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By Erhard M. Winkler

The rapid decay and disfiguring of stone monuments in urban and desert rural areas has challenged conservators to protect stone surfaces from premature decay. They attempt to halt the natural process of stone decay and possibly to restore the original strength lost mostly by chemical weathering and the loss of binding cement. Ageneral solution is not possible because the physical and chemical characteristics must be considered for different stone types. The failures of stone preservation and restoration are greater in number than the cures. The need for repair of stone decay goes back to evidence of Roman replacement of decaying stone. The presence of excess water in buildings has long been recognized. Moisture tends to enter masonry from air in humid climates, a most important but often underrated factor (Fig. 1) suggesting that sealing should be the answer. Undesirable staining and efflorescence result in accelerated scaling. Today, the great variety of chemicals available to the modem conservator for sealing. consolidating, or hardening stone fall into two very different categories: surface sealers and penetrating stone consolidants, or a combination of both. SEALERS Sealers develop a tight, impervious skin which prevents access of moisture. Surface sealing has saved monuments from decay by eliminating the access of atmospheric humidity. Pressure tends to develop behind the stone surface by moisture escape. Efflorescence, crystal growth action, and freezing can cause considerable spalling (Anderegg, 1949). Flaking results when moisture is trapped behind the sealed surface. Yellowing and blotchiness are also frequently observed. The following sealants are in common use today: linseed oil, paraffin, silicone, urethane, acrylate, and animal blood on stone and adobe. Extensive cracking and yellowing has resulted soon after application. In the past many such treatments have created more problems than cures: 1. Linseed oil and paraffin have been in use for centuries. Embrittlement and yellowing occur rapidly because these are readily attacked by solar ultraviolet radiation. 2. Animal blood as paint has temporarily waterproofed adobe mud and stone masonry. The origin of blood paint has a religious background rooted in the Phoenician and Hebrew cultures. Instant water soluble dried blood can substitute for fresh blood. Winkler (1956) described the history and technique of the use of blood. 3. Silicones have proven very effective and are long lasting. In contrast, acrylates, urethane, and styrene are generally rapidly attacked by UV radiation (Clark et al., 1975). Sealing of Different Rock Types Granitic rocks have a natural porosity traced to 4.5% contraction of quartz, during cooling of the parent magma, compared with only 2% contraction of all other minerals; protection against the hygric forces may require waterproofing of granite in some in- stances. The Egyptian granite obelisk in London is an example. Soon after its relocation from Egypt to London, Cleopatra's Needle was treated, in 1879, with a mixture of Damar resin and wax dissolved in clear petroleum spirit; surface scaling became evident after half a year of exposure to the humid London atmosphere. The treatment of the ancient granite monument from Egypt has denied access of high relative humidity (RH) in London to the trapped salts inherited from the Egyptian desert and has protected the monument from decay (Burgess and Schaffer, 1952). The sister obelisk set up in Central Park, New York City, has fared less favorably because similar treatment was done too late, only after the salts hydrated and hundreds of kilograms of scalings disfigured the obelisk surface (Winkler, 1980). Surface coating of other common stones may be needed. Crystalline marble absorbs moisture from high RH atmospheres: dilation may ensue when curtain panels bow as the moisture starts to expand during daily heating-cooling cycles. A good sealer may prevent the moisture influx provided that no moisture can enter from the inside of the building. Limestones, dolomites and all carbonate rocks are subject to dissolution attack by rainwater, especially in areas where acid rain prevails (Fig. 2). The interaction of sulfates in the atmosphere with the stone can be halted by waterproofing to avoid the formation of soft and more soluble gypsum. The stone surface attack can be diminished if nearly insoluble Ca-sulfite crusts can form, instead of Ca-sulfate. Replacement of fluorite or barium compounds at the stone surface acts as a hardener, rather than a sealant. Sandstones have generally high porosity and rapid water travel can occur along unexpected routes and from any direction. Any surface sealing may do more damage by scaling and bursting than if the stone is left without treatment. Sealing of sandstones is therefore not advised at any time. Testing the efficiency of sealants: Several authors discuss waterproofing materials, silicones, urethanes, acrylates and stearates, as to their water absorption, spreading rates of water on the treated surface, water vapor transmission, resistance to efflorescence, and general appearance (Clark et al., 1975). De Castro (1983) measured the angle of contact of a microdrop (0.004 cm3) on a stone surface as characteristic of the wettability. Laboratory tests and limited field performance are described by Heiman (1981). The crest of a Gothic sandstone arch, which was sealed with silicone,

