33rd International Conference on Ground Control in Mining

Development of Road Header Roof Bolting Module

Sean C Farrell,
Farrell, S.
Project Engineer
J.H. Fletcher & Co.
Huntington, WV

ABSTRACT the roadheading machine increases miner safety and streamlines

production while meeting the ground control support requirements.
In underground mining and tunneling, machine design is
predominantly dictated by mine conditions and individual customer BACKGROUND
desires. In partnership with Australian companies WDS Limited
and Cram Fluid Power, the engineering department of J.H. Fletcher Eagle Downs Coal is a mine that is currently in development,
& Company was tasked to design and manufacture roof bolting located in Central Queensland, Australia. The contract to develop
modules to be mounted off both sides of a roadheader, providing the twin 1.24 mile (2 kilometer) drifts has been awarded to
in-cycle bolting. WDS Limited, an Australian-based mining development and
engineering firm (Latimer, 2013). In the spring of 2013, J.H.
The objective was to produce a boom and bolt module that Fletcher and WDS were finalizing the specifications for a set of
would allow an operator to bolt from a remote location, eliminating booms and roof bolting modules to be mounted off the side of their
the need for miner to work in unsupported ground. The bolt Mitsui Roadheaders.
module needed to operate in front of the cutting boom, but retract
to a parked position out of the way during the cutting cycle. Due The critical requirements for the project were that the module
to Australian electrical approval requirements, it was desirable to must be able to work inby the roadheader cutterhead, be able
design the module with minimal use of electrical controls. The to retract to a parked position that would not interfere with the
need for multiple, complex, drill steel and bolt handling steps led roadheader during its cutting cycle, and be able to install two
to the need for a custom hydraulics package to automate several of different customer-specified bolts within 15-3/4 inches (400 mm)
the movements. of the face. WDS did not wish to use a pass-by bolter, a separate
piece of mobile equipment named for its narrow stance that allows
The result of the design is dual drill and bolt modules mounted it to pass by the side of cutting equipment and bolt the roof. This
to a multistage boom with over 24 feet (7.31 m) of extension. was driven by the desire to not expose equipment operators to the
Each unit rotates and tilts to meet the bolt pattern requirements in ground inby the last row of supported roof.
conjunction with the stow and load requirements. The bolt module
builds on previous designs incorporating a modular assembly with Design requirements for underground mining equipment in
each sub-component designed to be replaceable and adjustable Australia are shaped by the New South Wales Mining Design
independently from other machine components. Each major Guidelines (MDG) (New South Wales Trade & Investment, 2014).
component is painted a different color to help the operator make The project schedule was very tight; therefore, we did not want to
the connection visually from the module to the operator’s control introduce new electrical components because it would take time to
valves. Hydraulic package valves were designed to automatically design them to the MDG requirements. This shifted the focus for
control several of the sub-components during the drill cycle, drilling controls from a controller area network (CAN) bus-based
reducing the number of steps a drill operator would, otherwise, software to using a combination of sequences and cam valves.
have to do manually.
The initial proposal revolved around a traditional bolt module
This design removes the operator from working in unsupported from the Fletcher AR-D roof bolter, used primarily in US metal/
roof and away from other inherent hazards, putting them at a non-metal mines. This module consists of two drill feeds on a
safe distance on the operator’s platform. The cutting and bolting rotating shaft. One feed is dedicated to drilling the hole, while
equipment has been combined into one machine, which is the second feed picks up a bolt from a magazine that is capable of
advantageous in single entry drifts because there is no need to place storing multiple resin bolts and install them at the proper torque.
change equipment. The hydraulic package valves eliminate the Additionally, the module is fitted with a resin arm that swings to
need for any electronics, thus avoiding any electrical regulations the hole centerline. The reliability of this design has been proven
with respect to the controls. The addition of these modules to over the past three decades but, ultimately, was deemed to be

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unacceptable because the bolts could only be installed to within
39.37 inches (1 m) of the mine face.

