Resins in Mine Roof Support - I

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USE OF RESINS
IN MINE ROOF SUPPORT

by D. C. Mclea n
American Cyanamid Company

DAN. r. ANArNOzTOnOYAOz
ANTITIPOLOTIEIAI OIKCN E:=:DTCF IKC , .
l:.KOV¢A 64- TH J\ . 616 3 J3
11
THAErP. t,/N::i.l::i. : PAG AGI'< u
AGHNAI/144

Reprints courtesy of America n Cyanamid Company


USE OF RESINS IN MINE ROOF SUPPORT
by D. C. McLEAN

his report summarizes the work that has been unusually high rock wall stresses are encountered.
T done during the past several years in adapting res-
ins for use as auxiliaries in mine roof support. The
3) Air shafts as a possible alternate technique to
gunniting.
resins were applied in two ways: 1) by injection 4) Stopes where square setting is replaced with
into the strata, and 2) as a bonding agent for roof a cut-and-fill method.
bolts and reinforcing bar. The Explosives and Min- 5) Soft sandstones such as occur in the Grants
ing Chemicals Department of the American Cyan- area in New Mexico where good bolt anchorage is
amid Co. has worked during this period in cooper- often a problem.
ation with the Roof Control Research Group of the 6) Setting equipment foundation bolts and
U.S. Bureau of Mines, the Pattin Manufacturing anchor bolts and pins of several types.
Co., the J. H. Fletcher Co., the Homestake Mining It is also expected that resins can be utilized in
Co., the U.S. Steel Corp., the National Mines Corp. coal mining. The principle applications here would
and the Pocahontas Land Corp. in an effort to cre- be:
ate resin formulations and methods for applying 1) Mining areas where roof is composed of soft
them as a practical and safe type of roof support shales or mudstones.
for mining areas particularly where conventional 2) Roof in which fault planes, slips, and stress
support is inadequate, yet expensive. cracks occur frequently.
This work has involved much pioneering in a 3) Intersections where roof falls most often
field where theory, speculation, and pure mythology occur . .
predominates, and little basic engineering data is · · 4) Main haulage ways and air ways where per-
available. It is strange but true that, despite the manent bolt installations can be justified.
importance of roof control both from an operational 5) High walls and floors which undergo buckling
and safety standpoint, there is scarcely a mining and heaving.
company in this country that has an engineer, or
anyone, assigned to the study of roof support prob- Where excessive breaking and sloughing can
lems, except temporarily-after a bad roof fall. be expected (e.g. in air shafts, deep drifts, stopes,
The responsibility for improving roof control fractured ground), it is recommended that ex-
methods seems to have been placed entirely upon panded metal mesh or 9-gauge wire mesh be used
the shoulders of the USBM, various State depart- in conjunction with the resined bolts. Fig. 1 illus-
ments of mines, and individual roof bolt manufac- trates standard types of bonded reinforcing bar in-
turing companies. It was in cooperation with the stallations that have been used successfully in sev-
USBM that Cyanamid first developed resins for eral Canadian metal mines.
mining use.
RESIN INJECTION CONCEPT
APPLICATION FOR RESINS IN MINING In 1956, Maize and Wallace1 of the Roof Control
A survey of a large number of metal and coal Group, USBM, Bruceton, Pa., discussed the idea of
mines had indicated that conventional roof bolts injecting chemicals into stratified roof in coal mines
are entirely adequate for controlling ground 90 to in an effort to produce a consolidated, laminated
95 % of the time. However, there are difficult ground rock beam that would have sufficient strength to
conditions that occur in almost every operation that be self-supporting.
cannot be controlled by rock bolts alone. It is here Laboratory tests indicated that slate or tile
that resins, used in conjunction with roof bolts, "sandwiches" glued together with certain resins
have shown promise through making possible a form beams with 3 to 4 times the strength of the
different and more permanent type of bolt anchor- original unbonded material. Small scale under-
age than can be obtained in any other way. The ground tests in old roof were also encouraging. 2 It
resin-roof bolt combination provides a new ground was hoped ultimately that the additional safety
control device, the proper use of which can prevent feature of being able to inject resin ahead of the
much costly maintenance and repair work. working face to produce a consolidated roof befo7·e
The following applications are typical of those exposure could be realized. Cyanamid agreed to
occurring in metal mines in which resined bolts cooperate with the Bureau in investigating this
should prove most effective: concept, and during the years of 1957 to 1959, con-
centrated on the development of a special resin
1) Ore passes, dump chutes, slusher drift inter- and equipment for its injection. Two major tests
sections with feed raises (boxhole brows) where were carried out; one at the Renton mine at Ren-
conventional bolt life is short. ton, Pa., and one at U.S. Steel No. 14 mine at Gary,
2) Conventional drifts at depth (6600 ft) where W.Va.
The results obtained from this work can be sum-
D. C. McLEAN, Member of SME, is Asst. to Chief Metallurgist, marized briefly as follows. It was comparatively
lnt'l. Mining Tech. Service Dept., American Cyanamid Co., Stam- difficult to control the flow of resin in the roof.
ford, Conn. Resin alone gave less support than was desired in