Jan 1, 1994

By Michael A. Linkous, Mark J. Zdunczyk

Silica in the form of sand and sandstone is one of the most common, and at the same time, unique industrial minerals. Found in every rock type of every geologic age and virtually everywhere in the world, silica is used in products that touch just about every aspect of daily life. Imagine a world in the 1990s without computer chips, fiber optics, or glass, and you have just begun to understand how important silica is to the quality of life we enjoy. The elements silicon (Si) and oxygen (0) comprise roughly 60% of the earth's lithosphere to a depth of about 16 km. The crystal structure of silicon dioxide consists of one atom of silicon bonded to four surrounding atoms of oxygen to form a three-dimensional network of SiO, tetrahedra. This network makes up the mineral quartz (Murphy and Henderson, 1983), the most common detrital mineral in most sandstones. Quartz is also a major constituent of many igneous and metamorphic rocks and is widespread as a siliceous cementing agent in various rock types. Although quartz is common, sandstones, quartzites, and pegmatites and the unconsolidated sediments derived from them that have a silica content high enough and pure enough to meet today's market demands for quality and consistency are not common. USES AND SPECIFICATIONS Silica sand that is mined and processed for industrial uses must conform to the chemical and physical specifications set by customers. In the United States almost half of the silica sand produced is used in the manufacture of glass. Other important products include foundry sand, ground silica, blasting sand, and fracturing sand. Glass Sand Silica is the principal glass-forming oxide in a glass batch. Glass manufacturers develop model specifications for each source of silica sand used. These specifications broadly define the limits and ranges for chemical and physical properties of the sand and are used by the manufacturer in calculating the desired batch mix or formula. Some specifications may be critical to a glassmaker and require very stringent limits on the quantity of impurities in the sand. For example, the total iron oxide content of a batch is extremely crucial when making white or flint glasses (Mills, 1983). Iron is present in almost every raw material used in a glass batch and must be carefully controlled in order to obtain a consistent color in the finished product. It is difficult, however, for a raw material supplier to tightly control the chemistry of a naturally occurring material such as silica sand. To a great extent the commercial quality of a sand is determined by its geologic history. Realizing this, glass producers tailor their model specifications to each source of approved material. In general, a glass company is concerned most about the consistency of raw materials on a day-to-day basis. Soda-lime-silica glass was the earliest type of manmade glass (Baker-Can, 1967) and still accounts for most of the glass manufactured for commercial use today (Mills, 1983). It is relatively easy to melt and shape and is less expensive per ton to produce than most other types of glass (Baker-Can, 1967). Soda-lime-silica glass is used in fabricating containers, flat glass products, incandescent and fluorescent lamps, glass fiber, and many other products. Heavy minerals such as ilmenite, leucoxene, kyanite, and zircon are impurities on which strict limits are placed for a glass batch. Because of their refractory nature they either do not melt or only partially melt, which results in stones or feathers in finished glass. Aluminosilicates such as kyanite also contribute unwanted alumina to the batch as they partially melt. Limits are especially rigid for refractory mineral grains coarser than 0.60 to 0.425 mm (30 to 40 mesh). [Tables 1 and 2] present typical specifications for silica sand used in flat glass and container glass products. The percentages shown represent an average of many companies7 specifications.

Jan 1, 1994

By Raimo Matikainen, Pekka Särkkä

HISTORY The history of mining in the Outokumpu Co. shows continuous development of small and medium-sized mines, coupled with a permanent improvement in min¬ing methods and mechanization. Tables 1 and 2 provide a brief outline of the major events over the years of operation. Some of the mines have had relatively short lives as in the case of Nivala, Korsnas, Kylmäkoski, the surface pits of the Kotalahti, Vuonos, and Hammaslahti mines, and some very small pits. The sequence in which the mines started opera¬tions is shown in Table 1 and production increases in Table 2. GEOLOGICAL FRAMEWORK Most of the ore deposits in Finland (see Fig. 1) are situated in middle Precambrian (1500 to 2300 m.y.) formations corresponding to the Baltic shield. The ores and country rocks are generally firm, with a minimum compressive strength of 60 MPa (8700 psi). The sulfide ores, of importance to the national econ¬omy, can be divided into copper-nickel deposits, asso¬ciated with basic and ultrabasic rocks (1900 m.y.), and the sulfide ores found in well-preserved Svecokarelidic crystalline schists (1800 to 2300 m.y.) which contain varying amounts of copper, zinc, cobalt, nickel, and lead. Over 90% of the sulfide ore mined to date in Fin¬land and existing in the known ore reserves belongs to deposits situated in the main sulfide ore belt. This belt extends diagonally across the country over a breadth of Table 1. Sequence in Which Mines Began Operations 1913 Mining started at the Outokumpu mine (now called Keretti) 1928 Large scale systematic exploitation started in the Outokumpu mine Opening of mines: 1942 Nivala mine (1942-54) 1943 Yiojärvi mine (1943-66) 1947 Orijärvi mine (1947-54) (Mining started in 1757) 1948 Aijala mine (1949-58) 1952 Metsämonttu mine (1952-58 and 1964-74) 1954 Keretti's new mine plant 1954 Vihanti mine 1959 Kotalahti mine 1961 Korsnäs mine (1961-1972) 1962 Pyhäsalmi mine 1966 Virtasalmi mine 1967 Kemi mine 1970 Hitura mine 1971 Kylmäkoski mine (1971-74) 1972 Vuonos mine 1973 Hammaslahti mine 1978 Vammala mine Table 2. Ore Production of the Outokumpu Oy Mines Year 1000 t of Ore 1913-1928 252 1929-1954 13 075 1955 1 105 1960 1 784 1965 2 627 1970 3 269 1975 5 825 1976 5445 1977 4 939 1978 5 766 1979 5905 40 to 150 km, from Lake Ladoga to the coast of the Gulf of Bothnia. The main sulfide ore belt includes the Outokumpu copper-zinc, the Kotalahti nickel-copper, the Pyhäsalmi copper-zinc, and the Vihanti zinc ore zones. The Outokumpu ore district occurs in a mica schist area about 60 x 100 km, in association with belts of metamorphic Svecokarelidic quartzites, black schists, dolomites, skarn rocks, and serpentinites. The main ore minerals are chalcopyrite, pyrrhotite, pyrite, and sphalerite. In addition there are nickel and cobalt minerals such as cubanite and cobalt-pentlandite, which have been of economic importance. In this area, Outokumpu Oy exploits the deposits at Keretti and Vuonos. The latter was discovered as an extension of the Keretti ore field about 6 km to the northeast. The Kotalahti geological formation extends across nearly 400 km. The host rock of these mostly pipelike deposits is generally serpentinite, pyroxenite, or norite. The main ore minerals are pyrrhotite, pentlandite, and chalcopyrite. In this zone, the deposits of Kotalahti, Hitura, and Virtasalmi are at present under exploitation by Outokumpu Oy. The Vihanti geological formation is located in west¬ern Finland and is about 40 km wide and some 200 km long. The rock associations are crystalline schists including dolomites, mica schists, mica gneisses, gray¬wacke, and acidic or basic volcanic rocks, which change generally, in connection with the mineralization, into skarn and cordierite-anthophyllite rocks. The host rocks are dolomite, skarn, graywacke, and quartzitic rock and the principal minerals are sphalerite, chalcopyrite, galena, pyrite, and pyrrhotite. The accessory minerals are mainly cubanite, arsenopyrite, molybdenite, and native gold and silver. The two largest ore bodies being exploited at pres¬ent by Outokumpu Oy are the Vihanti mine, which pro¬duces zinc, lead, and copper, and Pyhäsalmi, which con¬tains copper and zinc. Deviating from the sulfide ore types described earlier is the Hammaslahti copper ore located in the southeast-

