246
X4
Category 4: Special Projects
Geometry and structural system
• Total steel weight: 25.2 t
• Height dimension: 6.4 m
• Overall length: 7.7 m
• Overall width: 7.5 m
Introduction
PHA company, situated in Prague, received an order
to calculate the steel training module for Roof supports
from the contractor Ostroj Inc. A Roof support is a
hydraulic unit used in the mining industry.
The steel training frame is designed for the presentation
of units for inclined and steep seams extraction. The
module is also intended for a miner training programme.
The newest types of the Roof supports are intended for
the seams endangered by rock bursts. Therefore, the
legs in the units are equipped with rock burst valves.
Roof supports have a unit width of up to 2.05 m, with
a hydraulic leg diameter of up to 400 mm that provide
the load bearing capacity of up to 1,150 t and a section
resistance of 140 kN/m
2
.
The Roof support units are designed for shearer or
plough Longwall systems. They are equipped with
various types of bases, legs and control systems, and/
or with accessories for inclined seams and for seams
endangered by rock bursts.
Design software
The structural analysis was calculated using a 3D model
in Scia Engineer software.
Design
The basic structural design was prepared in two models.
The first model was with resistant forces supplied by
Ostroj Inc. Company. The training frame was designed
to bear resistant forces which show functionality and
practical use of the Roof support machines.
The second model was designed according to Eurocode
standards EC3 in the transverse and longitudinal
directions, with stabilisation by bracing.
The Roof supports steel module is independent in
regard to anchoring and is a self-bearing structure.
The minimum floor slab load bearing capacity of
10kN m
2
was required.
There were also requirements for a frame mount and
demount according to the global container dimension
and weight.
All connections required the demountable (bolted) type
of joints. The structure can be mounted anywhere in the
world within five days.
Load
Design loads conform to the contractor’s requirement.
The point force from hydraulic cylinders is 203 kN x 2
in a line.
The training module is designed for interior exhibition
without wind and snow loads.
Design process
The training module was calculate in the Scia Engineer
program and exported to the Tekla program with Module
Scia 2 Tekla. The designer used the perfect combination
for the design and fabrication of steel constructions.
For a fast feedback, the designer used 3D export from
Tekla to the browser. With this export the contractor took
influence in his project.
Conclusion
Scia Engineer has been used for an unusual
mechanical structure design. The designer used the
advantage of programs for a cooperation between the
contractor, designer and different software.
Training Module for Roof Supports Ostroj - Opava, Czech Republic
Software: Scia Engineer