2 Reprinted f1·om MINING ENGINEERING, January 1964


! newly exposed roof where only a few, relatively Fig. 1- Typical resin bonded re-bar applications .
fine cracks had developed. Cure time, especially in A-Wedge type, bonded full

:%
a wet cold roof, was slower than desirable. In these length pennanently stressed

- particular tests, no openings in the roof appeared


to exist ahead of the working face into which resin
could be injected, hence the safety feature of pre-
is best suited for permanent
anchorage of foundation bolts,
especially for holes with di-
ante'ters larger or smaller
than those of commonly
available expansion shells.
stabilizing the roof could not be realized. At these
two mines preliminary bolting was found to be
necessary, requiring special sealed bolts to prevent
resin leakage through the bolt holes. The special
pumping equipment was too complicated for pro-

:~
duction operation, and the handling of bulk chemi-
cals was time consuming and objectionable. Resin
consumption was high, 5 to 40 gal per hole, thus
making costs unattractive.
In the positive side, it was definitely established
that resin cou ld be injected properly through pro -
portioning pumps into rock strata at pressures up
to 3000 psig without inducing catastrophic hydro- WEDGE TYPE

static rupture of the roof. Resin flow was observed B - Re-bar threaded at both
at distances as great as 40 ft from the point of in- ends with expansion shell,
bonded fnll length, perman-
jection. Hair line cracks were completely filled in ently stressed is used where
several instances. After 48 hours, the resin cured immediate roof support is re-
quired for safe working con-
properly and gave good bonding. Subsequent fail- ditions, or where a prestressed
bolt is needed. Typical ap-
ure in injected roof was never observed to occur plications are broken roof or
along a bonded crack. Positive indications were pillars, or intersections in
coal ntines.
obtained that resin, injected into roof which had
undergone extensive stress relief and had devel-
oped many cracks, could consolidate and effectively
strengthen a badly fractured roof. This has been
confirmed in subsequent . tests at two other loca-
tions, one a military installation.

LIMITED INJECTION TECHNIQUE


It was apparent from these tests that to apply the
resin injection technique at low cost, the quantity
THREADED REINFORCING BAR
of resin used would have to be held to a minimum.
Tests of this nature were made at Homestake C-Re-bar threaded at one
end with collar plate, bonded
mine where pillar failures in stoping areas occur due fnll length is useful in raises
to fracturing in metamorphosed wall rock when the and shafts where protection of
workmen is required during
a djacent ore is removed . In tests designed by R. subsequent operations. Wire
mesh can be hung on end of
Oitto of the USBM, Cyanamid resins in small quan- bolt, and nut tightened to
tities were injected into holes drilled perpendicular full torque when resin has
cured. Re-bar shown is
to the plane of the rock fractures. Before the resin straight, but a slight bend
\vas pumped, % - in. reinforcing bars were placed in put into it during insertion
will hold it in place while
the holes. Installation was relatively simple and resin is setting.
rapid. Resin cure was complete within 1 hour at
the ambient temperature of 80 °F , and total resin
consumption was about 50 gal per pillar at a cost
of approximately $200. After 3 years, the injected
portions of pillar and drift walls are intact in con-
trast to the adjacent walls, supported by standard
nonbonded roof bolts, where deterioration has con-
tinued.
THREAD ONE END TO HOLD MESH
These tests have been most encouraging and have
demonstrated that resin injection can be effective D-Dowel pin, bonded full
length is most useful in ore
in special metal mining conditions where conven- passes and chutes where
tional bolting provides support for only relatively continuously falling rock
loosens a regular bolt almost
short periods of time . These tests will be described immediately. The re-bar can
be replaced with wire rope
in detail in a future publication by the USBM. in some cases. Re-bar can be
wedged into hole by bend ing
slightly.
PATTIN RESIN PACKAGE This technique is a lso
excellent for anchoring
While working on resin injection methods, Cya- crushers, slushers to concrete
namid also undertook another cooperative investi- foundations .

