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SECTIONS FOR MINE ROADWAY SUPPORTS AND TUNNELS

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Ben Sweetland

“Success is a journey,

not a destination.”

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A1 PLANT

COMPANY PROFILE

KOCAER GROUP commenced its operations in the iron and steel sector in the early 1960s in Denizli. KOCAER ROLLING MILL, the first company of KOCAER GROUP, established its second and third facilities in the Aliaga Region/Izmir in 1996 and 2008 respectively. KOCAER ROLLING MILL is currently continuing its production activities in a total area of 270 thousand m2 in which 70 thousand m2 is covered facility.

Having higher objectives, KOCAER ROLLING MILL has increased its total annual capacity to 600.000 Mtons with the modernization investments. In addition to its standard products, for specific projects, the company manufactures special products, ranging up to 18 meters in its facilities for mining, ship building, railroads, automotive and agricultural machinery industries. Also, products with the desired quality, diverse dimensions and standards are manufactured based on the specific requests of the clients.

KOCAER ROLLING MILL has equipped all of its production lines with the technological infrastructure ensuring the manufacturing of uniform products.

KOCAER ROLLING MILL consistently enhances its success with a wide range of products, and manufactures Equal Angles (20 mm to 200 mm), UPN / PFC and UAC Profiles (30 mm to 300 mm), IPN, IPE, IPEA, and IPEAA Profiles (80 mm to 300 mm), RSJ Profiles (76 mm to 203 mm), T-Bars (25 mm to 50 mm), Flat Bars (20 mm to 150 mm), Square Bars, Round Bars (10 mm to 50 mm) and special grade high tensile flats and sections for railroad, automotive

and agricultural machinery industry, TH70/29-34 and GI120No profiles (DIN21530) for mining industry, Bulb flats for ship building, F2, F3-A and F7 type window sections which are designed by Kocaer (registered by the Turkish Patent Institute).

KOCAER ROLLING MILL controls every stage of its production process with the utmost attention in order to increase customer satisfaction. It certifies the quality in every stage of its process, from the raw material procurement to the delivery of the finished products, with its professional experts and high technology quality control equipment. The ISO 9001 International Quality Management System Certificate, CE Marking Production Control Certificate, IRAM S-Mark Certificate and the TSE Certificate of Compliance with Turkish and EN standards are just a few of the certificates which document this success.

With the help of the significant investment in the engineering force and infrastructure, KOCAER ROLLING MILL conducts its activities at its certified R&D department and accredited laboratories; first in the private rolling mills in Turkey; with superior attention in its advanced technology production facilities.

With export activities in over 100 countries, the KOCAER ROLLING MILL holds a significant place in the sector, and was included in the top 100 Largest Export Companies according to the Turkish Exporters Assembly since 2008; the 63rd on 2014 with an export turnover of more than USD200 million.

A2 PLANT

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MINE AND TUNNEL PROFILES STEEL GRADES

YIELD STRENGTH TENSILE STRENGTH ELONGATION (min) (min) (min)

σ yield σ tensile ε (N/mm2) (N/mm2) (%)

S 550 W ZN/TT/2012/1 550 730 18

S 480 W PN-H-84042 480 650 17

31Mn4 DIN 21530-3 350 550 18

17MnV7 DIN 1.0870 450 600-700 22

S235JR EN 10025 235 360-510 26

S275JR EN 10025 275 410-560 22

S355JR EN 10025 355 470-630 22

STEEL GRADE STANDARD

KOCAER ROLLING MILL HAS ESTABLISHED THE FIRST RESEARCH AND DEVELOPMENT CENTER CERTIFIED BY THE MINISTRY OF SCIENCE, INDUSTRY AND TECHNOLOGY IN LONG STEEL SECTOR OF TURKEY

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TH PROFILES

DIN 21530

MASS SECTIONAL AREA B H Ix Iy Wx Wy

(kg/m) (cm2) mm mm (cm4) (cm4) (cm3) (cm3)

