International Journal of Mining Science and Technology 28 (2018) 145–151

Contents lists available at ScienceDirect

International Journal of Mining Science and Technology

journal homepage: www.elsevier.com/locate/ijmst

Development and evaluation of corrosion resistant coating for

expandable rock bolt against highly corrosive ground conditions
Kevin Jinrong Ma ⇑, John Stankus, Dakota Faulkner
Keystone Mining Services, LLC of Jennmar Corporation Inc, Pittsburgh, USA

a r t i c l e i n f o a b s t r a c t

Article history: Expandable rock bolts are widely used in hard rock mines as an efficient ground control product.
Received 21 June 2017 However, capacity and service life can be significantly reduced if the metallic body is subjected to corro-
Received in revised form 20 August 2017 sion. In some hard rock mines in the U.S., highly corrosive ground conditions exist, and it has been
Accepted 29 October 2017
reported that inflatable rock bolts have corroded within a few months after installation. To provide min-
Available online 2 January 2018
ing industry a cost-effective inflatable bolt and combat the corrosion issues, Jennmar Corporation, Inc.,
and its subsidiary Keystone Mining Services, LLC (KMS), analyzed corroded bolt samples, identified root
Keywords:
causes, evaluated properties of various coating materials, and developed a new inflatable rock bolt,
Rock bolt
Hard rock
Python M3TM, that is protected with an innovative PyFlexU2TM coating. The new generation Python M3TM
Corrosive ground condition features improved steel chemistry for reliable performance, modified profile for better inflation, and sur-
Bolt corrosion face preparation and coating application. The PyFlexU2TM is impervious to liquid and air, durable, and UV
resistant. With a flexible, adhesive, and highly corrosion-resistant undercoating, and a very hard sacrifi-
cial surface coating, the PyFlexU2TM coating system provides the Python M3TM superior protection against
chemical corrosion and physical scratch damage. The under-coating has exceptional flexibility and adhe-
sion to prevent coating micro-cracks or fractures after bolt inflation and possesses excellent corrosion
resistance to acids (pH < 3), alkalis (pH > 11), fuels, and salt solvents. The corrosion and scratch resistant
PyFlexU2TM coating offers very effective bolt protection for extra longevity in highly corrosive environ-
ments. The Python M3TM coated with PyFlexU2TM has been tested in the most challenging conditions,
including laboratory corrosion tests in extreme acidic and basic solvents, rock slurry, and borehole
scratch insertion tests. With demonstrated corrosion and scratch resistance, the product has been greatly
welcomed by hard rock mines in the West and is currently installed in large scale. This paper identifies
the root causes of the bolt corrosion, discusses the analysis process, and details laboratory and under-
ground tests carried out on the Python M3TM coated with PyFlexU2TM. The Python M3TM and PyFlexU2TM
are subjects covered by pending U.S. Patent Applications assigned to FCI Holdings Delaware, LLC.
Ó 2018 Published by Elsevier B.V. on behalf of China University of Mining & Technology. This is an open
access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

1. Introduction However, support capacity and service life of an expandable

Expandable rock bolts have been widely used for rock reinforce-
ments, particularly in underground hard rock mines, for over 35
years due to low cost, easy installation, effectiveness, and favorable
deformability in shear mode. An expandable rock bolt, such as
Python, is made of a steel tube that is folded into an Omega shape
in the cross-section (Fig. 1). During installation, the bolt is inserted
into a borehole and inflated with high pressure water. The inflated
tube generates frictional full-length anchorage due to contact
stress and mechanical interlock at the bolt-rock interface.
⇑ Corresponding author.
E-mail address: kma@jennmar.com (K.J. Ma).
rock bolt can be significantly reduced if the metallic body is sub-
jected to corrosion. Grounds containing sulfur or chloride content,
when exposed to air and water, can produce acidic environments,
which quickly initiates metal corrosion and reduces the effective
strength and diameter of the bolt body. Under such conditions, a
rock bolt will deteriorate rapidly. Prior studies indicate that the
ultimate strength of a rock bolt dropped significantly due to pitting
or stress corrosion cracking [1]. The bolt corrosion problem in cer-
tain geo-environments becomes so severe that it can cause failure
of the reinforcement. In some hard rock mines in the U.S., highly
corrosive ground conditions exist, and it has been reported that
expandable rock bolts have corroded within a few months after
installation. The unexpected bolt failures have resulted in roof falls,
interrupted mining production, and have forced the mine operator

