Investigations on the corrosion behaviour of Rock bolts in mines

Dr. Lakshman Neelakantan

Assoc. Professor, Department of Metallurgical and Materials Engineering
Indian Institute of Technology Madras-Chennai 600 036

Steels (TMT bars) are often used as rock bolts in mines, which undergo various types of
corrosion. The corrosion rate of these steels is influenced by ground water composition,
flow rates, pH, temperature, CO2 content, surface conditions, presence of corrosion
inhibitors, applied stress, residual stress (due to welding), and H2S etc. It is challenging
to mimic these experiments in laboratory scale, which requires understanding the
environment existing at each mine.

Methodology:

1) The first effort would be to collect the test water from the specific mine of interest
and to analyse the water using ICP-OES to know the type of ions, their concentration,
pH and NaCl content etc.
2) Subsequently, we can try to simulate this electrolyte in laboratory for testing. In case,
simulating these solutions in lab is difficult, then we need to get the solution from
the active mine site. – Test water studies (~1 lakh)
3) Corrosion studies using Potentiostat (DC and AC techniques)- This would be carried
out on the steel bars used by using a 3-electrode electrochemical cell. The
environment would be electrolyte simulating the mine field, or actual test water
collected at the specific mine. This would be followed by post corrosion
characterization. - Accelerated studies (~3 lakhs)
4) Exposure studies shall be carried out to monitor the corrosion process (100 % humid
conditions). If the test water can be successfully simulated, then salt spray/cyclic
corrosion studies can be carried out at our lab. It should be noted that, our existing
facility might not be able to withstand the environment, hence we might need to
design/procure a new machine for this purpose (acid resistant). Also, as this work
requires longer duration (need to be specified), more running cost and
 consumables will be required. This would be followed post corrosion
characterization studies. - Exposure studies. (~10 lakhs)
5) Finally, the influence of load (using a test rig) and dripping of environment on
corrosion behaviour of rock bolt steels can be performed. In fact, this would provide
more actual information on corrosion as in the mine field. This set up can be easily
fabricated by outsourcing and can be installed in our lab for testing. - Effect of stress
on corrosion behaviour. (~5 lakhs)

S.No. Head TOTAL/Rs.

1 Salary @ 20000 p.m. for 12-18 3,60,000
months
2 Consumables, small salt spray 20,00,000
for mine solution (acid resistant),
test rig fabrication, spares and
maintenance existing equipment
etc.
3 Contingencies 1,50,000
4 Travel (if any) 50,000
5 Total 25,60,000
6 Institute Overheads @ 30% of 7,68,000
Total
7 Grand Total 33,28,000*

*18 % Service tax which should be added, which may change as per the notification of
Govt. of India.: i.e., Rs. 5,99,040
Total: Rs. 39, 27,040 (~ 40 lakhs)

Please note: This is rough estimate.