TH 21 20,9 26,7 127,0 108,0 324 410 60 64

TH 25 25,0 31,9 136,0 118,0 455 558 74 82

TH 29 29,0 37,0 150,0 124,0 598 799 94 106

TH 34 33,8 43,1 171,0 136,5 870 1.182 122 138

TH 36 35,9 45,7 171,0 138,0 928 1.244 128 146

TH 40 39,9 50,9 172,0 145,0 1.120 1.440 153 167

TH 42 41,8 53,3 172,0 146,4 1.181 1.499 159 174

TH 44 43,7 55,7 172,0 147,8 1.243 1.559 165 181

SIZE

PROFILE PROPERTIES

TH profiles are widely used in underground mines and railroad/highway tunnels, providing not only a higher resistance but also a yielding support to stabilize the underground cavities.

One of the most significant advantages of TH profiles against I and H profiles is their ability to provide same high tensile momentum on both cross sections (X-X and Y-Y) throughout the profile.

Besides the ease of assembly, dismantling and high performance at the junctions; they maintain full support

during the decreasing cross section of the underground cavity by sliding on each other without major deformation.

Next to the superior design advantages, the use of high tensile steel (31Mn4-S480W-S550W) during the production also maintains high durability performance.

The major accessories of TH profiles are the clamps enabling the ease of sliding of the profiles on each other and the traversal junctions that assist to work the profiles simultaneously. It is crucial to torque the clamps and the traversal junctions for the system to work efficiently.

THE ADVANTAGES OF RUNNING TH JUNCTIONS

B

H

y

y

xx

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GI PROFILES

DIN 21530

PROFILE PROPERTIES

MASS SECTIONAL AREA SECTIONAL AREA h b s t d e r Ix Iy Wx Wy

(kg/m) d (cm2) b (cm2) mm mm mm mm mm mm mm (cm4) (cm4) (cm3) (cm3)

29,5 35,7 39,1 120,0 100,0 8,8 15,3 86,0 54,0 15,0 1.243 1.559 165 181

SIZE

GI 120No

s

t

b

d

h xx

y

y

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HEA PROFILES

Dimensions: DIN 1025-3:1994 (IPBl Series)Tolerances: EN 10034:1994

Xh h1

a

b

y

eyyv

r v X

X

h b s t G A Jx Wx ix Jy Wy iy Ss sx (mm) (mm) (mm) (mm) (kg/m) (cm2) (cm4) (cm3) (cm) (cm4) (cm3) (cm) (cm3) (cm)

