BULLFLEX® System

2

Introduction

The BULLFLEX® System has been developed as a special supporting member for underground excavation. It consists of patented textile groutable hoses made of high-strength fabric, which are subsequently filled with cement-bonded construction material,

featuring an excellent load-bearing capacity.

The BULLFLEX® System is available in different dimensions, allowing an optimum alignment to the excavation or support perimeter.

All system components are light-weight and easy to transport and to install.

DYWIDAG-Systems International (DSI) has long-time experience in the application of the BULLFLEX® System which has been successfully used in various projects.

Contents

Introduction ...................................................................................................................3

Fields of Application ......................................................................................................3

Main Advantages ...........................................................................................................4

System Description .......................................................................................................4

System Components .....................................................................................................6

Specifications ................................................................................................................7

Installation Procedure BULLFLEX® Support Pillars .......................................................8

Characteristics Support Pillars ......................................................................................8

Load-bearing Capacity Support Pillars .........................................................................9

Further References ........................................................................................................9

Material Logistics and Pumping and Mixing Equipment .............................................10

General Health and Safety Regulations .......................................................................10

Fields of Application

Hard Rock Mining

Coal Mining

Mine Rehabilitation

Tunnel Rehabilitation

TBMs and Foundations 1)

Support Pillars

Auxiliary standing support, artificial

pillars, and cornerslumps

Secondary support in room & pillar and

longwall mining

Repair works in overstressed or fault zone areas and rehabilitation of visitor mines

Roof Support Backfilling

Backfilling of steel support for

permanent main roadways

Yielding support system –

displacement minimization

Re-establishment of the load-bearing

capacity and yielding ability of destructed

tunnel linings

Foundation and prestressing of pipe umbrella support or rib support systems

Roadway Packs and Dams

Multiple entry roadways, gaseous seams, and deep mining operations

Structural Bulkheads

Sealing against backfilling media

Permanent sealing of roadways Partition of storage or waste facilities

Stoppings Ventilation walls, sealings, and face shuttering

Structural Sealings

Sealing of existing re-lined tunnels and annular gaps of civil

structures

O-Ring Sealings: Launch and receptions

of TBMs, sealing against water (liquids) and compressed air

1) See separate brochure BULLFLEX® Structural Sealings

3

Support Pillars: Coal

Roof Support Backfilling

Structural Bulkheads Stoppings

Roadway Packs and Dams

Support Pillars: Hard Rock

Main Advantages

■ Fast, safe, and clean support system ■ High load-bearing capacity ■ Immediate load transfer and defined grout consumption

■ Active setting load and controlled residual load

■ Shrink-free ■ Quick and easy to install ■ Easy handling on-site due to light-weight components

■ Application possible even in limited space

■ Inflation can be achieved using various filling media

■ Flexible support characteristics thanks to different variations of pillar diameter and filling media

System Description

The BULLFLEX® System is used wherever a fast support solution is required. Due to its active setting load and immediate load transfer, BULLFLEX® groutable hoses work like a strong hydraulic prop that can be left in position as a permanent support.

When using certain filling media, BULLFLEX® groutable hoses are shrink-free because of their patented encasement – woven fabric hoses made of high-strength fibers.

Depending on the required supporting load or geometry, the BULLFLEX® System can be easily adapted to on-site conditions using different diameters or filling media with varying compressive strengths.

4

Concrete lining

Hanging wall

Hanging wall

Longwall

Footwall

Footwall

BULLFLEX® Pillars

Sidewall

Belt with fixation eyelets

BULLFLEX® frame, grouted

BULLFLEX® fabric with airtight sealing foil

Front view Side view

Sidewall

Prop

Filling port

BULLFLEX® hose

Grout filling

TH steel support

BULLFLEX® Support Pillar

BULLFLEX® Support Pillar

Welded wire mesh, supported by the

BULLFLEX® hose system, in contact with the lining

Force and form fit between BULLFLEX®

hose and steel support

System Description

Support Pillars

■ Active pre-loading feature ■ Increase of safety support factor or extraction rate

