Masole, Nyeleti Venus2024-07-142024-07-142023-01Masole, Nyeleti Venus. (2024). Support Design Approach for Crusher Chambers: A Case Study of Palabora Mining Company. [Master's dissertation, University of the Witwatersrand, Johannesburg]. WIReDSpace. https://hdl.handle.net/10539/38918https://hdl.handle.net/10539/38918A research report submitted to the Faculty of Engineering and the Built Environment, University of the Witwatersrand, Johannesburg, in partial fulfilment of the requirements for the degree of Master of Science, in the School of Mining Engineering, in 2024.This report project aimed to design a support system for crusher chambers at Palabora. The research project focused mainly on the two crusher chambers (12m wide by 25m high and 61m long) planned for the Lift 2 project as part of the ore handling system. The main research questions that the researcher sought to answer were; what are the differences between Lift 1 & Lift 2 in rock mass characterisation, classification and the ground control district?; how suitable is the Lift 1 crusher chamber support system for Lift 2?; what could be support requirements for Lift 2 crusher chambers in terms of empirical, analytical and numerical design methods and what are the recommended support design approaches for Lift 2 crusher chambers? The methodology used to design support for the Lift 2 crusher chambers was based on determining the expected failure mode first and then selecting suitable design methods to cater for the extent of failure. This study combined empirical and analytical methods to determine the failure mode and required support system. The results were then validated using Finite Element Method numerical modelling software called RS2 (Phase 2) from RocScience. Research findings revealed that the ground control district, classification and characterisation of rock masses differ slightly between Lift 1 and Lift 2. Jointing in dolerite dykes (DOL) was slightly dense in Lift 2 compared to Lift 1 and was associated with increased mining depth. Furthermore, the Lift 1 crusher chamber support system was found to be suitable for Lift 2 but must incorporate dynamic support. Unwedge (RocScience) analysis simulated wedge type of failure in the crusher chamber walls. The empirical and analytical design approach proposed cable bolt lengths of between 6m and 9 m and 3-4 m for roof bolts with bolt spacing of 1.4 m and 1.0 m respectively. The simulation results using RS2 confirmed that the cable bolt length and spacing were appropriate. The recommended support system was expected to provide sufficient support to the crusher chamber in terms of controlling rock mass deformation and yielding. The general conclusion was that the design approach selected for crusher chambers must be able to adequately represent rock mass behaviour and the support required to maintain long-term stability.en©2024 University of the Witwatersrand, JohannesburgLarge excavationsSupport designRock mass behaviourPalobora MiningRocScienceLift 1 & Lift 2 in rock mass characterisationUCTDSDG-9: Industry, innovation and infrastructureDissertationUniversity of the Witwatersrand, Johannesburg