HE 100 A 96 100 5 8 16,7 21,24 349,2 72,76 4,06 133,8 26,76 2,51 41,14 8,0

HE 120 A 114 120 5 8 19,9 25,34 606,2 106,3 4,89 230,9 38,48 3,02 58,85 9,8

HE 140 A 133 140 5,5 8,5 24,7 31,42 1033 155,4 5,73 389,3 55,62 3,52 84,85 11,6

HE 160 A 152 160 6 9 30,4 38,77 1673 220,1 6,57 615,6 76,95 3,98 117,6 13,4

HE 180 A 171 180 6 9,5 35,5 45,25 2510 293,6 7,45 924,6 102,7 4,52 156,5 15,2

HE 200 A 190 200 6,5 10 42,3 53,83 3692 388,6 8,28 1336 133,6 4,98 203,8 17,0

HE 220 A 210 220 7 11 50,5 64,34 5410 515,2 9,17 1955 177,7 5,51 270,6 18,8

HE 240 A 230 240 7,5 12 60,3 76,84 7763 675,1 10,05 2769 230,7 6 351,7 20,6

HE 260 A 250 260 7,5 12,5 68,2 86,82 10450 836,4 10,97 3668 282,1 6,5 430,2 22,5

HE 280 A 270 280 8 13 76,4 97,26 13670 1013 11,86 4763 340,2 7 518,1 24,4

HE 300 A 290 300 8,5 14 88 112,5 18260 1260 12,74 6310 420,6 7,49 641,2 26,2

HE 320 A 310 300 9 15,5 97,6 124,4 22930 1479 13,58 6985 465,7 7,49 709,7 27,9

HE 340 A 330 300 9,5 16,5 105 133,5 27690 1678 14,4 7436 495,7 7,46 755,9 29,7

HE 360 A 350 300 10 17,5 112 142,8 33090 1891 15,22 7887 525,8 7,43 802,3 31,5

HE 400 A 390 300 11 19 125 159 45070 2311 16,84 8564 570,9 7,34 872,9 35,2

HE 450 A 440 300 11,5 21 140 178 63720 2896 18,92 9465 631 7,29 965,5 39,8

HE 500 A 490 300 12 23 155 197,5 86970 3550 20,98 10370 691,1 7,24 1059 44,4

Size

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IPN PROFILES

Dimensions: DIN 1025-1:1995Tolerances: EN 10024-1996

h

b

Y

XX

s

14 %

Y

t

r1r2

b4

h b s t G A U Jx Wx ix Jy Wy iy Ss lt lw (mm) (mm) (mm) (mm) (kg/m) (cm2) (m2/m) (cm4) (cm3) (cm) (cm4) (cm3) (cm) (mm) (cm4) (mm6)

IPN 80 80 42 3.9 5.9 5.94 7.57 0,304 77,7 19,50 3,20 6,29 3,00 0,91 21,60 0,87 0,09

IPN 100 100 50 4.5 6.8 8.34 10.6 0,370 171,0 34,20 4,01 12,20 4,88 1,07 25,00 1,60 0,27

IPN 120 120 58 5.1 7.7 11.1 14.2 0,439 328,0 54,70 4,81 21,50 7,41 1,23 28,40 2,71 0,69

IPN 140 140 66 5.7 8.6 14.3 18.2 0,502 573,0 81,90 5,61 35,20 10,70 1,40 31,80 4,32 1,54

IPN 160 160 74 6.3 9.5 17.9 22.8 0,575 935,0 117,00 6,40 54,70 14,80 1,55 35,20 6,57 3,14

IPN 180 180 82 6.9 10.4 21.9 27.9 0,640 1450,0 161,00 7,20 81,30 19,80 1,71 38,60 9,58 5,92

IPN 200 200 90 7.5 11.3 26.2 33.4 0,709 2140,0 214,00 8,00 117,00 26,00 1,87 42,00 13,50 10,50

IPN 220 220 98 8.1 12.2 31.1 39.5 0,775 3060,0 278,00 8,80 162,00 33,10 2,02 45,40 18,60 17,80

IPN 240 240 106 8.7 13.1 36.2 46.1 0,844 4250,0 354,00 9,59 221,00 41,70 2,20 48,90 25,00 28,70

IPN 260 260 113 9.4 14.1 41.9 53.3 0,906 5740,0 442,00 10,40 288,00 51,00 2,32 52,60 33,50 44,10

IPN 280 280 119 10.1 15.2 47.9 61.0 0,966 7590,0 542,00 11,10 364,00 61,20 2,45 56,40 44,20 64,60

IPN 300 300 125 10.8 16.2 54.2 69.0 1,030 9800,0 653,00 11,90 451,00 72,20 2,56 60,10 56,80 91,80

Size

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SAMPLE DRAWINGS OF GALLERY CROSS SECTIONS

TH - GI Mine and IPN-HEA Tunnel Applications

4 piece (Horse Shoe) gallery 3 piece (Horse Shoe) gallery

Diversion channel Railroad and highway tunnel

S

H

S

S S

h

Trapezoidal gallery section

h

S

h

S

h h

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TH 29-34 CLAMPS AND TRAVERSAL JUNCTIONS

Clamps are produced with 31Mn4 and S480W steel grades.

NPU 65-80-100 traversal junctions are produced according to the customers’ applications ofTH 29-34 / GI Profile assembly intervals

*Traversal junctions are assembled with bottom and top notched clamps.

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Success isa journey,

not a destination.

www.kocaergroup.com.tr

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