gation with the Pattin Manufacturing Co., the ob-


jective of which was to produce a resin package
which could be used to cement expansion shells
into place in roof bolt holes . The basic principle is
to provide shell anchorage which is permanent
(especially in soft ground) and not subject to de-
terioration due to shell slippage, corrosion or rock NOT THREADED

Rep1·int ed fTom MINING ENGINEERING, JanuaTy 1964 3


16 , - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - , 16

14 14

12,76 2
12
15, 458

(f)
0
z
::::> 10
0 9,650
Q._
0 0
0 0
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I 8 I 8
0 0
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0 7,4 33 0
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2

0
oL------OL
. 2----~0.-4-----0~.6------0~.-8----~
1. 0-------'1.2 OL-_____ L_ _ _ _ _ _L __ _ _ _-L------~-----L-------'
BOLT DISPLACEMENT -INCH 0 0.2 0 .4 0 .6 0 .8 1.0 1.2
BOLT DI S PLAC EM ENT - IN C H

Fig. 2--PuU test performance of %-in bolt anchorage Fig. 3--This puU-test data is also for a % -in. bolt which
supplemented with ROC-LOG product. Compare with is anchored with 3/s-in. expansion shell only.
Figs. 3 and 4, all replicate tests.
installations were made for each type tested. Pull
weathering effects. Details are given in U.S. Pat. tests were made after one week.
Nos. 2,829,502 and 2,952,129 and in several foreign In the writer's opinion, the curves indicate that
patents issued to J. B. Dempsey, president of Pattin both bonding materials are capable of greatly im-
Mfg. Co. proving anchorage of an expansion shell, increasing
the holding power in several instances by a factor
The Pattin package was a small dual compart- greater than 100 % . What is more important is that
ment film pack containing about 3 oz of a new the anchorage capability has been increased from an
bonding material which is available under the unsatisfactory maximum of about 5000 lb to values
trademark ROC-LOC . When installed, the sepa- greater than 8000 lb. Although the tests described
rator between compartments is slipped off, and here involve the use of only 3 oz of resin, the Pattin
the two components are kneaded together for package is available in a range of sizes so that bolts
about 1 minute. The mixed package is then pushed can be grouted any desired distance, including full
into the top of the bolt hole. A standard roof length.
bolt and shell assembly is next pushed vigor- THE ROCK GRIP RESIN PACK
ously up into the hole, smashing the package against
the top of the hole and forcing the mixed paste to Recently, Cyanamid in cooperation with the
flow around the shell, thus completely encasing it. Rockiron Co. of Sudbury, Ont., developed a unique
The shell is then tightened immediately in the usual and effective resin kit for completely cementing
manner. Depending upon rock temperature, the roof bolts.
paste cures in 1 to 8 hr and is not adversely effected The mechanical devices used in this kit for trans-
by moisture. ferring resin into a bolt hole are simple and inex-
pensive, yet permit rapid installation of fluid resin
The anchorage performance characteristics · of with which roof bolts of any type can be used. This
this type of bonded shell installation are shown in kit is sold exclusively by American Cyanamid Co.
Fig. 2. Comparative data for standard unbonded and is described below.
shells and shells bonded in the same manner with Favorable results with these kits containing both
a typical epoxy resin are shown in Fig. 3 and Fig. polyester and epoxy resins have been reported from
4. These data are another contribution of the Roof several operations in Canada.
Control Group of the USBl\13 • The roof tested is com-
posed of a soft, wet, badly weathered shale at THE GERMAN RESIN CARTRIDGE
57 °F . All bolts were installed initially at a load During the past few years, the Germans have also
value of approximately 5000 pounds. This load been quite active in developing a polyester resin
was selected to insure that anchorage capacity package for use with a special bolt for supporting
would not be exceeded, since preliminary testing soft ground in coal mines. These developments have
in this particular roof area had disclosed that at been described by F . Schuermann.'
higher loadings, a high percentage of "spinners" This is a glass capsule about 1 in. diam by 12 in .
occurred (expansion shell rotated in hole, losing long containing a mixture of polyester and quartz
anchorage completely). Ten replicate %-in. bolt sand and a thin glass catalyst container. The capsule