https://doi.org/10.1016/j.ijmst.2017.12.023
2095-2686/Ó 2018 Published by Elsevier B.V. on behalf of China University of Mining & Technology.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
146 K.J. Ma et al. / International Journal of Mining Science and Technology 28 (2018) 145–151
Fig. 1. Expandable rock bolt (Python by Jennmar).
to perform expensive and strenuous rehabilitation on a regular
basis due to safety hazard concerns.
In the past, the mining industry commonly relied on either a
cathodic sacrificial coating (zinc galvanization, zinc epoxy, etc.)
or barrier-type coating (epoxy, polyurethane, plastic, etc.) to pro-
tect the expandable rock bolt. However, in highly corrosive condi-
tions, both coating systems are either ineffective or vulnerable due
to micro-cracking or splitting of the coating during bolt inflation, or
scratch damage of the coating during bolt insertion. Zinc in the
cathodic sacrificial coating, such as galvanized finish or zinc epoxy,
is an excellent corrosion-resistant protection in alkaline conditions
but performs poorly in an acidic environment. The barrier-type
coating will not provide bolt body a good protection against corro-
sion unless the coating material is inherently stable in extreme
acidic condition and stays intact during bolt insertion and expan-
sion. For example, there is evidence that the polymeric coating
‘‘Obdura AP” is ineffective due to coating micro-cracking during
inflation and its inherent vulnerability combating extreme acidic
conditions [2]. It is technically difficult to develop a barrier-type
coating for an expandable bolt that requires a significant amount
of flexibility and a great deal of surface hardness to resist scratches.
To provide the mining industry a cost-effective, expandable
rock bolt and combat the corrosion issues, Jennmar Corporation,
Inc., and its subsidiary Keystone Mining Services, LLC (KMS), ana-
lyzed corroded bolt samples and ground condition, identified root
causes, evaluated properties of various coating materials, and
developed a new rock bolt Python M3TM that is protected with an
innovative PyFlexU2TM coating.
The new PythonM3TM features improved steel chemistry for reli-
able performance, modified profile for better inflation, and surface
preparation and coating application. The PyFlexU2TM is impervious
to liquid and air, durable, and ultraviolet (UV) resistant. With a
flexible, adhesive, and highly corrosion-resistant undercoat and a
very hard sacrificial topcoat, the PyFlexU2TM coating system pro-
vides the Python M3TM a superior protection against chemical cor-
rosion and physical scratch damage. The Python M3TM coated
with PyFlexU2TM has been tested in the most challenging condi-
tions, including laboratory corrosion tests in extreme acidic and
basic solvents and borehole scratch insertion tests in the field.
With demonstrated corrosion and scratch resistance, the product
has been greatly embraced by hard rock mines in the U.S., and is
currently in large-scale usage in the mining industry.
2. Corrosion root cause analyses
To identify root causes of corrosion failure of the expandable
rock bolt, field samples, including corroded bolt samples and rele-
vant rock samples, were collected from collaborating hard rock
mines and tested in Jennmar Research Center in Pittsburgh, PA.
2.1. Inflation test of expandable rock bolts
If the coating is not flexible enough, the coating in vicinity of the
folded area of the expandable bolt can be prematurely damaged
during inflation. To verify the hypothesis, bolt samples were col-
lected and inflated in an unrestricted manner.
Prior to the test, the samples were visually checked, and the
coating on all of the samples was fairly uniform and free of any
pre-existing damages. Visual inspection after inflation indicated
that some samples showed micro-cracks and large cracks at the
shoulder area, as shown in Fig. 2. The coating was cracked,
debonded from the base metal, and could be peeled off. In addition,
a series of micro-cracks occurred on two shoulder areas almost
along the entire bolt length. Preliminary laboratory inflation tests
indicate that, if there is a lack of sufficient flexibility, coating failure
could occur during bolt inflation.
2.2. Analysis of field bolt sample
It is reported that the expandable bolt rusted quickly (within
months), could be pulled out manually, and the coating flaked
off. Fig. 3 shows the corroded Omega-AP bolts recovered from
underground. By visual inspection, it appears that the corrosion
is worse at the tongue and shoulder of the previously folded area
than at the back of the bolt.
To identify primary corrosion chemical species and corrosion
mechanisms, the field bolt sample was analyzed via scanning elec-
tron microscopy/energy dispersive spectroscopy (SEM/EDS) of the
rust on the field sample. The corrosion analysis indicates that the
following:
(1) The sample experienced a semi-uniform and pitting corro-
sion. The contact pH measured approximately 5.5 on the bolt
surface.
(2) Analysis of the corrosion products collected from the cor-
roded bolt surface via back scattered electron (BSE) images
and EDS spectra (Fig. 4) indicated that the corrosion prod-
ucts contain significant amounts of sulfur and chlorine.
(3) Data collected indicate that, with the chlorine detected pri-
marily at the corrosion front, chloride corrosion is likely
the primary driving mechanism.
(4) It was concluded that the failure appeared to be environ-
mentally governed and caused by corrosive attack by acidic
ground conditions.
2.3. Evaluation of corrosive ground condition
To evaluate the corrosiveness of the strata that the expandable
rock bolt was subjected to, rock samples were collected from nine
different sites that are considered representative of corrosive
ground conditions in the collaborating mine. The rock samples
were evaluated for pH units per EPA Method 9045D, sulfate analy-
sis per EPA Method 3050B, acidic digestion, and chemical compo-
sition using Inductively Coupled Plasma-Atomic Emission
Spectrometry (ICP-AES) following EPA Method 6010C. Table 1 are
the test results of pH units and sulfate concentration.
Fig. 2. Coating cracks due to bolt inflation (Omega-AP).
 K.J. Ma et al. / International Journal of Mining Science and Technology 28 (2018) 145–151 147