Jan 1, 1982

By Frank G. Horino, V. E. Hooker

INTRODUCTION The determination and use of mechanical properties of rock in engineering and rock mechanics are rapidly developing. Many of these properties are determined on intact rock specimens; thus, their application and repre¬sentation of rock mass properties may be limited. How¬ever, relative information often provides useful guidance in the solution to mine design and stability problems. Summarized in this chapter are some of the stan¬dardized techniques and procedures currently used to obtain these mechanical properties. Typical applications of the use of these properties are also presented. Stan¬dardized techniques include those advanced by the American Society of Testing and Materials (ASTM), International Society of Rock Mechanics (ISRM), US Bureau of Mines (USBM), Canadian Dept. of Mines and Technical Surveys, South African Institute of Min¬ing and Metallurgy, and other individual investigators. Information on the mechanical properties of rock and the behavior of the rock under a given system of stresses represents a necessary part of the information for rational engineering design for any given mining op¬eration. The mining method, the type and extent of sup¬port, the extraction ratio, the overall dimensions of the mine, and the orientation of the rooms and pillars are all decisions that are influenced by the mechanical prop¬erties of the ore, roof, and floor material under various stress systems and the magnitude and direction of the in situ stresses (Hooker, Bickel, and Aggson, 1972). Initial mechanical property information regarding a structure or mine property is generally obtained by two basic techniques: (1) static and dynamic property tests are conducted on intact and fractured rock specimens of exploratory drill core, and (2) dynamic properties are obtained by borehole logging techniques. When mining access becomes available, and as the mining horizon is expanded, additional information can be ob¬tained to verify preliminary mine design values. This chapter presents some of the standardized tech¬niques and equipment currently used in obtaining me¬chanical property data in the laboratory. The properties considered are: (1) uniaxial compressive strength of intact rock core specimens, (2) uniaxial compressive strength of rock cores containing planes of weakness, (3) triaxial compressive strength of intact rock core specimens, (4) triaxial compressive strength of cores with a plane of weakness, (5) Young's modulus, (6) Poisson's ratio, (7) density or apparent specific gravity, (8) modulus of rupture, (9) indirect tensile strength, and (10) creep characteristics. Where possible, an at¬tempt will be made to evaluate each property measure¬ment in relation to the problems of rock mechanics and application of results. TEST SPECIMENS The selection and care of drill core for laboratory testing require some consideration. It is recognized that laboratory-determined properties are not necessarily rep¬resentative of an in situ rock mass property. However, relative information between beds or zones of interest is still valuable information in selecting mining horizons and preliminary design criteria. To provide statistical data the number of drill core samples selected to repre¬sent each of the areas of interest should be from a mini¬mum of three to a maximum of ten test specimens. A judgment must also be made on site as to whether the recovered drill core should be wrapped and sealed in plastic to preserve moisture. On the one hand investiga¬tions of air-dried and saturated specimens have shown that moisture significantly affects the elastic properties and strengths of many rock materials (Obert, Windes, and Duvall, 1946; Colback and Wiid, 1965); on the other hand it is apparent that most core drilling is done with water which may saturate the specimen to a greater extent than in the in-situ condition. Whether or not the decision is made to retain the moisture, the core should be delivered to the laboratory as soon as possible after recovery for subsequent specimen preparation and testing. Specifications Shape: The shape of the specimens influences lab¬oratory testing in two ways: (1) time and cost of sam¬ple preparation and (2) strength of the material. Cy¬lindrical specimens of drill core are by far the least time-consuming to prepare for static or dynamic labora¬tory testing. In addition, the cylindrical shape lends it¬self to a more uniform stress distribution throughout the sample than other shapes, such as rectangles and hexa¬gons. The compressive strengths of various shapes have been studied (Grosvenor, 1963, and Price, 1960), and results indicate that the cylindrical specimens usually provide the highest strength for a given height-diameter ratio. However, reduction in strength from a cylindrical shape to a rectangular in situ pillar is not regarded as significant in relation to other considerations such as planes of weakness in a pillar or safety factors in the design process. Length-Diameter Ratio: The length-to-diameter ra¬tio, LID, has a significant effect on the compressive strength. Various recommendations have been made to use standard LID ratios ranging from 2 to 2.5 to 3 (ASTM, 1975c; ISRM, 1972). However, past work by others such as Obert, Windes, and Duvall (1946) has shown that excellent results can be obtained using LID ratios from 2 > (LID) > >/s. In selecting an LID ratio for testing, one should keep in mind the amount of material available for testing. In many instances, this may be limited. Thus, a shorter specimen such as 1: 1 LID may be necessary to provide enough test data for statistical analysis of results. Sec¬ond, it may be desirable to obtain elastic constants dur¬ing the test. This generally requires instrumentation such as linear variable differential transformers (LVDTs) or strain gages near the center of the specimen. In this case, an LID of 2.5 or 3 is desirable so that the instru