4 Reprinted from MINING ENGINEERING, January 1964


'
16 r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - , ROC-LOC MINING KITS
Ex per ience has indicated that no single type of
resin kit would meet all needs, and that a variety
17, 366
14 of styles of resin kits should be made available. It
was also Cyanamid's conclusion that a fully grouted
bolt provided the best type of ground support. As
12
a result, three types of ROC-LOC Mining Kits have
been developed, a brief description of which fol-
lows:
U1 Plastic Bag or "Sausage Kit" (ROC-LOC 20 Min-
0 10
z
:J
ing Kit) . This is a two-compartment unit contain-
0
a_ ing 20 cu. in. of bonding agent. A reinforcing
0
0
0
rod rapidly rotated by an impact wrench is driven
_: 8
I
through the plastic bag. This completely shreds the
0 package, thoroughly mixes the two components in
"'0
--'
the hole, and distributes the resin uniformly around
"~ the bolt.
6
--,
Single Hole Canned Kit (Rock Grip type called
ROC-LOC 60 Mining Kit). The two chemical
ingredients, constituting a total volume of 60 cu.
4
in., are mixed thoroughly in the larger container
and then forced by hand pressure into a transfer
tube. The transfer tube permits the simple placing
2 of the thick ROC-LOC paste into the top of the bolt
hole, thus eliminating the possibility of air entrap-
ment. Any type of bolt, including those with ex-
0
pansion shells, can then be pushed up through the
o~----~0.-2-----o~.4------o~.6------o~.8------1L
.o----~1.2 paste easily, causing it to extrude along whatever
BOLT DI S PL ACEMEN T - INCH
length of bolt is desired. The degree of coverage of
Fig. 4--This test series is of %-in. bolts using a typical the bolt will be determined by the amount of resin
epoxy resin to supplement anchorage. Tests made by put into the hole. It is designed to provide sufficient
U.S. Bureau of Mines. material to completely bond a 6-ft. % -in. diam re-
inforcing rod into a 1 % -in. drill hole. Total instal-
is placed in the top of the hole and completely lation time required is 8 to 10 minutes.
smashed and mixed by rapidly rotating the bolt as it Multiple Hole Canned Kit (ROC-LOC 540 Mining
is inserted. The bolt can be tensioned after some 20 to Kit). This kit contains 540 cu. in. of ROC-LOC in-
30 minutes. The degree of (purchase) amounts to 1.2 gredients in a 3-gal pail and is the most practical
to 1. 7 tons per em of insertion length, this figure kit for filling a large number of bolt holes which
falling by amounts up to 50 % in damp boreholes. can be drilled in advance of actual bolt placing.
The special "bolt" required for use with this The mixed paste is sucked into the transfer tube
resin pack is a l-in. rod threaded on both ends. The by a simple plunger arrangement on the end of a
resined end has about 14 in. of thread and has no small flexible plastic hose. The plunger can then
shell. The bottom end has about 4 in. of thread and be used to push the resin out of the transfer tube
a specially forged square end to permit attachment into the top of the bolt hole. This arrangement also
to a rapidly rotating driving machine. This bolt can permits the placing of any quantity of resin that
be tightened only after the resin has set. is considered necessary. With a little experience, a
German coa-l mines are reportedly using about two-man crew can completely install nine 6-ft bolts
5000 of these resin bolts per month, and major im- in about 20 minutes . This, of course, does not in-
provements in ground control have been reported clude drilling time.
as a result of their use. This is highly significant
since ground support problems in German coal PHYSICAL AND CHEMICAL PROPERTIES
mines are usually more severe than those in most The mixed Cyanamid product is a nontoxic, thick
American mines. paste which flows readily when stirred or pumped,
but becomes essentially immobile when placed into
INORGANIC CEMENT-TYPE BOLTS an overhead hole. The mixture hardens in two
f Perfo, Injekto, and Williams bolts are closely
akin to resin-bolts in that they use inorganic ce-
stages: ( 1) the gel stage, in which it becomes a
jelly-like plastic mass which is then no longer
/. m ents to completely grout bolts, whereas the resins transferable or workable; and (2) the cure stage
are synthetic organic chemicals. The cement-type during which it gradually forms a hard resilient
bolts have proven effective in ground control on mass with the evolution of some heat. The times at
many locations all over the world. However, their which the gel stage and full cure occur are a func-
effectiveness is limited to a large degree by the tion of the formulation used and the rock tempera-
physical and chemical properties of the cement ture, and both stages can be controlled over wide
u sed, and the transfer of cement up a hole is in- ranges. As normally supplied for metal mine usage,
h erently cumbersome and time consuming. While the gel time or pot life is about 30 minutes, and
cement grouted bolts will probably always have a sufficient cure to attain the bonding strengths in-
well-earned place in controlling difficult ground, it dicated occurs in 8 to 24 hours over the tempera-
is expected that forthcoming work will demon- ture range 40 to 70 °F. The higher the rock tem-
strate that resins are more universally applicable, perature, the faster the cure. It is a simple matter
especially as a production method in bad ground. to speed up cure times at low mine temperatures