Roof Support Backfilling

■ Full load distribution versus point loading

■ Change from a passive to an active support system

Structural Bulkheads

■ Defined support system for backfilling applications

■ Active vertical and horizontal prestressing

Stoppings

■ Light and heavy duty versions ■ Low weight and rapid installation

Roadway Packs and Dams

■ Combined support and sealing system ■ Flexible pillar height

5

System Components

■ BULLFLEX® groutable hoses ■ Endless round woven hoses made of Polyamide 6.6

■ High resistance against tearing and no longitudinal seams

■ Anti-static, flame resistant, and self- extinguishing

■ Working pressure up to 4 [bar] (58 [psi]) ■ Air and water permeable ■ Retention of the grout mineral content while draining due to the special filter effect of the BULLFLEX® System

■ Compliance with filter self rescuer systems ■ Off-size diameters and special designs are available on request

■ Patented product technology

Diameter Length / Height

[in] [mm] [ft] [m]Support Pillars 11 - 38 1) 280 - 960 4 - 23 1.5 - 7.1

Roof Support Backfilling 9 - 16 230 - 400 Length as requiredRoadway Packs and Dams 16 - 38 1) 480 - 960 4 - 23 1.5 - 7.1

Structural Bulkheads 11 - 38 1) 280 - 960 Length as requiredStoppings Flat fabric Length as required

1) Larger diameters available on request

■ BULLFLEX® filling ports ■ Pre-manufactured with integrated upper closure, filling port(s), and bottom plate ■ With check valve, inner diameter 32 [mm] (1¼ [in]) or 50 [mm] (2 [in]) ■ Number of filling ports depending on the length/height of the BULLFLEX® groutable hoses

■ BULLFLEX® filling nozzle ■ BULLFLEX® multiple-use formworks

■ For installation of larger-size BULLFLEX® groutable hoses, multiple-use steel formworks are required

■ Stabilization and fixation during installation (inflation) ■ Filling material

■ See page 10

6

System Components

Standard Dimensions 1)

Hose diameter Pillar diameter Designation

[mm] [in] [mm] [in] [–]230 9 280 11 9 - 11"320 13 380 15 13 - 15"400 16 480 19 16 - 19"500 20 590 23 20 - 23"630 25 740 29 25 - 29"800 31 960 38 31 - 38"

1) Intermediate and larger diameters available on request

Specifications

Characteristics 1) Unit Value Notes

Material [–] Polyamide 6.6 NylonWeight [g/m2] / [oz/yd2] Approx. 660 / 19.44

Fabric thickness [mm] / [in] Approx. 1 / 0.04

Minimum tensile strengthL 2)

T 3) [N] / [lbf]12,000 / 2,69824,000 / 5,395

100 [mm] / 3.94 [in] widthAccording to ISO 10319

Corresponding maximum elongationL 2)

T 3) [%]2020

According to ISO 10319

Elastic elongationL 2)

T 3) [%]1515

According to ISO 10319

Minimum seam strength [kN/m] / [lbf/ft] 155 / 113

Airflow through fabric at pressure [mbar] ([psi])

10 (0.15)20 (0.30)30 (0.45)

[l/min] / [gal/min]6.5 / 1.713 / 3.419 / 5.0

At 100 [cm2] / 15.5 [in2]

Residual tensile strength [%] 20 - 30After 1 year and under light

exposure in Florida

1) The indicated values are laboratory values and may deviate on-site2) Longitudinal3) Transversal

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Installation Procedure BULLFLEX® Support Pillars

1. At the pillar position, gravel and boulders must be removed from the footwall. If possible, the footwall area should be horizontal or parallel to the incline of the hanging wall.

2. Subsequent mounting of the temporary or permanent formwork, which should reach up to a height of approx. 200 [mm] (8 [in]) below the hanging wall.

3. Placement of the fabric into the formwork and fixation by loops attached to the fabric.

4. Inflation of the BULLFLEX® Pillar through one or several back-pressure valves until full contact with the roof has been established.

5. Increase of the filling pressure up to 4 [bar] (58 [psi]) to achieve active pre-loading.

6. If temporary formwork has been used, it may be removed as soon as the concrete filling has reached a curing strength of 5 [N/mm²] (725 [psi]) and then re-used for setting the next pillar.

Note: During inflation (cement injection), all default and recommended personal protective equipment must be used. BULLFLEX® Pillars are resistant against mine water inflow; the fabric itself is only soluble in concentrated inorganic acids and phenol.