THE DESIGN

Fletcher has operated with a singular focus for many years: to

work with a vigilant focus on finding ways to improve mining
processes and reducing risk for the people who work there.
From this focus has come the development of a series of semi-
autonomous bolt modules designed to allow an operator to install
roof bolts from a remote location. A recent iteration of this module,
deployed in South Africa, met the bolt installation requirements for
the Eagle Downs project. Figure 1. Side view of early proposal with linkage style
boom extension.
This module allows WDS to install bolts to within 15-3/4 inches
(400 mm) of the face as required. It also was lighter and packaged
tighter than the AR-D bolter, qualities that were desirable given
the massive length of boom that would be required to reach inby
the cutterhead. However, the module was not without drawbacks.
The unit did not have the long history like the AR-D, nor had
Fletcher developed one without the use of electrical components.
Additionally, the South African unit was designed around 67-inch
(1.7 m) long bolts and would need to be lengthened to work with a
106-inch (2.7 m) bolt. Figure 2. Side view of final design showing module extended in
its drilling position.
The top centralizer uses three arms that close in an innovative
camera shutter concept. The arms are able to fully retract to allow
a roof plate to pass through, but they provide complete support
to the drill steel or bolt when deployed. With a change out of
the manipulator hand and top centralizer clamps, as well as the
bolt carousel plates, the customer is able to use a variety of bolt
types and sizes. The resin arm also has a replaceable nozzle
to accommodate shooting resin cartridges for one bolt type or
pumping grout for the post grouting operation that takes place with
the mechanical bolts.
Figure 3. Side view of final design showing module in
It was determined that the boom structure holding the module parked position.
would need approximately 24 feet (7.3 m) of reach. This would
require a new boom design incorporating one of the largest The project not only presented the engineering staff with new
extensions that Fletcher has ever built. A parallel linkage design and unique challenges, but also challenged Fletcher welders to
(See Figure 1) was part of the early proposals. This design develop new techniques to fabricate these large booms. The size
allowed for some of the extension to be accounted for off the of the boom sections was such that manufactured shapes, such as
side of the machine. The links reduced the amount of boom square or rectangular tubing, were not practical. Therefore, we
section that would be cantilevered out of the cradle, but they had opted to fabricate box sections out of high-strength steel. The outer
drawbacks. The links traveled in an arc, creating the need for booms reached over 28 feet (8.5 m) in length and required even and
complete clearance above the boom to avoid crashing components complete pre-heating to weld properly. Custom heat tables were
together. Below the boom, where the links were located, also constructed to assist in the fabricating and pre-heating the booms.
needed to remain clear to allow operation. After several months The welding for each component was completed in one continuous
of development, WDS ultimately decided that the space the links session in an effort to not waste the energy of pre-heating, as well
occupied was needed for mounting other components, and the as to prevent the long boom from bowing due to repeated heating
design moved in a different direction. and cooling cycles.

What resulted was an improved design that was built: a two The final challenge in the design phase was being able to
stage box section boom, with 146 inches (3.7 m) of extension for complete the functions required to drill and install bolts with the
each section (See Figure 2 and Figure 3). Through experience with module (See Figure 4) from a remote location nearly 40 feet (12.2
Fletcher metal/non-metal bolters, Fletcher identified that the area m) away. The following list details the steps required to drill
the boom rollers contacted on the box sections could potentially be the hole:
a weak spot. In lieu of a single boom roller, large dual diameter
rollers were mounted onto a central pivot, keeping the surface 1. Use Manipulator hands to retrieve drill steel from storage rack.
stresses to acceptable levels. The dual rollers were used on the 2. Position drill steel over drillhead and couple into drill chuck.
front and back of the cradle, on the bottom of the outer boom and 3. Slightly open Manipulator hands to act as drill guide.
the top of the inner boom.

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was no way to return the midpoint to its home position without
actuating an upper cam valve. In an aborted drillings cycle, this
may not be possible. The updated package allowed the manual
return of the midpoint centralizer. This also allowed Fletcher the
opportunity to upgrade the size of all the sequence and shuttle
valves internal to the block, reducing the pressure losses in
the system.

CONCLUSIONS

As of Spring of 2014, the booms and modules are currently in

Australia and being fitted to the roadheader machines by WDS.
The first of two roadheaders is due to leave their facility and travel
to the mine site at the beginning of April 2014.

