Research and application of heap spraying technology based on safe and high-efficiency supporting structure
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摘要:
针对煤矿井下作业环境的特殊性和现有支护技术的不足，提出了堆喷技术，确定了工艺参数，研发了堆喷外加剂（S2），揭示了S2强化堆喷料性能的作用机理，形成了一套完整的堆喷构筑矿用支护结构体的工艺方法，并应用于沿空留巷等工程实践。结果表明：①堆喷技术可以根据需要构筑支护结构体，不受空间断面限制，操作工远离危险区，安全高效控制围岩；②堆喷料潮拌及输料管路分段加水工艺，提前湿润物料，可以促进堆喷料水化作用、增强粘附性及和易性、降低粉尘和回弹率；③S2的促凝组分包括NaAlO2、Al2(SO4)3、NaF、Al(OH)3和快硬硫铝酸盐水泥（SAC-42.5），增粘抗裂组分为硅灰（GS）、聚丙烯纤维（JB），提高了支护结构材料的凝结速度和抗压强度，且具有微膨胀特性；④现场堆喷标准试件的单轴抗压强度测试结果为1天12.0 MPa，3天18.1 MPa，7天27.5 MPa，28天42.1 MPa，90天42.3 MPa，具有高强承载能力，且后期强度不倒缩，强度增长过程分为三个阶段：初期快速增长阶段（龄期0～14 d）、中期持续增长阶段（龄期14～28 d）、后期稳定阶段（龄期＞28 d）；⑤堆喷技术构筑巷旁隔离墙实现沿空留巷，拓展了矿用支护结构体的高效施工方法。
Abstract:Aiming at the special characteristics of underground coal mine operation environment and the deficiency of existing support technology, heap spraying technology was proposed, technological parameters were determined, heap spraying admixture (S2) was developed, the mechanism of S2 was revealed, and a complete set of heap spraying construction technology was formed and applied to gob-side entry retaining. The results show that: ① Heap spraying technology can be used to construct the supporting structure according to need, which is not restricted by operating space and the operator is far away from the danger zone, so that the surrounding rock can be controlled safely and efficiently. ② Heap spraying material tide mixing and conveying pipeline segmentation with water process, wetting materials in advance, can promote material hydration, enhance adhesion and workability, reduce dust and rebound rate. ③ The accelerating components of S2 include NaAlO2, Al2(SO4)3, NaF, Al(OH)3 and fast-hardening sulfoaluminate cement (SAC-42.5), and the viscosifying and anti-cracking components are silica fume (GS), polymer propylene fiber (JB), S2 improves the compressive strength of the supportintg structure material and has micro-expansion properties. ④ Uniaxial compressive strength of the standard specimens molded by heap spraying is 12.0 MPa at 1 d, 18.0 MPa at 3 d, 27.5 MPa at 7 d, 42.1 MPa at 28 d and 42.3 MPa at 90 d, with high strength supporting capacity, and late strength does not shrink, the strength growth process is divided into three stages: the initial rapid growth stage (age 0−14 d), the medium sustained growth stage (age 14−28 d), and the later stable stage (age>28 d). ⑤Heap spraying technology can build the isolation wall along roadway to realize gob-side entry retaining, having a positive effect on expanding the construction method of supporting structure.
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图 15 直角梯形结构体不同配筋模型及失稳结果
Figure 15. Different reinforcement models and destabilization results of right-angled trapezoidal structures
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图 16 直角梯形结构体不同配筋应力−应变曲线
Figure 16. Stress-strain curves of different reinforcements of right-angled trapezoid structure
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图 17 堆喷巷旁隔离墙沿空留巷支护示意
Figure 17. Schematic of gob-side entry retaining by heap spraying wall
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图 18 沿空留巷围岩变形量与工作面距离的关系
Figure 18. Relationship between surrounding rock deformation and working face distance of gob-side entry retaining
表 1 堆喷料各组分的作用及参数
Table 1 Function and parameters of each component of heap spraying material
组分 材料 材料参数 功能 堆喷主料 水泥（P·O 42.5） 425号普通硅酸盐水泥 胶凝材料 砂 细度模数为2.6～3.0的天然砂 细骨料 石子 粒径为5～10 mm的碎石 粗骨料 堆喷辅料 堆喷外加剂（S2） 无机多功能复合料 支护结构材料制备的关键掺料 水 洁净且pH值为6～8 拌和作用 
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表 2 堆喷外加剂原材料的化学成分
Table 2 Chemical composition of raw materials
材料 化学成分质量占比/% SiO2 Al2O3 Fe2O3 CaO MgO SO3 TiO2 Loss SAC-42.5 8.72 34.13 2.31 39.86 1.42 7.11 6.15 0.30 硅灰（GS） 7.65 52.17 2.38 36.15 1.59 0.04 — 0.02 石膏（G） 0.36 0.03 0.05 41.60 0.05 52.08 — 5.83
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表 3 堆喷外加剂（S2）的配方
Table 3 Composition of heap spraying admixture (S2)
S2 所用原材料质量/(kg·t−1) GS SAC-42.5 G SM Al(OH)3 Al2(SO4)3 NaF MV JB JS S2-1 130 230 70 501 25 20 3 2 14 5 S2-2 140 220 80 489 30 18 2 2 14 5 S2-3 150 210 90 477 35 16 1 2 14 5 S2-4 160 200 100 464 40 14 1 2 14 5 S2-5 170 190 110 451 45 12 1 2 14 5
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颗粒间接触模量/GPa 1.0 黏结刚度比 1.5 颗粒间摩擦因数 0.5 平行黏结模量/GPa 0.5 平行黏结刚度比 1.5 黏聚力/MPa 20 抗拉强度/MPa 20 内摩擦角/(°) 45
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