Characteristics Support Pillars

Pillar diameter 1)

Max. recommended pillar height 2)

Active pre-loading 3)

Injection material consumption 4)

Average inflation time 4)

[mm] [in] [m] [ft] [kN] [kips] [m3] [ft3] [sec]480 19 3.6 12.0 101 23 0.18 6.4 85590 23 4.4 14.5 153 34 0.27 9.7 125740 29 5.2 17.0 241 54 0.43 15.2 200960 38 7.1 23.5 397 89 0.71 25.0 330

1) Other dimensions available on request2) At a slenderness ratio of 30, rounded3) Calculated at a filling pressure of 4 [bar] (58 [psi]) and for two contact areas (hanging wall and footwall), rounded4) Calculated for 1 [m] (3.3 [ft]) pillar height and at a flow rate of 130 [L/min] (34.5 [gal/min]), rounded

8

16 - 19" 20 - 23" 25 - 29" 31 - 38"

Height [m]

F m [k

N]

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

1.0 1.5 2.0 2.5 3.0 3.5 4.0

Height [ft]

F m [k

psi]

0

250

500

750

1,000

1,250

1,500

3 5 7 9 114 6 8 10 12

Further References

■ Van Zanten, R. V.: Geotextiles and Geomembranes in Civil Engineering. A.A. Balkema. Rotterdam/Boston, 1986. ISBN 90 6191 6240. Page 156 ff.

■ Safe application of mine roadway support systems. Rock Mechanics Technology Ltd, 2004. ISBN 0 7176 2847 7

■ Breinig, F., Opolony, K.: Geplante Doppelnutzung einer Rechteckanker-strecke in 1200 m Teufe im Flöz D2/C. Martens, P.N. (ed): Aachen International Mining Symposia 2004. Glückauf, Essen, 2004. Page 159 ff.

■ Declaration of conformity and material data sheets

■ German approval for underground application (No. 18.43.21-61-40)

■ British COAL acceptance scheme (No. NMM 5318) for the use of the material (fabric) as underground support element

Load-bearing Capacity Support Pillars

US Customary Units

Type Height [ft] and load-bearing capacity [kips]

[in] 3 4 5 6 716 - 19" 353 342 331 321 31020 - 23" 542 529 516 503 49025 - 29" 866 849 833 816 79931 - 38" 1,476 1,454 1,433 1,412 1,390

Type Height [ft] and load-bearing capacity [kips]

[in] 8 9 10 11 1216 - 19" 299 289 278 267 25720 - 23" 476 463 450 437 42425 - 29" 783 766 750 733 71731 - 38" 1,369 1,347 1,326 1,304 1,283

SI Units

Type Height [m] and load-bearing capacity [kN]

[in] 0.9 1.2 1.5 1.8 2.116 - 19" 1,570 1,522 1,474 1,427 1,37920 - 23" 2,412 2,353 2,295 2,236 2,17825 - 29" 3,850 3,777 3,703 3,630 3,55631 - 38" 6,564 6,469 6,374 6,279 6,183

Type Height [m] and load-bearing capacity [kN]

[in] 2.4 2.7 3.0 3.4 3.716 - 19" 1,332 1,284 1,236 1,189 1,14120 - 23" 2,119 2,061 2,002 1,943 1,88525 - 29" 3,483 3,409 3,336 3,263 3,18931 - 38" 6,088 5,993 5,898 5,802 5,707

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Cement storage silos with mixing and pumping system Ready-mix truck and grout pump

Material Logistics and Pumping and Mixing Equipment

Two Concepts for Optimum Installation Performance

Recommended Injection Material 1)

Characteristics Unit Value Remark

Composition [%]25-50% Portland cement

75-50% Fly ashAlternatively, stone powder or a mixture of fly ash

and sand can be used instead of fly ash 2)

Compressive strength after 1 day [N/mm²] / [psi] > 2 / > 290 ASTM C1019Compressive strength after 28 days [N/mm²] / [psi] > 25 / > 3,630 ASTM C1019

Slump class [–] Medium-high ASTM C143Max. grain size [mm] / [in] 3.8 / 0.15 Default aggregate grading curve