Table 2
Acid digestion and ICP-AES test results.
6
Item Sample # (10 )
Analyte 2 3 5
Calcium 18,200 115,000 18,600
Iron 43,000 21,300 41,400
Magnesium 1330 59,700 11,100
Potassium 3210 19,400 3250
Silicon 266,000 145,000 307,000
Fig. 3. Corroded bolt sample (Omega-AP). Sodium 208 338 228
Nickel 114 35.3 29.5
Zinc 1150 77.9 42.9
Chloride 11.7 12 182
Sulfate 11,000 5680 8760

(1) If there is a lack of sufficient flexibility, the coating material

could experience premature damage and develop micro-
cracks during bolt inflation.
(2) If there is a lack of sufficient surface hardness, coating mate-
rial could be prematurely damaged due to scratch by sharp
rock edges inside of the borehole during bolt insertion.
(3) Current coating materials are inherently vulnerable to
chemical attack in extreme acidic ground condition.
(4) Aggressive ground conditions-characterized by an abun-
dance of chloride salts and sulfate salts in the strata, pres-
ence of water and air, and relatively high underground
temperature-are the primary factors contributing to the cor-
rosion and deterioration of the rock bolts.
(5) The concomitant presence of sulfate ions with chloride ions
serves as a major cause of accelerated rock bolt corrosion.
From a chemical corrosion perspective, once the coating
material is damaged for whatever reason, the base metal
of the rock bolt will be in direct contact with acidic environ-
Fig. 4. EDS spectrum collected from corrosion products.
ment, and an iron chloride corrosion product will form over
time. The iron chloride product is dissolvable in water and
chemically unstable. With a loss of water and presence of
Table 1 carbon dioxide, oxygen, and sulfate, the iron chloride con-
Test results of pH units and sulfate analysis. verts to an iron carbonate, iron oxide, or iron sulfate corro-
Location # pH unit Sulfate concentration sion product, leaving the chlorine to advance the corrosion
front further into the base metal.
1 5.42 3500  10 6, 0.350%
2 3.60 11,000  10 6, 1.110%
3 8.24 5680  10 6, 0.568% 3. Improvement of python bolt
4 4.19 11,400  10 6, 1.14%
5 6.16 8760  10 6, 0.876%
A few improvements were made on the Python rock bolts. First
6 5.49 7490  10 6, 0.749%
7 3.71 5850  10 6, 0.585% of all, to ensure a reliable and better performance of the bolt, a new
8 4.02 8160  10 6, 0.816% high-strength low-alloy steel with improved steel chemistry is
9 4.65 9050  10 6, 0.905% used for bolt body, ferrule, and end cap in Python production. Also,
the fabrication production line was upgraded using state-of-art
As shown in Table 1, only sample #3 demonstrates an alkaline technology, including an automatic roll former, robotic welder,
ground condition (pH 8.24), while the remaining rock samples and other equipment.
show an acidic condition with pH units ranging from 3.6–6.16. Most importantly, after a careful evaluation, Jennmar revised
All rock samples except #1 have a sulfate concentration ranging the profile of the Python bolt without compromising the perfor-
from 5680  10 6 to 11,400  10 6. The test results clearly indi- mance of the product. Fig. 5 shows a comparison of the profile of
cate that the acidic ground condition is a major factor that con-
tributes to the bolt corrosion.
Based on pH and sulfate test results, the three most representa-
tive rock samples (#2, #3, and #5) were selected for acid digestion
and ICP-AES tests with a focus on dominant chemical components.
Table 2 are the test results of the three representative rock
samples.