Reprinted from MINING ENGINEERING, January 1964 5


Table I. Pull Tests Da ta fo r Bonded Re-bar Bol ts in Hard Igneous Roc k

Temp . ss · F 55 •F 9o •F 9o•F 9o·F


Cu re T ime 2 Weeks 3 Weeks 1 Week 2 W eek s 2 W eek s
Hole Condition Wet Wet Wet Wet Wet
% " Re-ba r Bolt Re -bars hamme re d 5
L e ngths min. prior to pulling
4" 10.5T Bond 10.5T B ond
Slipped in Slipped in
hole hole
6" 17.0T Bolt B roke 14.0T Bon d 1l.OT Bond 14.5T Bolt Broke 7.0T Bond
Slipped in Slippe d in Slipped in
h ole hole hole
8" 15.0T B olt Broke 15.0T B olt B roke 9 .0T Bond 14.0T Bolt Broke B.OT Bond
Slippe d in Slipped in
hole hole
10" 12.0T B olt B wke 16 .0T B olt B roke
12" 15.0T Bolt Broke 16.0T B olt B roke 12.0T Bond 15.0T Bolt Broke 15.0T B olt Broke
Slipped in
hole
14" 14.0T Stripped 15.5T Bolt Broke
T hreads
16" 17.0T Bolt Broke 16.0T Bolt Bro ke
18" 16.0T Bolt Broke 15.5T Bolt Broke 18.0T B olt B roke 15.0T Bolt Broke 17.0T Bolt B r oke
20 " 16.0T Bolt Broke 14.5T Stripped
T hread s
22" 16.0T Stripped 17.0T B olt Brokt
Thre ads
24" 16.5T Bolt B roke 14.5T Bolt Brok e 15.0T Bol t Bro k e 16.0T Bolt Broke 15.0T Bolt Broke

T = Short T o n s .
N OTE : In tes ts w here bonding a ge nt slipped i n hole, bolts w ere still able to s u pport loads of 1 ton less than the loads producing slippage.