Jan 1, 1982

By James Watson Baxter

Fluxes are used to promote pyrometallurgical processes that rely on adhesion (soldering or brazing) or fusion (gas and arc welding) to join metallic surfaces. In the adhesive processes, the metal surfaces to be joined are not melted; the join is formed using a filler metal with lower melting point than the base metal. Fusion welding involves use of heat in excess of the melting point of the base metal. The fused joint may be achieved either by simply fusing together metal surfaces brought in contact with each other or by introducing additional molten metal of similar composition to form a fused joint. ADHESIVE PROCESSES--SOLDERING AND BRAZING In order for molten filler metal, solder or braze, to spread in a manner that creates a successful join; the work surfaces on the base metal must be thoroughly cleansed. Fluxes remove stubborn oxide films and other surface contaminants, promote wetting of the work surfaces, add fluidity to the solder or braze, and enhance workability and ease of spreading. Brazing processes involve higher temperatures than those reached in soldering. Brazing fluxes, which must remain active and effective at the higher temperatures, differ from those employed in soldering. Some common fluxes used in adhesive processes are rosin for soldering tin and electrical connections, hydrochloric acid for use in soldering galvanized iron and other zinc surfaces, and borax for brazing. Soldering and brazing are similar processes, the primary difference being the temperature at which the joining operation is carried out. Soldered joints, produced with low-melting-point fillers (solders) that melt and flow at temperature less that 450°C (Althouse et al., 1988) can sustain loads of 1 to 1.7 MPa for extended periods of time (Anon., 1966). Brazing involves the use of filler materials with melting points commonly above 500°C and generally provides stronger joints than those obtained with solder. Both processes require local application of heat to melt and spread the filler so that the molten filler can wet (adhere to) the base metals by alloying and diffusion. Soldering Soldering is a means of joining metals by adhesion using a metallic bonding alloy as the filler, commonly a mixture of lead and tin. However, the adhesion of solder depends more on its ability to be keyed into minute surface irregularities than on alloying. The most familiar application is to provide and secure electrical connections. Soft solders can range from 1 to 70% tin with the remainder mostly lead. However, for general-purpose, soft-solder work, the alloy is commonly 50% lead-50% tin. Higher lead contents provide a wider range in the melting temperature and, for this reason, a 60% lead-40% tin alloy, which yields a mushy mixture, is used for wiped joints in lead sheet and pipe work. Conversely, 40% lead-60% tin alloys are used in soldering tin and other low- melting-point materials for which a narrower range of melting temperature is required. There are numerous other solder compositions such as tin-silver, 95% tin-5% silver and antimony-tin, 95% tin and 5% antimony (Carlin, Jr., 1992). Heat needed to melt and spread the solders is commonly provided by electrically heated, copper-tipped soldering irons or by means of torches; the solder is applied by hand, usually face-fed by means of wire. For wiped joints in plumbing and lead-cable splicing, the solder is manipulated with cloth pads. The molten solder wets the joint surfaces and is drawn, by surface tension, into minute fissures and capillary openings. Other applications involve use of induction heaters and furnaces with pre-shaped solder appropriately placed prior to fluxing and heating. In some processes, the joints are immersed in molten solder. Constituents and Role of Soldering Fluxes: Soldering fluxes generally fall into one of three categories: highly corrosive fluxes, intermediate fluxes, and noncorrosive fluxes. These same categories are sometimes designated inorganic, organic and rosin-based respectively (Althouse et al., 1988). Common constituents of each group are discussed briefly below. Corrosive Fluxes (Inorganic). Work with aluminum, magnesium, stainless steel, high alloy steel, aluminum bronzes, and silicon bronzes is carried out at temperatures in the upper portion of the range for solder operations. Soldering these materials requires use of highly active, corrosive fluxes to remove and prevent the formation of the especially stubborn, hard, oxide films that form on these materials upon exposure to the atmosphere. The corrosive fluxes consist of inorganic acids and salts that are applied either as pastes or dry. They are active at elevated temperatures and, since they remain active after the soldering is completed, must be completely removed. The main constituent of most corrosive fluxes is zinc chloride with a melting temperature well above the solidus temperature of most commercial tin-lead solders. It is made by the action of hydrochloric acid on zinc. When zinc chloride is used alone, un- melted particles of this corrosive salt get caught up in the joint and weaken it. For this reason, other inorganic salts such as ammonium chloride (NH4Cl) or sodium chloride (NaCl) may be added to lower the melting temperature. A mixture of zinc chloride and ammonium chloride is very effective because the excellent oxide reducing properties of ammonium chloride and the protective action of the molten zinc chloride combine to produce a fluxing action superior to that achieved when either is used alone. In addition to zinc chloride, ammonium chloride, and sodium chloride; common con-

