Capsule Technology for Grouting of rock
to be used as grouting material for roof bolting in mines/ tunnel and other
construction work
BACKGROUND:
This invention relates to a composition for making Development of suitable Resin Capsules for
grouting of bolts to control mine root/tunnel/ road embankment/ irrigation cannel, etc bolt
materials.
PRIOR ART:
In early years of mining timber was the primary material being used as supports of the
underground excavations. In below ground mines, good quality treated timbers were available
in ample and was also being imported from Burma (Now Myanmar). Increased exploitation of
forest resources and rampant deforestation resulted in scarcity of timbers even for house hold
uses. Steel then came into market as substitute and is invariably used in the industry including
domestic uses.
As soon as the roof in a coalseam/tunnel roof is exposed the immediate roof starts dilating and
getting detached from the over lying layer of roof strata causing it to fail if not supported
properly. Roof bolts are therefore being used as common support in underground mines all over
world along with the resin grout to reinforce the strata and provide adequate in the excavation.
Some modified cement capsules arc being used in coalmines to control roof fall. But their
effectiveness is slow and cement materials are found to be porous and their use in watery strata
is difficult. The setting time is 15min but it achieved with in two hours. Therefore it was
necessary to develop resin capsule suitable for grouting of bolts.
STATEMENT OF INVENTION
It is highly desired that the roof bolts once installed should immediately start taking load of the
roof strata and prevent dilation so as eliminate chances of roof fall. Resin grout is a very
effective composite material which sets very fast and prevents roof dilation. Although rapid set
cement capsules are also being used as grout in roof bolting, but its setting time and time to
provide reinforcement in the strata is too long to arrest the roof dilation. During impending
loading on the rool bolts due to stressing of the strata also cement grout provides less resistance
than the resin grout because resin has higher strengths than the cement grout.
It is therefore necessary to developed suitable composite suitable to provide desire result and
fulfill the objective support th the mines/ tunnel and other excavation project.
Roof Bolts arc now being used as common support in underground mines all over the world
along with the cement or resin grout to reinforce the strata and provide adequate support in the
excavation. Since past ten to fifteen years, cement grouted roof bolts have almost replaced the
timber support in coal mines in India.
The main object of the present invention is to provide a composition and it manufacturing
technology for suitable cement capsule for grouting of bolts to control mine roof bolt which
obviates the above noted drawbacks.
Another object of the present invention is to provide optimum composition from the novel roof
bolt composition, which obviates the above noted drawbacks.
Still another object is to provide a synergistic composition for roof bolting having average
soaking and quick setting time in the range of 2 to 3 minutes, final setting time in the range of
12 to 15 minutes; compressive strength in the range of 6 to 18 MPa, which is sufficient to
grout the arch for a long time.
DETAIL DESCRIPTION OF THE INVENTION
Yet another object of the present invention is to provide a anchorage strength in tones after 30
minutes which can increase the roof stability.
A further object is to provide a novel composition for roof bolting which would be grouted the
roof in 40 -50 mm diameter to enhance the stability of the roof. The composition of the present
invention is safe in handling and non - hazardous during preparation.
DETAIL DESCRIPTION OF THE INVENTION
Accordingly, the present invention provides a composition for development of
suitable resin capsule for grouting of bolts to control mine roof. The composition
and resin cartridge will be suitable for grouting of tunnel, road, irrigation, hydro
project or other construction projects, which comprises:
In an embodiment of the present invention, the synergistic composition may consist of the
composition is in two part
Table 1: (A) Resin mixture
Specification of polyester resin
Chemical name: 1,3-Denzen dicarboxylic acid, polymer with 1,4-cyclohexane dimethanol, 2,2-
dimethyl 1-1,3-propanediol and 2,5-furandione
Average molecular weight: 2200
Physico-chemical properties
Appearance: light amber liquid
Odour: pungent styrene smell
Specific Gravity: 1100 - 1150 kg/m3
Viscosity: 250 - 500cps
Specification of Dicumyi peroxide
Chemical formula: [C6H5C(CH3)20]2
Molecular weight:270-37
Specific gravity: 1020kg/m3
Solubility in water: Insoluble
Specification of calcium carbonate
Fine powder
Bulk density: 1200kg/m3
Table 2: HARDNER (B)
Preparation of primary resin mixture
All ingredients were weight for 5kg in batch process and mixed together by using mechanical
mixture. The bulk density, viscosity was measured by using density meter and viscometer, it
was poured into a double wall poly-tube.