Because the machines have not yet been deployed to the mine, a
review of the project objectives is in order to determine the success
of the project:

•  The bolt modules and booms successfully meet all the roof
control requirements.
•  A change out of parts allows conversion between multiple
bolt types.
Figure 4. ISO view of bolt module. •  The need for an operator to work in unsupported ground is
virtually eliminated.
4. Actuate feed and rotation to begin drilling hole. •  No electrical allowed for quick adherence to MDG rules.
5. Move midpoint centralizer to drill centerline. •  Complex steps are aided by semi-autonomous hydraulic
6. Close midpoint lock to guide drill steel. drilling operations.
7. When drill depth allows, open manipulator hands.
8. Retract manipulator hands to stored position. The machines are due to be the center point of a multiple-year
9. Open midpoint centralizer lock. project at Eagle Downs Mine. We have, at this point, met all the
10. Retract midpoint centralizer to stored position. engineering and manufacturing challenges. As this design goes to
11. Open top centralizer. work in its intended environment, J.H. Fletcher & Company looks
12. After hole has reached full depth, reverse feed direction to bring forward to providing more innovative solutions to improve operator
drill steel out of hole. safety and mine production.
13. Move manipulator hands to drill centerline.
14. Close manipulator hands to guide retracting drill steel. REFERENCES
15. Stop the drillhead at the correct height for uncoupling.
16. Uncouple drill steel and clamp with manipulator hands. Latimer, C. (2013). “WDS wins massive Eagle Downs coal
17. Lower drillhead and store drill steel. contract.” Australian Mining. http://www.miningaustralia.com.
au/news/wds-wins-massive-eagle-downs-coal-contract
This list does not include boom positioning, applying resin/
grouting, or installing and torqueing the bolt. The tasks required New South Wales Trade & Investment. (2014). Mining Design
can be overwhelming for a drill operator without the assistance of Guidelines. http://www.resourcesandenergy.nsw.gov.au/miners-
a computer system to help automate the process. Through a series and-explorers/safety-and-health/publications/mdg
of custom package and cam valves, Fletcher was able to automate
steps 5 through 15, significantly aiding the drill operator in their
duties without adding any electric components that would need to
meet the Australian MDG regulations.

BUILDING/TESTING

In early January 2014, with the assembly of the booms and

modules nearing completion, test drilling began. It was quickly
determined that the new style top centralizer was fouling with drill
cuttings. The pieces were modified with reliefs in the housings to
allow for the cuttings to clear when the centralizer arms retract.

The test drilling also identified areas for improvement available

in the hydraulic system. The midpoint centralizer did not have a
manual override to retract it to its parked position. Deployed by
actuating a cam valve during the forward drilling cycle, there

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Development of Mechanized Ground Support Installation Equipment
for Improved Safety in Narrow Vein Mine Conditions
William Kendall, Manager ofKendall, W.
Research and Development Engineering
J.H. Ferster, M.
Fletcher & Co.
Huntington, WV

Mark Ferster, Ground Control Engineer

Stillwater Mining Co.
Nye, MT

INTRODUCTION frequently results in long term damage to hearing, shoulders, arm

and wrist joints, and back injuries. This reduces the quality of life
Stillwater Mining Company, with its two underground, hard for the operator and also results in higher personnel turnover rates
rock mines in South Central Montana, is the largest primary for the mining company.
producer of palladium and platinum in the Western Hemisphere.
Platinum Group Metals (PGMs) are mined from a specific zone Mechanized equipment has the possibility to improve
within the Stillwater Complex, a layered mafic/ultramafic igneous workplace safety, reduce operator exposure (compared to hand-
intrusion, named as the J-M Reef. Over much of the J-M Reef, the held equipment), and provide improvements to the health of the
economically minable, mineralized horizon is contained at typical underground hard rock miners (Figure 1 – Jackleg Operation).
horizontal widths of 6.5 ft to 8 ft wide. This feature of narrow
mining widths has made it challenging to safely and effectively
mine these areas of the J-M Reef using mechanized cut and fill and
sublevel sill development mining methods. Mechanization of most
or all of the steps of the mining process is important to Stillwater
in the continuous pursuit of high standards in safety and health.
Mechanized bolting within the J-M Reef ore production headings is
an important piece of reaching these objectives.

In general, metal/non-metal mining requires varied mining

techniques, as compared to more traditional bedded mineral/
resource deposits. Narrow vein mining is a selective mining
technique that generates a minimal amount of waste material while
obtaining the more valuable ore deposits. Drilling and bolting
in narrow vein mining has traditionally been performed with air-
powered, hand-held “jackleg” equipment because mechanized
equipment is, typically, too large for the selective narrow vein
techniques. In addition, traditional hand-held pneumatic equipment
provides significant flexibility for small-opening, narrow-vein
developments, reducing waste rock handling and improving ore
recovery management. The hand-held equipment is also relatively
inexpensive to purchase. Due to its simplicity, it is also relatively
easy to train operators to use hand-held equipment.