Jan 1, 1994

By Lewis L. Oriard

INTRODUCTION In recent years, there has been a trend in the direction of larger drilling equipment and larger diameter blastholes. Although this change has improved the efficiencies and reduced the costs in many operations, it has increased the potential for damage to underground openings. In addition, in many instances one now finds more sophisticated delicate instruments, automated control facilities, and a large variety of structures in proximity to blasting activity. The combined effect of larger-scale blasting activity and its proximity to various features of interest is such that there is an increased need for a more refined analysis of blasting effects and their control. BLASTING EFFECTS ON ROCK SURFACES The Breakage Mechanism In order to develop techniques for controlled blasting, one must first understand the features of the mechanisms by which blasting causes rock breakage to occur. These features have not been easy to demonstrate, mostly due to the difficulty in making tests and observations at the high stress levels and short time durations involved. When an explosive charge is detonated, the material surrounding the charge is subjected to a nearly instantaneous, very high pressure [on the order of 1.4 to 13.8 GPa (0.2 to 2.0 X 106 psi), depending on the explosive]. If the charge is coupled to "average" rock, this pressure will pulverize the surrounding rock for a distance on the order of 1 to 3 charge radii in hard rock, and to a greater distance in softer rock (this is also dependent on the type of explosive). As the pressure wave passes into the rock, high tangential stresses cause radial cracks to appear, and the nearly discontinuous radial stress zones gen¬erated by the shock front may cause tangential cracks to appear. The extent of these cracks depends on the energy available in the explosive, how quickly the energy is transmitted to the rock, and the strength properties of the rock. The discontinuous shock front is quickly dis¬sipated, but the expanding gases generate a longer-acting pressure. A compressive pulse travels to the nearest face or internal rock boundary where it is reflected in tension. The tensile strengths of most rocks are roughly 40 to %o of their compressive strengths, so the rock may now fail in tension whereas it may have been able to support the diminished compressive phase without failure. The ten¬sile deflection typically produces a failure described as tensile slabbing or scabbing. Laboratory experiments and field experience have pretty well established that several mechanisms are involved. These include (1) the classical case of tensile parallel slabbing when the pressure pulse is reflected at a free surface; (2) failure under quasi-static compressive loading (the shape is normally irregular due to discontinuities in the rock); (3) radial cracking under the action of tangential stresses at the periphery of the expanding pressure pulse; (4) peripheral cracking at the discontinuous shock front which is quickly dissipated; and (5) additional mass shifting due to the venting of the explosive gases. The first three items have received much attention in the laboratory and the literature. The complex effects of gas venting are difficult to test in the laboratory because of the difficulty in reproducing the many weak planes and discontinuities typical of most field conditions, which play such a prominent role in determining the behavior of the rock mass subjected to blasting. Unfortunately, gas venting effects can be pro¬jected to significant distances under certain field conditions, and are sometimes difficult to control. It is not unusual for gas venting to be the overriding factor in determining the final geometric shape and physical condition of the finished excavation. Sources of Damage For the purposes of this discussion, damage includes not only the breaking and rupturing of rock beyond the desired limits of excavation but also an unwanted loosening, dislocation, and disturbance of the rock mass the integrity of which one wishes to preserve (such as mine pillars, underground openings, etc.). The sources of damage include, of course, all those physical features of the rock breakage mechanism. Each of these effects must be limited to the desired zone of breakage and excavation if the integrity of the remaining rock mass is to remain undiminished. The primary zone of rock breakage usually can be controlled in the normal process of field experimentation to determine proper charge sizes and location for primary excavation. However, it frequently happens that there is damage from sources which are more difficult to account for in the design process, which are often overlooked. These are (1) the overbreak due to poor drilling control, (2) dislocation of rock (mass shifting) due to venting of explosive gases, and (3) loosening or dislocation due to the influence of seismic waves (ground vibrations). CONTROL OF ROCK BREAKAGE Importance of Geometry In studying the rock mass and blasting design con¬siderations, it is important to keep in mind the geometric relationships among charge size, shape, and position, and the physical features of the rock mass to be preserved. The features of principal interest are the external shape and position of the rock mass relative to blasting, and the position and attitude of any weak planes in the rock mass. The Sequence of Blasting and Excavation Events Unfortunately, there are too many times when the task of preserving delicate rock is considered hopeless, and because of this attitude, no further effort is ex¬pended towards caution or control. In such cases there is often a failure to recognize the importance of the se¬quence of the procedures. Attention to this can greatly reduce unwanted effects at minimum cost. Perimeter Control The requirements for perimeter control are highly dependent on the special needs of each particular proj¬ect. The desirable degree of control is a highly variable