by adding an accelerating agent d u ring t h e mixing bolt tension due to rock d eterioration at the collar
operation. plates. T his appears to be on e of t h e m aj or sources
This material has been especially develop ed for of difficulty.
use under wet or dry con ditions. T h e outstanding 5) The strata remain sealed off from t h e attack
useful properties for min in g app lication are t h e of air and atmosph eric moist ure to w hich m any
high tensile strength (2 000 to 8000 psi) com pres- typ es of roof fai lure are attributed .
si ve strength ( 10,000 to 20,000 psi ) and the excel- In a d dition to the above, special b olts totally
lent corrosion resistance . cemen ted with resins can offer t h ese a d dition al
featur es:
REINFORCING BAR ANCHORAGE 1) A wid e variety of types of su p p ort are pos-
CHARACTERISTICS sible with the same equipmen t. ( See Fig. 1) .
In granite, fully cu red material p rovides load 2) T he fast setting resins give qu icker support
bearing strength of 15 tons p er linear foot of than cemen t .
bonded bolt length with a % - in. re-bar in a 1.25 3) T he resins are less cu mbersome and less costly
in . drill hole . In concrete, anchorage strength for to in stall t h an cement.
the same bolt hole size combination is greater than 4) Bolts can be installed tension ed or unten -
11 tons per linear foot . See T able I for typical pull sioned.
test data . 5 ) R esins are chemically inert, h ence afford ex-
An interesting observation made in collecting the cellent corrosion protection from acid environ-
d a ta in Table I was t h at once the re- bar had slip - ments, esp ecially su lfate waters which rapidly de-
p ed , the load could be reapplied, several tim es, a n d teriorate con crete.
each time the original slipp age load ing would be
rea ched before fu rther movement occu rred. T h u s, COSTS OF RESINS
with bonded re- bars, it may be possible to build a O bviou sly, the cost of a resin installation will be
"shock absorber" effect in to the roof so t h at instan- a f unction of t h e q u antity of resin u sed , which in
taneous shock loads will not cause catastroph ic t u rn is established by the depth and diameter of
failu re as might occu r with a standard bolt when the bolt hole, the size of bolt used , and the type of
the h ead is Sl.J.ddenly sheared off. anchorage requ ired. A s an a pproxim ation, how -
ever, resin costs for a six foot hole u sing % - in. re-
THE CASE FOR RESINED BOLTS
bar would b e $2.50 to $4.50 at the present time .
These are the advantages to be gained from bolts W h en ease of installation, time of effectiveness, and
completely grouted in place with resins or cements. the n umerou s advantages to be gain ed are taken
1) Within a relatively sh ort time, good bolt an - into account, this cost is competitive with the ce-
chorage is achieved regardless of how faulty the men t grou ted bolt. In fact, in many in stances it is
initial installation might have been. a relatively inexp en sive permanent installation for
2) There is no dep endency upon sustained single which t here is n o good substitute at any price.
point anchorage, which may be q u ite risky . T he
bolt is anchored along its en tire length , giving ade- REFERENCES
q u ate anch orage for bonding distances as short as 1 E . R. M a ize and J . J. Wallace : Cementation of Bituminous-Coal-
12 in. of bolt length. Mine Roof Stra ta, Part 1. USBM RI 5304, N ov. (1956) .
o E. R. Maize and R. H . Oitto, Jr. : Cemen tation of Bituminou s -
3) T here is no subsequ ent support failure d u e Coal-Mine Roof Strata-Injection of Epoxy and Poly ester Type
Resins. USB M R I 5439, (195 9 ).
to accidental loss of anchorage at either th e shell 3 J . A. McC ormick a nd J . B . S hutack : P rogre ss Report-De ter-
or the collar plate. mination of Fea s i bility of U sing Resin to I mprove Roof-bol t An-
chor ages in S oft M a teria l : U n p ublished report, USB M (D ec. 1961) .
4) The u se of grouts in conjunction with bolts 4 F. Schuennann : Measures against the relaxation movements oc-
curring in roactwa y walls . Wissenschaftler beim S tein kohlenbergbau-
provides the only meth od for preventing loss of verein in E ssen , (1960) .

6 Reprinted f r om M I N ING ENGI N EER ING, J anuary 1964


AMERICAN CYANAMID COMPANY CYANAMID INTERNATIONAL
EXPLOSIVES & MINING CHEMICALS DEPT. MINING CHEMICALS DEPARTMENT
WAYNE, NEW JERSEY WAYNE, NEW JERSEY

CYANAMID AUSTRALIA PTY. LTD.


DISTRICT OFFICES Atlas Building, 406 Collins Street
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635 DORCHESTER BLVD., WEST
MONTREAL 2, QUEBEC
(514) 866-5611

SALES OFFICES
TORONTO MONTREAL VANCOUVER, B. C.
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(416) 247-8721 (514) 721-7441 (604) 682-3891

I \

For further information, please contact the office most convenient for you.

nAN. r. ANArNOzTOnOYAOz
ANTITIPO~On E I AI OlKO N E:=:O.._IEPIKOY
l:KOY¢A 64 - THA. 6 16 833
TH J\E r P . t./NH~. : "PAGAMAGI'l "
A GH NAI/1 44

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