W/C ratio [1] 0.7 - 0.9Setting time [min] 30 - 120

1) Further references: ASTM C1107; ASTM C827; ASTM C143; EN 1045; EN 206-12) Aggregates may not consist constituents harmful to concrete

Main Factors affecting the Workabiliy of the Injection Medium

■ Water-cement ratio ■ Amount and type of aggregate and cement

■ Ambient temperature ■ Chemical admixtures

Requirements Pumping and Mixing Equipment

■ Application of either a separate mixing and pumping unit, or a combined mixing/pumping device

■ Pumpable with standard worm pumps for flooring or injections works with a nominal power of 7.5 to 12 [kW] and a minimum flow rate of 20 [l/min] (5 [gal/min])

■ Default filling rates should be in the range of approx. 21 - 48 [gal/min] (80 - 180 [L/min])

General Health and Safety Regulations

■ Ensure that injection hoses are laid out without kinks, avoid contact with any sharp edges in order to prevent the fabric from being damaged

■ Wherever there is a change of direction, the bending radius must not be less than six times the outside hose diameter

■ Screw pumps are high-pressure pumps, therefore only steel-reinforced hoses may be used for grout transport

■ Before starting the machine, ensure that easily workable grout is being used

■ The intake hose must not leak anywhere (especially at connections), and the inner side of the hoses must be sufficiently lubricated

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Please Note: This brochure serves basic information purposes only. Technical data and information provided herein shall be considered non-binding and may be subject to change without notice. We do not assume any liability for losses or damages attributed to the use of this technical data and any improper use of our products. Should you require further information on particular products, please do not hesitate to contact us. 04

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USADSI Underground Systems, Inc. 9786 S Prosperity Road West Jordan, UT 84081, USA Phone +1-801-973 7169 E-mail dsiunderground@dsiunderground.com www.dsiunderground.com

DSI Underground Systems, Inc. 447 DuPont Rd. Martinsburg, WV 25404, USA Phone +1-800-332 3308

DSI Underground Systems, Inc. 700 Technology Drive South Charleston, WV 25309, USA Phone +1-800-547 4751

DSI Underground Systems, Inc. 5400 Foundation Blvd. Evansville, IN 47725, USA Phone +1-812-214 2968

DSI Underground Systems, Inc. 9344 Sunrise Road Cambridge, OH 43725, USA Phone +1-800-457 7633

DSI Underground Systems, Inc. 26161 Old Trail Road STE2 Abingdon, VA 24210-7631, USA Phone +1-276-623 2784

DSI Underground Systems, Inc. 1774 Mellwood Ave Louisville, KY 40206-1756, USA Phone +1-502-473 1010

DSI Underground Systems, Inc. 1032 East Chestnut Street Louisville, KY 40204-1019, USA Phone +1-502-583 1001

CanadaDYWIDAG-Systems International Canada Ltd. 3919 Millar Avenue Saskatoon, SK S7P 0C1, Canada Phone +1-306-244 6244 E-mail orderdesk@dsiunderground.com www.dsiunderground.com

DYWIDAG-Systems International Canada Ltd. 199 Mumford Road Unit C&D Lively, ON P3Y 1L2, Canada Phone +1-705-692 6100

DYWIDAG-Systems International Canada Ltd. 853 Boulevard Rideau Rouyn-Noranda, QC J9Y 0G3, Canada Phone +1-819-762 0901

DYWIDAG-Systems International Canada Ltd. 15 Toulouse Crescent Sturgeon Falls, ON P2B 0A5, Canada Phone +1-705-753 4872

DYWIDAG-Systems International Canada Ltd. 17 Burns Rd., Unit 2 Whitehorse, YT Y1A 4Z3, Canada Phone +1-867-393 2841

MexicoDS International México, S.A. de C.V. Av. Aviación No 1002 Bod. 15 Parque Industrial FERRAN I San Juan de Ocotán Zapopan, Jalisco 45019, México Phone +52-33-3366 57 94 E-mail dsimexico@dsiunderground.com www.dsiunderground.com

BrazilDSI Underground Brasil Rua Um, 276 Distrito Industrial da bela Fama Nova Lima/MG, Brazil Phone +55-31-35 42 02 00 E-mail vendas.brasil@dsilatinamerica.com www.dsiunderground.com.br

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