Hand-held equipment has been routinely used to safely install

ground support and to develop production faces in hard rock mines Figure 1. Picture of jackleg drilling.
for many years. Although it is effective, the hand-held equipment
requires operator exposure to certain inherent hazardous conditions With the goal to improve the safety and health of the mining
in the active face/development mine areas. These include falling workforce, the Stillwater Mining Company, in conjunction with
rock, tripping hazards, bending/twisting/lifting hazards, high noise J.H. Fletcher & Company, initiated the development of a machine
levels, and chemical fumes from the hammer exhaust. Based on for narrow opening ground support installation in February 2012.
health and safety statistics from the Stillwater mines, operation J.H. Fletcher has a long, proven history for the development of
of the rotary-percussive hand-held equipment adversely affects mechanized drilling and ground support installation machines to
the long-term health of the operator—continual jackleg operation improve safe extraction of mineral resources.

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The machine had to be acceptable to the miners and be cost approved canopy. The machine uses a low profile rotary percussive
effective. It needed to not only provide a safer environment for drill head and can install virtually any type or length of bolt.
ground support installation, but also match the flexibility of the
hand-held equipment, perform the ground support installation in a During the first six weeks of 2014, they were trammed up and
productive manner, and compare favorably to the current support down numerous ramps and operated by a variety of operators in
installation process. This meant the machine had to be able to different areas of both mines to gain experience. Modifications
install a variety of roof support types and mesh for surface control. were made as needed. In mid-February of 2014, the machines were
It also had to provide a reliable tram system, capable of negotiating turned over to the mines as production machines.
uneven floor, make 90-degree turns in narrow openings, and travel
ramps of up to 19% grade (Figure 2 – Stope Cross Section). The machines were evaluated against the following
design requirements:

•  Improve safety (versus a jackleg)

•  Tram effectively, negotiate ramps and intersections, and
be stable
•  Tram, drill, and bolt in 6.5-ft-wide stopes
•  Reach to a maximum bolting height of 14.5 ft
•  Install bolts as perpendicular to all rock faces as practical
•  Install 5-ft friction bolts
•  Install 8-ft and 12-ft torque tension rebar bolts with no
changes to the machine
•  Aid in the handling of 4 ft x 8 ft wire mesh panels
•  Be efficient enough to support (drill, bolt, and mesh) two 9-ft-
deep to 11-ft-deep places and tram up to 1.5 miles in one shift

The following are comments on the evaluation points.

Figure 2. East Boulder heading size drawing. Improve safety versus a jackleg

J.H. Fletcher design engineers worked with Stillwater engineers, •  Operator is under a protective canopy for protection from rock
operators, managers, and maintenance personnel at both mine falling while bolting and installing mesh.
sites to identify specific characteristics and requirements (mine •  Operator only handles drilling tools and bolts versus handling
opening irregular dimensions, available power systems, operational the jackleg with hoses and handling mesh.
production sequencing, etc.). Throughout the process, Stillwater •  Wire mesh can be installed remotely using the machine—
personnel were actively involved in the design of the machines. In no temporary supporting of mesh on scaling bars or using
2013, Stillwater ordered two machines, one for each mine, to allow “mickies” (short split set bolts which fit inside existing split
evaluation of the concept and the machines (Figure 3 – Bolter set bolts)
on Surface). •  The noise level is reduced versus a jackleg. Maximum noise
level at the operator’s ear was measured at 113.6 dba. (For
reference, a jackleg drill operates at 117 dba to 125 dba.)
•  The lifting and swinging boom keeps the operator close to the
drilling area, even at a maximum working height of 14.5 ft.

Tram effectively, negotiate ramps and intersections, and

be stable

(see Figure 4 – Machine Articulated and Figure 5 – Basket

Offset to Chassis)

•  The machine efficiently trams up and down the ramps (up to

19% grades) and negotiates turns and 90-degree intersections.
•  Engine torque during tramming is between 33% on flat
ground to a maximum of 47% on 19% grade. No overheating
Figure 3. Picture of bolter on the surface at East Boulder Mine. is experienced.
•  Machine is very stable while tramming and bolting.
The machines (one for the East Boulder Mine and one for the •  Operator visibility and lighting is adequate while tramming
Nye Mine) were delivered at the end of 2013. They are 4.5 ft and bolting.
wide, rubber tired, articulated chassis, diesel tram, electric bolt,
HDR-D/E bolters. They use a lifting and swinging boom to keep
the operator close to the work area. The operator can tram from
the chassis or the bolting platform where they are under an MSHA

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Figure 4. Picture of machine articulated.

