Abstract
M.Ing.
Safety within the mining industry is a primary concern for everyone involved. More specifically, active below-ground stope support for South African Mines is becoming increasingly important due to a renewed emphasis on the safety and well-being of the people actually working underground. It is imperative that all stope support systems
are rigorously tested, continuously, both under laboratory conditions and in-situ to prove
their performance and manufacturing standards. The Rocprop was initially manufactured in 1995 with the first two hundred props being installed at East Driefontein Consolidated Gold Mine in the Carletonville area. In the three years since the first introduction over three hundred thousand Rocprops have been manufactured and sold to South African Mines with the number steadily increasing. The Rocprop is a tubular support consisting of two tubes — a Ø139mm 'inner' tube and a Ø152mm 'outer' tube. One end of each tube is sealed by dome ends which are welded onto the tube mouths. The two tubes, cut to identical lengths, fit inside one another and extend telescopically during installation. Once the desired height has been reached, leaving enough tube overlapping to ensure the support does not buckle, the wedge is hammered in locking the prop at that height. The water is then removed after which the prop will provide active support of the rock mass above it. One of the components responsible for the Rocprops success is a dome end. This is either a forging or a pressing welded onto each end of the support and allows continual concentric loading throughout the life of the Rocprop. At present the dome ends are pressings, manufactured into hemispheres from 10mm mild steel plate in one action.
The reason for the Rocprop's success is its performance characteristics. It's all metal
construction, ease of installation, reliability and predictability in both seismic and static
conditions, fire resistance, blast resistant, economically viability and versatility have made
the prop successful. Reasons for the research were to investigate the dome end forming process in general and to investigate current numerical analysis techniques ability to predict loads during manufacture, the final shape, spring-back and other local deformation areas. Also to investigate alternate manufacturing methods such as cold forming, which provides advantages such as better mechanical properties and higher structural capabilities. The use of alternate materials in the Rocprop manufacture has been an ongoing process for MSP, manufacturer and current licensee holder of the Rocprop. A substitute for the current dome end manufactured from mild steel was investigated. For the substitute to be viable the material should be stronger, weigh less and be cost effective. In depth knowledge about the forming of the dome end at various velocities was gathered, providing information for further optimisation of the component.