In the world of underground mining and tunneling, safety and structural stability are non-negotiable. As operations dig deeper and conditions get tougher, Shotcrete Solutions have become a critical part of maintaining secure, productive environments. Among the top performers in this space is Tunnel Guard—a smart, efficient liner that’s redefining how underground teams approach secondary support.
What Is Tunnel Guard?
Tunnel Guard is a thin spray-on cementitious liner (TSL) designed for fast, effective secondary support in underground mining and tunneling. Unlike traditional shotcrete, which is typically applied at 50mm thickness, Tunnel Guard does the job at just 8mm. That means quicker application, lower material use, and faster results. It also cures fast—reaching nearly half of its full strength in just 6 hours.
Key Benefits of Tunnel Guard in Underground Safety
1. Strength Where It Counts
Tunnel Guard isn’t just a thin layer—it’s tough. It penetrates deep into cracks and joints in the rock mass, locking everything together like a cement-based glue. This improves cohesion between fractured rock layers, reducing movement and making excavations much more stable and secure.
2. Fast Curing = More Productivity
Time is always ticking underground. With Tunnel Guard’s rapid curing ability, crews can move to the next blast much sooner. That means less downtime and smoother progress—especially in projects where every hour counts.
3. Big Results, Less Material
At only 8mm thick, Tunnel Guard uses far less material than traditional shotcrete—without sacrificing performance. Just one 25kg bag covers a full square meter at that thickness. Compare that to the seven 30kg bags you’d need to cover the same area with 50mm of shotcrete. The savings on transport, labor, and handling are substantial.
4. Safer Worksites, Less Waste
Applying Tunnel Guard generates minimal rebound—meaning less flying material and fewer hazards for crews. Reduced rebound also cuts waste, making each application more efficient and cleaner.
5. Built for Sustainability
Tunnel Guard is non-toxic, non-flammable, and safe for both workers and the environment. Plus, by sealing the rock and reducing exposure to oxygen and water, it helps preserve excavated areas for long-term use.
Performance Comparison: Tunnel Guard vs. Traditional Shotcrete
Independent lab tests show that Tunnel Guard outperforms traditional shotcrete—even with a much thinner application:
| Test Type | Tunnel Guard (8mm) | Wetcrete 40MPa (50mm) |
| Tensile Strength | 13.78 MPa | 0.68 MPa |
| Tensile Bond | 3.56 MPa | 0.39 MPa |
| Shear Bond | 5.61 MPa | 1.02 MPa |
| Shear Strength | 9.74 MPa | 1.23 MPa |
These numbers highlight what many field crews have already seen: Tunnel Guard delivers more support with less material.
Efficiency That Saves Time and Labor
Because Tunnel Guard requires less material and sets quickly, your team spends less time on application and cleanup. That leads to faster shift turnover, smoother workflows, and lower overall labor costs—benefits that really add up over the course of a project.
Frequently Asked Questions (FAQs)
1. What’s the main advantage of Tunnel Guard over traditional shotcrete?
Tunnel Guard offers better performance at a thinner layer, which means faster application, reduced material use, and significant cost savings.
2. Can Tunnel Guard be applied in wet conditions?
Yes, Tunnel Guard bonds well in both wet and dry environments, making it highly adaptable underground.
3. How does Tunnel Guard improve safety?
By curing quickly and minimizing rebound, Tunnel Guard helps stabilize rock faster and reduces the risk of falling debris during application.
4. Do I need special equipment to apply Tunnel Guard?
Standard shotcrete solutions works, but machines like the Hencon Altecreter can make the process even more efficient and streamlined.
5. Is Tunnel Guard environmentally friendly?
Yes, it’s non-toxic, non-flammable, and helps preserve excavated rock by sealing it from environmental wear.
Summary
Tunnel Guard is changing the game for Shotcrete Solutions in underground mining and tunneling. With its fast curing, impressive strength, efficient application, and eco-friendly design, it checks all the boxes for modern underground support. Whether you’re aiming to boost safety, save on costs, or increase your project’s pace, integrating Tunnel Guard into your operations is a smart, future-ready move.
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