Figure 7. Picture of bolter in the stope.

Figure 5. Overhead picture with basket parallel to chassis.

Figure 6. Picture of SV-32 Hammer.

Tram, drill, and bolt in 6.5-ft-wide stopes

(see Figure 6 – Low Profile Hammer, Figure 7 - Bolting, Figure

8- Bolting, and Figure 9- Canopy Contour)

•  Machines have successfully bolted in stopes 6.5 - 8 foot wide.

Figure 6 – Low Profile Hammer, Figure 7 - Bolting
•  They fit and bolt in 6.5-foot-wide stopes. Figure 8- Bolting,
and Figure 9- Canopy Contour
•  Machines are averaging approximately 3 hours to bolt a
Figure 8. Picture bolting at maximum height.
cut. They have bolted cuts in approximately 2.5 hours. This
time isexpected to improve with planned modifications and
improved operator skill level.
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MAJOR ACCOMPLISHMENTS

•  The machine fits in the 6.5-ft-wide stopes with angled hanging

and foot walls
•  The machine is very stable.
•  There is adequate room for the operator, positioning of the
feed, and handling of steels and bolts, even when the canopy
is up to the back.
•  The machine drills very well. It drills at 3/4 in/sec (3.75 fpm).
•  The machine inserts 5-ft friction bolts in 9–10 seconds.
•  Noise level at the operator has been lowered by over
3 Decibel.
•  Zero injuries have been experienced during the trial period.

MACHINE ACCEPTANCE BY THE OPERATORS

Figure 9. Picture of canopy and roof.
Although the machines have met all technical specifications, the
•  Drill and bolt time for a 5-ft friction bolt is approximately operators have not fully accepted them. Part of the reason for non-
2 minutes. acceptance is cultural. It is a significant change, due to complexity
•  As expected, correct tooling, two-piece 8-ft bolts, feed of the machine versus a jackleg. The new machine also requires
length, and safe mesh handling are all critical to safe, the operators to learn a new piece of equipment and change their
efficient operation. operating techniques. In addition, further modifications to the
•  Even bolting at full back height, there is adequate room for machines are required to reduce the reach of the operator when
the operator, positioning of feed, and handling of steels changing drill steels and handling bolts, improve controls, and
and bolts. improve feed positioning ability.

Install bolts as perpendicular to all faces as practical SIGNIFICANT PROBLEMS – INEFFICIENCIES

(See Figure 10 – Bolts Perpendicular) Although the new machine is an improvement, there are still
some inefficiencies to address. The operators must become familiar
with the controls and gain experience in using a mechanized piece
of equipment. This can be a difficult change for many operators.
Ergonomics must also be improved. Currently, the valve placement
obstructs the operator movements. The movement direction and
number of control valves has proved to be a challenge. Efficiency
in positioning of the machine is limited by lack of a basket
extend and auto basket level. During planned upgrades all control
valves will be replaced with electro-hydraulic joysticks and a 3
operating mode selector system to reduce the number of controls,
space required, and to provide logical movement direction of the
handles. Written labels will be replaced with pictograms back
lit with distinctive light colors based on mode of operation. Auto
basket level and basket extend will be added. Changes will be made
to the feed positioning system to provide a more open material
Figure 10. Picture of bolting the hanging wall. handling area.

WHERE WE GO FROM HERE
•  Lifting boom allows bolts to be installed perpendicular to
faces even at height. (Figure 10 – Bolts Perpendicular) Stillwater is very committed to continuing development of new
•  The machine possibly allows for changes to the blast pattern generation drilling and roof bolting machine to replace jacklegs.
for better ore recovery since the high reach bolts can be To date they have shown that they are safe to operate with reduced
installed at a better angle than was possible with jacklegs. operator exposure and no injuries to date, reduced noise level,
flexible in the type and length of bolts which can be installed,
Handling mesh with feed and comparable to a jackleg from a productivity standpoint
(planned upgrades should significantly improve efficiency). The
•  Operators can wire together up to three pieces of mesh and lift current machines will run until the upgrades are available in mid-
them into position using the feed. 2014. After the upgrades are complete, Stillwater will re-evaluate
•  The operator can bolt the mesh into place without leaving the both machines.
machine, installing “mickies,” or setting scaling bars.

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