Jan 1, 1982

By Neil J. Dahmen, Howard J. Handewith

INTRODUCTION Tunneling machines were introduced into civil con¬struction in the 1800s, but their practical applications were not realized fully until the 1950s. As of 1977, tunneling machines were being used on most tunneling projects of substantial size. As in civil construction, the mining applications of tunneling machines have included long drives such as tunneling for long ore-body develop¬ment drifts, long haulage tunnels, longwall access drifts, and long crosscut developments. Tunneling machines ranging from 1.75-m (5.7-ft) to more than I1.0-m (36-ft) diam are available from several manufacturers; machines for mining applications generally have ranged between 1.75 and 6.0-m (5.7¬and 20.0-ft) diam. Tunneling machines usually operate at or near horizontal grades and are supported by a rail-haulage backup system. However, declines and inclines have been made using alternative backup equip¬ment. Either circular or shaped tunnels may be bored, depending upon the particular equipment used. Using tunneling machines to bore openings through rock offers several advantages over the use of the drilling and blasting technique. These advantages include a rapid advance, continuous operation, uniformity of the opening size, smooth walls, and safe working conditions. Compared to drilling and blasting, boring reduces the disturbance of adjacent rock, thereby reducing the ground-support requirements and the exposure to water inflows. The smooth walls provide natural arching and present minimum resistance to the flow of air. A tunneling machine should be considered a spe¬cialized mining tool that is well-suited to certain mining applications. Properly applied and sustained, a tunnel¬ing machine contributes to realizing substantial econo¬mies in the development of underground mines. All costs herein are expressed in 1977 US dollars, unless otherwise noted. The mention of trade names and manufacturers is not intended to imply an endorse¬ment of any specific equipment. TYPES OF TUNNELING MACHINES As listed in Table 1, five principal types of tunneling machines were being manufactured in 1977. Each type of machine offers a special solution to a specific mining problem. Although each of these types of machines is described herein, most of this chapter is devoted to the full-face rotary rock-tunneling machine that has demon¬strated the greatest production in both civil construction and mining applications. Full-Face Rotary Rock-Tunneling Machines As shown in Fig. 1, a full-face rotary rock-tunneling machine consists of a rotating head that is fitted with rock-cutting tools and is forced into the tunnel face. This head is supported by a bearing on a structural support member that, in turn, is held in place by a hydraulically positioned wall-gripping mechanism. Both torque and thrust are reacted from the cutterhead, through the structural support and gripper mechanism, and to the tunnel wall. The rock cuttings fall to the invert at the tunnel face, and they are removed by means of cutterhead buckets or scoops that transfer the cuttings to a conveyor belt. After advancing the cutter¬head through a preset boring stroke, the tunneling machine is advanced by hydraulically pulling the gripper mechanism in from the tunnel walls, stroking forward, and resetting the gripper to the new forward position on the wall; the machine then is set for the next advance stroke. Full-face machines cut only circular openings. Ma¬chines with diameters as small as 1.8 m (6 ft) and as large as 6.1 m (20 ft) have been used in mining applica¬tions, excavating rock with unconfined compressive strengths in excess of 276 000 kPa (40,000 psi). Although special machines have been designed to turn on a radius of 30 m (100 ft) in both horizontal and vertical directions, the conveyors and backup sup¬port equipment generally limit tunneling machines to turns with a radius of more than 60 m (200 ft). The full-face rotary rock-tunneling machines have provided the fastest and most reliable production of any mining method or machine. These machines can be equipped to place any of a variety of ground-support systems, and they can be provided as "open" machines, as shown in Fig. 1, or as "shielded" machines, as shown in Fig. 2. The open machines have the advantage of allowing the ground to be supported as near to the tunnel face as possible. The shielded machines have been designed principally to allow placing precast con¬crete segments. The shielded machines completely pro¬tect the equipment and personnel at the heading, but they are economically limited to permanent long-life haulageways where full lining is required. Partial-Face Rotary Rock-Tunneling Machines As shown in Fig. 3, the partial-face rotary tunneling machine is equipped with a cutterhead that rotates slowly at about 0.21 rad/s (2.0 rpm). The single-disk cutterhead produces the tunnel section shown in Fig. 4 by means of an oscillating motion. These machines work on the undercutting principle, and they are avail¬able in spring-line dimensional increments of 0.1 m (0.32 ft) from 1.5 to 2.1 m (5.0 to 7.0 ft); the vertical dimensions are 2.4 to 3.2 m (8.0 to 10.5 ft), respec¬tively. Depending upon the tunnel width, the cutterhead disk may be fitted with from 8 to 16 drag-bit cutters. Penetration is achieved by means of hydraulic rams that force the tungsten-carbide bits into the rock mass. The operation is cyclic, with cutting occurring only on the upstroke. On the downstroke, the rotating cutter¬head draws the fallen muck from the invert into the panzer-type conveyor for rearward transfer. This feature allows time to either reposition ore cars or to exit the tunnel with muck trains while the machine is cutting, as shown in Fig. 5. Boom-Type Rotary Excavators The boom-type rotary-excavator tunneling machines commonly are known as boom-type continuous miners

Jan 1, 1982

By R. R. Graham

Echo Bay Minerals operates a 650 tpd gravity float gold circuit at their Manhattan facility. The objective of this paper was to document the gold recovery by size distribution. This was accomplished by studying the material balance of each size fraction as it progressed through each gravity Circuit separator. It proved to be an impossible task. Figure I depicts the gravity circuit. The gravity cyclone underflow goes to two duplex Pan American type jigs. The jig overflow reports to the OK Flash Float Cell. The cyclone hutch product is reground and goes to a full size wilfly table. The rougher table concentrate reports to a pilot size Wi1fly cleaner table. The cleaner and rougher table tails circulate back to the jig feed. The gravity circuit was composite sampled for two to four hours per day for four days. Each sample was taken every 20 minutes. Each composite sample was filtered, dried, repu1ped, and screened through a wet/dry screening procedure. Each size fraction was checked for gold value by fire assay fussion technique. A material balance was run on each size fraction. The tables listing the results are enclosed.