2.4. Root causes of bolt corrosion

The following factors served as root causes of corrosion failure

experienced by expandable rock bolts in the field: Fig. 5. Improvement of bolt profile.
148 K.J. Ma et al. / International Journal of Mining Science and Technology 28 (2018) 145–151

Fig. 8. Flat samples with different coatings.

Fig. 6. Comparison of shoulder gap at cap end.

the Python and current Python M3TM. The improvement results in

multi-fold benefits to coating application. With a wide gap, 100%
of metal surface can be easily cleaned and prepared for an optimal
coating application. With improved surface preparation, adhesion
of coating material to base metal is greatly improved. The wide
gap also enables an accessible space for coating application at Fig. 9. Coating flexibility test sample (PyFlex).
the bolt end and prevents the coating splitting issue after inflation.
Fig. 6 shows a comparison of the shoulder gap at the cap end of the
original Python bolt and the new Python M3TM bolt.

4. Development of PyFlexU2TM

To develop a viable coating system for the Python M3TM bolt, a

comprehensive research, development analysis, and laboratory
tests were conducted at Jennmar Research Center. KMS outlined
a coating specification, collaborated with various coating compa-
nies to identify the most suitable coatings, prepared bolt and flat
Fig. 10. Coating adhesion test.
panel samples that were coated with nine different coatings, and
initiated a detailed testing program.

4.1. Expected specifications of coating material

It is expected that a suitable coating shall be technically viable

and cost-effective with the following properties:

(1) A wide range anti-corrosion against acidic (pH 3 or lower) or

basic (pH 11 or higher) ground conditions.
(2) Reliable adhesion strength.
(3) Certain amount of elasticity to prevent micro-cracks during
bolt inflation.
(4) Good abrasion resistance.
(5) Good UV resistance against sunlight.
(6) Durability under various atmospheric conditions.
4.2. Evaluation of candidate coatings (phase I)
Nine different coatings were identified as candidates. Various
bolt samples (Fig. 7) and flat panel samples (Fig. 8) were prepared.
To evaluate the performance of the different coatings, various lab-
oratory tests were conducted, including the following:
Fig. 11. PyFlex coating after 60 h immersion in acidic solution.
(3) Coating flexibility evaluation per ASTM D4115 (Fig. 9). To eval-
uate micro-crack development of the coating, the flat panel
samples were bent 180° at 0.48 cm radius.
(4) Adhesion of coating to base metal (Fig. 10) per ASTM D4541.
(5) Immersion test in acidic solution per ASTM G31. Each of the
prepared bolt samples was partially immersed in sulfuric
acid (96% concentration) solution. Fig. 11 shows a test sam-
ple (PyFlex) after 60 h immersion.
(6) Hardness of coating material.
(7) Scratch resistance of coating.

(1) Coating thickness evaluation per ASTM D 7091.
(2) Coating integrity evaluation after unrestricted inflation. The
inflated bolt was checked for the appearance of wrinkles,
blisters, delamination, macro-cracks, and cracks or peel-off
of the coating material.
Fig. 7. Bolt samples with different coatings.
4.3. Development of PyFlexU2TM coating
With the Phase I laboratory test results, PyFlex coating material
was identified as the best candidate. The material has exceptional
flexibility and adhesion to prevent coating micro-cracks or frac-
tures after bolt inflation and possesses excellent corrosion resis-
tance to acids (pH < 3), alkalis (pH > 11), fuels, and salt solvents.
To further improve surface hardness and scratch resistance of the
coating against physical damage during bolt insertion in the field,
a very hard sacrificial topcoat (U2) is applied on the unfolded area
of the Python bolt, where deformation is not very demanding dur-
ing bolt inflation.
The combination (PyFlexU2TM) of the corrosion-resistant under-
coat PyFlex and the scratch-resistant topcoat U2 satisfies coating
 K.J. Ma et al. / International Journal of Mining Science and Technology 28 (2018) 145–151 149

Table 3
Mechanical properties of PyFlexU2TM.