Resin I filler+ diluter+acilator-----------> resin composite (A)
Preparation of hardener mixture
The mixture of 5kg was prepared by using ingredient in Table 2. The density and viscosity
were measured. The results are shown in Table 3. The hardener was packed in glass tube or
double wall ploy tube by using pressure packing system.
Packing
The mixture A is to be packed in double wall ply-tube and hardener tube was placed in centre
of tube or it was introduced in upper layer of ploy tube. The diameter of ploy tube was 20-
50mm diameter of 100 micron in thickness poly tube in 30-50 cm length. It is shown in Figurel
(b) Faster setting resin capsule.
(c) Doable chamber (wall) potytube slow setting
Figure l(a)(b)(c): Resin capsules prepared in industry
Special Feature
It is a feature of the present invention that the mixture is not a mere admixture but a synergistic
mixture having properties, which are different to the mere aggregation of the properties of the
individual ingredients and there is no chemical reaction in the composition.
Explain mixing process of chemicals
The following examples are given by way of illustration and should not be construed to limit
the scope of the present invention.
Example
All ingredients as shown in Table 1 and 2 were taken to prepare 5kg in batch. The ingredients
were mixed in mechanical mixture for 15 -20 min and packed in double wall Polly tube. The
tubes were store in dry place. All test parameters were tested as per -
> Compressive Strength - BS 7861 Part 1,1996
> Elastic Modulus - BS 7861 Part 1,1996
> Creep Test - BS 7861 Part 1,1996
> Bond Strength - BS 7861 Part 1,1996
> Shear Strength - CBS 7861 Part 1,1996
The results are shown in Table 3.
Evaluation of it mechanical properties
Bnlk density
The bulk density was measured by using measuring cylinder of 500ml capacity. A known
weight of cement mixture was poured and volume was measure after 5 time tapping at height
of 5-6cm.
Bulk density = mass/volume
Compressive strength
Five cartridge was cut by using knife mixture was mixed 30sec to 45sec and poured in 50mm
size mould (Figure 2). The compressive strength was measured by using universal testing
marching Figure 3.
Figure 3: Compressive strength testing machine
Anchorage strength gain test
Six to seven cartridges were inserted in steel pipe of 45 to 50mm in diameter. The 23 -24mm
anchorage milled steel of 1.5 m in length was pushed by rotation till it was completely pushed
in tube. The system was attached with anchor pull machine, tests were conducted till failure.
The results are shown in Table 3. The system is shown in Figure 4.
We Claim:
A composition and packing technology as claimed in claims above wherein the
composition consists of:
1. Development of suitable resin capsule for grouting of bolts to control mine roof fall to
enhance the safety of mines, tunnel and other structures. The technology comprises for
composition, mixing and loading of resin capsul.
Development of suitable resin capsules technology for grouting of bolts to control
mine roof, tunnel and other excavation project. The composition, substantially as herein
described with reference to the examples.
The compressive strength was more than 85MPa and bond strength was above 20
tonne. The set Lime was in between 5 sec to 95Sec. depend up on geo-mining condition
The resin capsule will be suitable for anchoring with MS steel bolt or FRP bolt.

Resin capsule was found suitable to control strata failure in coalmines, tunnel and other
underground structures. It water absorption capacity is negligible. It suitable dry and watery
strata. It bond strength is 2 to 10 times higher than cement capsules.