Jan 1, 1989

By Daniel A. Servigna, Pedro V. Porcayo, Humberto F. Preciado

This case study presents successful conversions of two conventional slurry tailings storage facilities (TSFs) to filtered tailings storage facilities in Durango, Mexico, for two mining operations with production rates ranging from 1,200 to 4,500 t/d (1,320 to 4,960 stpd). In both cases, the decision to make the conversion was driven by: • Ability to increase the storage capacity via stacking of filtered tailings. • Reduction of the tailings’ impacted footprint. • Mitigation of long-term geotechnical stability risks. • Alleviation of environmental risks by reducing tailings water as a source of pollutants, and a net reduction in process make-up water demand. The case studies can be divided in two classes: class 1 facilities, where slurry tailings are loaded almost immediately with filtered tailings because of storage area limitations; and class 2 facilities, where the conversion is immediate but the available area allows gradual or eventual loading of the previously stored slurry tailings. The condition where slurry tailings must be loaded almost immediately represents the greatest engineering challenge because of the geotechnical risks of instability and liquefaction (under both static and dynamic loads). Regardless of whether these facilities are converted immediately or eventually, they all require monitoring of pore water pressure conditions within the slurry tailings being loaded as the depth of placement of the filtered tailings above the slurry tailings increases. Additionally, where loading rate exceeds the pore pressure dissipation rate, tailings dewatering may be required to increase the rate of consolidation and strength and mitigate the risks of foundation failure.

Jul 1, 2025

By William E. Mead

The process of selecting a building site for a major structure is a complex procedure involving the consideration of a multitude of factors. The approximate geographic location for a structure is usually fixed by its intended function, though often there may be several site alternatives. Socio-economic, logistic, marketing and political factors are the primary site determinants. Also critical in site planning, however, are the environmental factors, both natural and man-made. These factors will influence the precise siting location within the limits allowed by the primary determinants and will dictate some of the basic design criteria. This paper discusses environmental factors, principally those which are natural conditions, that must be analyzed for five different groups of structures. The importance of thorough site environmental analysis based upon the principles of applied earth science is described. Significant elements to be considered in an appraisal of the geology, hydrology, seismology and meteorology are outlined.

Jan 1, 1968

By Nader Shahcheraghi, Verya Nasri, Mehdi Bakhshi, Ali Haghighat

An accidental fire load is one of the major loads considered in design of segmental linings in transit tunnel. Typically, a two-dimensional coupled thermo-mechanical finite element analysis (FEA) is conducted. The conventional approach involves using standard fire curves (temperature-time curves) which can lead to a significant overestimation of fire load and tunnel lining thickness in metro tunnels. The focus of this paper is on the cutting-edge approach, using 3D computational fluid dynamics (CFD) analysis of real train fires in metro tunnels and coupled thermo-mechanical finite element analysis (FEA) to accurately and cost-effectively design fiber-reinforced concrete (FRC) segmental tunnel linings for large-scale metro projects.

Jun 23, 2024

By Timothy Batchler, Khaled Mohamed, Morgan Sears

The National Institute for Occupational Safety and Health (NIOSH) initiated a testing program to assess the effects of lateral loading on various standing supports used in underground coal mines. This study is not intended to endorse a particular type of standing supports nor to provide a comparison between different types of standing supports. This paper aims to measure the lateral loading capacity of two types of standing supports and evaluate how it affects their vertical loading capacity and yielding mechanisms. The study utilizes the Mine Roof Simulator (MRS) at NIOSH Pittsburgh. Type-1 support is characterized by telescopic tubes made from ASTM A-513 steel with a specified locking mechanism, and Type-2 support comprises a single component constructed from ASTM A500 Welded Grade C pipe. Vertical load tests were carried out to assess the designed performance of Type-1 and Type-2 props. Type-1 props demonstrated a "constant yielding" behavior, achieving an ultimate capacity of up to 140 kips. Type-2 props showed a "load shedding" behavior, reaching peak verti- cal loads of up to 191 kips. Buckling analysis revealed that Type-1 props were not designed to buckle, and Type-2 props failed due to buck- ling rather than material yielding. Under vertical pre-loading, lateral loading tests showed that Type-1 props can withstand about 9 kips, and Type-2 props can withstand about 10.79 kips of lateral load. This represents roughly 6% of their vertical loading capacities. Testing props under lateral loads in addition to their intended vertical loads showed that the lateral loads could influence their loading mechanisms. Type-1 props did not exhibit the expected "constant yielding" behavior under lateral load but instead showed "load shedding" decreasing their rated vertical capacity by 70%. At high vertical pre-loading, Type-2 props demonstrated "constant yielding" behavior instead of the anticipated "load shedding," leading to a 60% reduction in their rated vertical capacity. These findings provide valuable insights into the behavior of these props under different loading conditions, aiding in their efficient use and design in underground mining operations.

Jun 25, 2024

By L. F. Delgado

Environmental and cost pressures sparked renewed interest in gravity separation. Industrial sands in Mexico are generally processed by screening, desliming, and flotation. Gravity separation with spirals was evaluated as an alternative to flotation in order to lower operating costs and decrease water pollution. Outstanding operating results are obtained in glass and foundry sand operations, plus a more competitive position for Mexican producers due to lower operating costs. Coal fines, generally recovered by flotation, have the same cost and environmental advantages when processed with spirals.