Item Result Test standard

Taber abrasion 12 mg (weight loss) ISO 9352, CS-10, 1000 g
Adhesion >8 MPa ISO 4624, 20 mm dolly
Hardness Under 60 shore D ASTM D2240
Top >84 shore D
Impact resistance >18.2 J ASTM D2794, 1.5 mm steel; ball diameter: 15.9 mm
Tensile strain at break 460% ISO 527
Tensile strength 23 MPa ISO 527

Table 4
Corrosion resistant properties of PyFlexU2TM.

Item Result Test standard

Salt spray resistance: 2000 h 0 mm steel substrate corrosion ISO 9227
NSS, with scribe
Salt spray resistance: 3500 h <1 mm steel substrate corrosion ISO 9227
NSS, with scribe
UV stability: 2000 h No damage ISO 4892-3
Corrosion resistance 20 °C 60 °C ISO 2812 and ISO 4628
Acid Excellent Excellent
Alkaline Excellent Excellent

design expectations and offers very effective bolt protection for
extra longevity in highly corrosive environments. Tables 3 and 4
summarize the mechanical properties and corrosion-resistant
properties of the PyFlexU2TM coating.
5. Evaluation of PyFlexU2TM (phase II)
The Python M3TM bolt coated with the PyFlexU2TM were tested
rigorously for long term corrosion-resistant performance in labora-
tory and for scratch resistance in the field.
5.1. Laboratory testing
5.1.2. Long-term immersion test in mine rock slurry
To approximate corrosion environment in the field, the nine
representative rock samples were crashed, pulverized, and sieved
into powder (18-mesh material). A rock slurry was prepared by
mixing the rock powder with distilled water in a water-to-
powder ratio of 1:3 by weight. The bolt samples (inflated Python
M3TM from production, surface scratched Python M3TM from field,
and uninflated Brand AC) were immersed in the nine different rock
slurries for 56 d. To accelerate the corrosion, a thermostatically
controlled spot heater was used to maintain a constant high tem-
perature in the range of 85 ± 5 °F. Test results indicate the
following:

To evaluate long-term corrosion-resistant performance, a series

of Python M3TM bolts coated with PyFlexU2TM were tested along
with reference samples (Brand AC).

