Block Caving
may, for example, consist of grouted threadbar (or cable)
figure 13.10-7 extraction level under construction using an
advanced undercut, DoZ mine, indonesia
figure 13.10-8 Drawpoint construction-forming jumbo,
henderson mine
can begin to compact and “accept” the weight of the ground
above. The abutment stress is redirected to the undercut level
and far less damage is seen on the extraction level.
A separate level for undercutting is required and typically
has twice the development as the other undercutting methods.
Because development and construction occur ahead of the
undercutting and drawbelling, this method requires relatively
greater up-front capital and use of development resources. It
can be difficult to recover a drawbell if it is not blasted prop-
erly. If this becomes necessary, a hung drawbell needs to be
drilled from the adjacent drawbell to the unblasted drawbell
through the minor apex.
PRePRoDuCTion DeveloPMenT AnD
ConSTRuCTion
When initial mine development is complete, and depending
on the geotechnical requirements for the area, a significant
amount of preproduction ground support may be required in
the extraction level to maintain panel and drawpoint integrity
for the duration of the caving and production periods. The pro-
duction period can last from 3 to 5 or more years depending
on the drawdown rate and column heights. The ground support
1443
bolts, wire mesh, and shotcrete throughout the extraction area
and will vary depending on ground conditions.
Preproduction work is followed by drawpoint construc-
tion, which typically consists of two lintel steel sets placed at
the mucking point of the drawpoint to protect the brow and
pillar from erosion by the caving material. The goal is to main-
tain the opening for the life of the ore column with a minimum
of repair. Figures 13.10-7 and 13.10-8 show typical drawpoint
construction. The lintel sets are often concreted and bolted
in place, with the posts being set into concrete in the floor.
The drawpoint and panel floors are typically concreted. Some
operations choose to add surface hardening products and steel
wear bars (often this is simply used rail) to prevent early floor
wear from both mucking and tire wear by the LHDs. If the
area has particularly poor ground, a full series of steel sets and
concrete may be applied to the drawpoint and panel section in
addition to the two lintel sets.
A typical drawpoint and corresponding section of panel
may cost in the range of US$250,000 to US$500,000, depend-
ing on the level of support required. Designing for adequate
drainage in the panels is key as water can play a major role in
early floor cracking and wear. A good general rule is to keep
panel roadways at a minimum 3% gradient to ensure adequate
drainage.
Some mines are small enough that a separate ore handling
level is not required (e.g., Palabora and Northparkes). Where
the footprint is larger and the haul distance to the crusher
is prohibitively high, a separate haulage level is employed.
As the panel and drawpoints are being constructed, the rel-
evant orepasses, ore handling systems, and ventilation infra-
structure must keep pace. Orepasses can be drop raised, raise
climbed (mechanically or manually), or raise bored down to a
handling level. The top of the orepass is usually fitted with a
grizzly and often a rock breaker for oversize material. Grizzly
dimensions vary depending on the orepass size and handling
method, and can range from 400 # 400 mm up to 1,000 #
1,000 mm openings for mines with the larger equipment that
can handle material of that size. Grizzlies should be sized to
the estimated fragmentation parameters; otherwise, excessive
choking can occur and clearing the obstructing material will
decrease the LHD efficiencies. Ideally, as much of the rock
reduction or breaking as possible should be done at the pri-
mary crusher to reduce secondary breaking requirements on
the extraction level. This requires the largest-sized grizzly
openings that can be delivered to by the LHD without causing
hang-ups in the orepass or other downstream systems. With a
1,000 # 1,000 mm grizzly the orepasses would need to be at
least 4,000 mm in diameter, with chutes and transport systems
sized accordingly. The DOZ mine in Indonesia initially used
1,000 # 1,000 mm grizzlies on a 4,100-mm-diameter orepass.
These fed into large chutes and 55-t-capacity haul trucks that
dumped at a 1,370 # 1,955 mm gyratory crusher.
Figure 13.10-9 shows a typical grizzly installation from
the DOZ mine. The grizzly openings are 800 mm, feeding into
a 4.1-m-diameter bored orepass. The bumper is 300 mm high.
The orepasses can vary in length and angle depending
on the haulage level elevation. Orepass diameter is a function
of grizzly size and expected material types. A good general
rule is to keep the orepass diameter greater than three to four
times the size of a grizzly opening to minimize the potential
for hang-ups. The base of the orepass is fitted with a typical lip
and gate chute arrangement that is used to load either trucks