Jan 1, 1994

By R. J. Nankee

Recent on-going efforts to develop commercial coal cleaning beneficiation processes using chlorinated solvents-as the separating media will be described. True heavy media separations were performed on raw coal feedstocks, including Pennsylvania anthracite; Western, Eastern, and Midwestern bituminous; and lignite coals. Separation techniques included bath-type devices, cyclones, and liquid/liquid partitioning. Details on separation devices, removal of solvent, and recovery and recycling of solvent will be discussed. Projected costs of full-scale plants will be given for various coal sizes. A number of the coals evaluated are good candidates for beneficiation using chlorinated solvents. Coal beneficiation is desirable to provide needed coal quality. These needs include low ash fuels for coal water slurries and low sulfur fuels to meet emission regulations. In October of 1985, a paper, "Chlorinated Solvents for Coal Beneficiating"' was presented at the fall meeting of SME-AIME at Albuquerque, New Mexico. It reported the results obtained from various coals as feedstocks and of the separations using chlorinated solvents. These beneficiation results depended on true heavy media gravity and liquid/liquid partitioning separations. This paper will include detailed descriptions of the liquid/liquid partitioning process used in "Dow's Advanced Coal Cleaning Technology?2 and of the "Dow Solvent Recovery Technology.?3

Jan 1, 1987

By Daniel G. Ganey

Kerr-McGee Coal Corporation has used diesel face haulage and support equipment at its dual-seam Galatia Mine in Southern Illinois since production activities commenced in 1983. The mine began production from its lower seam, the Harrisburg No. 5 coal seam, in October 1983 and from the upper Herrin No.6 coal seam in April 1985. Before production began, the company developed a program designed to make use of the flexibility offered by diesel equipment. While productivity was an important goal, the top priority of the program was to provide a safe and healthy work environment for the miners. Management believed that high productivity would naturally follow. History has proven this belief to be true.

Jan 1, 1990

By O. M. Bishop

Large reserves of copper are contained in waste dumps which have been created by open-pit mining of porphyry-type copper deposits in the Western United States. Nearly 6 billion tons of copper-bearing material exists in the waste dumps at present, and another billion tons will be added each three to four years as additional material is stripped from the present mines and new open-pit mines are developed. The dumps constitute an enormous resource containing some 7 to 10 billion dollars worth of copper. Increased attention is being given to the recovery of copper by leaching from these dumps as attested by the fact that in 1968 approximately $175 million of copper was recovered by leaching operations. During the leaching process, however, numerous problems exist which prevent complete extraction of the copper from the dumps. Probably the most important problem encountered is the incomplete contact of the copper-bearing materials by the leaching solutions. This problem is mainly created by the formation of physically compacted and chemically cemented layers within the dumps which prevent solution flow to many sections of the interior of the dumps.

Jan 1, 1970

By Theodore Balberyszski

The gradual depletion of high-grade sulphide mineral deposits has turned the attention of the mineral industry to the recovery of metals from the oxides and silicates. Anionic (fatty acid) and cationic collectors have in some cases made flotation of non-sulphides possible, although in general, flotation of oxide ores is not as yet an economic process. Consequently, many attempts have been made to sulphidize the surface of the relevant oxide mineral and thus make it amenable to flotation. (1) (2) (3) In recent years, Bautista and Sollenberger(4) have investigated the conversion of a number of oxides to sulphides by reacting them with molten sulpur. This paper presents the results of investigations carried out at the School of Mineral and Metallurgical Engineering at the University of Minnesota to study the flotation characteristics of some sulphidized minerals. It is divided into two parts; Part I describes the sulphidization of a number of oxides and a silicate, and Part II presents the flotation behavior of the products of sulphidization.

Jan 1, 1968

By S. M. Khandrika

It is shown that dewatering of fine coal particles (D50 : 21 microns) is enhanced near the point of zero charge. The coal surface is modified by the addition of copper ions and adjusting pH to precipitate surface active metal hydroxy species which promote agglomeration and produce low moisture cakes. Filtration kinetics data are used in calculating filter cake parameters from an integrated form of Darcy's law. The influence of copper ions and pH on filter cake parameters and correlations among them are presented.

Jan 1, 1993

By R. C. Bunge

The selective flotation of semi-soluble salts with fatty acids is often negatively affected by the interaction of the potential determining cation with the ionic surfactant in bulk solution. This problem can be avoided by floating at low pH which involves the emulsification of the collector. The research presented here focuses on the influence of the Ca2+ ion on the flotation of fluorite with palmitic acid at low pH. Our results show that the surfaces of collector emulsions are dominated by precipitation phenomena similar to those encountered in bulk. In turn, fluorite in palmitic solution at intermediate pH displays surface properties similar to those of the collector by itself. This may be due to two alternative mechanisms (i) adsorption of bulk precipitate on the fluorite surface or (ii) the formation of a bilayer of surfactant ions on fluorite. Possibly, both mechanisms occur simultaneously.

Jan 1, 1993

Shallow ore deposits are mined by surface methods but a depth is reached in the case of most deposits after which underground methods are applied for the extraction of the remaining ore. The determination of this depth and its analysis is the subject of this paper. In order to determine transition depth from open-pit to underground mining on the basis of the allowable and economically feasible overall stripping ratios, an economic-mathematical equation is first introduced. Using the achieved equation and an analytical procedure on a particular two-dimensional hypothetical tabulate deposit, an effective formula is then established. The formula introduced here, together with the procedure adopted, could be used in all similar mining situations by the mining design engineer.

Jan 1, 2010