5.1.1. Long-term immersion test in chemical solution

Inflated bolt samples were immersed in acidic and basic solu-
tions, including HCl (pH < 3), H2SO4 (pH < 3), NaOH (pH > 11),
and NaCO3 (pH > 11). The 56-d immersion tests indicate that, in
terms of corrosion resistance against sulfuric and hydrochloride
acid under a low pH (<3), the PyFlexU2TM coating appears to be
much more effective as compared to the Brand AC coating. Fig. 12. PyFlexU2TM (top) and Brand AC (bottom) immersed in H2SO4 for 56-day.
Fig. 12 is a comparison of PyFlexU2TM and Brand AC samples
immersed in sulfuric acid solution. The PyFlexU2TM coating stayed
intact and slightly lost surface gloss, whereas the Brand AC was sig-
nificantly damaged and discolored. Blisters, undercoat corrosion,
and localized corrosion occurred to the Brand AC sample. Coating
material immersed under the liquid became chalky and brittle.
The coating material had cracks 2.54–3.81 cm long, and substrate
metal was exposed and corroded.
Fig. 13 compares PyFlexU2TM and Brand AC samples immersed in
HCl solution. The PyFlexU2TM coating stayed intact and slightly dis-
colored. Brand AC was discolored and slightly become chalky.
Some Brand AC coating material broke, and the base metal was
exposed. Fig. 13. PyFlexU2TM (top) and Brand AC (bottom) immersed in HCl for 56 d.
150 K.J. Ma et al. / International Journal of Mining Science and Technology 28 (2018) 145–151
Fig. 14. Brand AC samples immersed in #8 (top) and #4 (bottom) rock slurry for 56
d.
The PyFlexU2TM production sample had no discernable coating
damage.
(1) The PyFlexU2TM field samples, which have pre-existing
scratches on the coating, had no discernible under-coat cor-
rosion. Coating material still adhered to the substrate and
did not have blisters, pops, or peel-offs.
(2) Most Brand AC reference samples had no discernable coating
damages. However, two Brand AC samples had blisters or
bubble pop-ups. Fig. 14 shows the Brand AC samples
immersed in Location #8 and #4 rock slurry. The Brand AC
developed a few small-to medium-sized blisters.
5.1.3. Accelerated salt spray test
To evaluate corrosion resistance of the PyFlexU2TM coating, an
840 h salt spray corrosion test was conducted following ASTM
B117-16. Fig. 15 compares the condition of coating of PyFlexU2TM
and Brand AC. It is clear that the PyFlexU2TM coating has a better
corrosion resistance in an accelerated salt spray test.
5.1.4. Accelerated ultraviolet exposure
To evaluate performance and potential material degradation of
the coating due to sunshine exposure, a continuous 840 h UV resis-
tance test was conducted by following ASTM D 4587-11 Cycle 4.
No visible corrosion could be found on the PyFlexU2TM sample,
whereas less than 1% red corrosion was identified on the Brand
AC sample.
5.2. Field testing
Two types of underground tests were conducted: (1) standard
installation test and (2) installation scratch test. The standard
installation test consists of installing 10 bolts in the normal man-
ner. A hole was drilled using a standard 37 mm drill bit, the Python
M3TM was inserted into the drill hole, and inflated to 326 bars to
anchor the bolt. The installation scratch test consisted of drilling
a 37 mm hole, inserting the Python M3TM into the drill hole, fully
removing the bolt from the drill hole, and inflating the bolt in an
unrestricted manner. The inflated samples were then examined
Fig. 15. PyFlexU2TM (top) and Brand AC (bottom) after 840 h salt spray test.
Fig. 16. PyFlexU2TM (left) and Brand AC (right) after insertion test.
Fig. 17. Coating splitting of Brand AC (left bolt) after inflation.
for scratches and peeling. Two Brand AC bolts were also tested
for comparison during the second tests.
All 10 samples installed for the standard installation tests were
inflated properly to the required 326 bars. No leaks or anomalies
were detected during the installations. The bolt operator stated
that the new Python M3TM inflated faster than the Brand AC bolts.
The increased rate of inflation can be attributed to the new Python
M3TM profile design.
A total of 20 Python M3TM samples and two Brand AC bolts were
installed for the installation scratch test. The Python M3TM coated
with PyFlexU2TM had minor scratches on the topcoat (Fig. 16) but
showed no areas scratched through the coating to the bare metal.
In addition to scratch damage, one Brand AC sample had a 2.54 cm
long split 10.16 cm from the ferrule end after inflation (Fig. 17).
6. Summary and conclusions
Wide utilization of expandable rock bolts in underground hard
rock mines in the U.S. demands a reliable and cost-effective,
corrosion-resistant coating for the expandable bolt to combat
highly corrosive ground conditions. Previous coating systems,
either cathodic sacrificial coating or barrier-type coating, appear
to be either ineffective in acidic ground condition or vulnerable
to physical damages.
To develop a viable coating system, Jennmar and KMS con-
ducted various laboratory tests, analyzed corroded bolt samples
and field rock samples, and identified root causes of bolt corrosion
and coating failure. A new generation Python M3TM rock bolt was
developed with improved steel chemistry for reliable performance
and a modified profile for better inflation, surface preparation and
coating application. After evaluating properties of various candi-
date coatings, an innovative PyFlexU2TM coating system was
 K.J. Ma et al. / International Journal of Mining Science and Technology 28 (2018) 145–151
developed. With a flexible, adhesive, and highly corrosion-resistant
undercoat and a very hard sacrificial topcoat, the PyFlexU2TM coat-
ing system provides the Python M3TM bolt superior protection
against chemical corrosion and physical scratch damage.
The Python M3TM coated with PyFlexU2TM has been tested in the
most challenging conditions, including various long-term corro-
sion tests in extreme solvents (acidic solution, basic solution, and
salt solution) and mine slurry, long-term salt spray, long-term
UV exposure in the laboratory, and borehole scratch insertion tests
in the field. It is concluded that the new generation Python M3TM
rock bolt coated with the corrosion and scratch resistant PyFlex-
151
U2TMTM coating offers the underground hard rock mining industry
a viable and cost-effective expandable rock bolt to combat highly
corrosive environments in an efficient and cost-effective manner.
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