Overcast System for Mine Ventilation

Abstract

An overcast system to block an intersection between two or more mine passageways so as to prevent the mixture of intake air with return air. The overcast system includes a first sidewall formed of one or more prefabricated panels, a second sidewall formed of one or more prefabricated panels, and a top member formed of one or more prefabricated panels, such that the top side spans the width between the first sidewall and the second sidewall. A fire-resistant coating is applied to at least a portion of the first sidewall, the second sidewall, or the top member to provide an air-tight, fire-resistant structure. Each of the one or more prefabricated panels is formed from a composite material having one or more structural studs embedded at least partially therein.

The invention claimed is: 
     
         1 . An overcast system comprising:
 a first sidewall formed of one or more prefabricated panels;   a second sidewall formed of one or more prefabricated panels;   a top member formed of one or more prefabricated panels, wherein the top member spans the width between the first sidewall and the second sidewall; and   a fire-resistant coating applied to the first sidewall, the second sidewall, and the top member;   wherein each of the one or more prefabricated panels is formed of a composite material having one or more structural studs embedded at least partially therein.   
     
     
         2 . The overcast system of  claim 1 , wherein the composite material is expanded polystyrene (EPS). 
     
     
         3 . The overcast system of  claim 1 , wherein the one or more structural studs are S-shaped steel studs. 
     
     
         4 . The overcast system of  claim 1 , wherein each of the one or more prefabricated panels comprises two structural studs embedded at least partially therein. 
     
     
         5 . The overcast system of  claim 1 , wherein the fire-resistant coating is fiber-reinforced composite rock coating. 
     
     
         6 . The overcast system of  claim 1 , further comprising one or more wing walls attached to the top member. 
     
     
         7 . The overcast system of  claim 1 , further comprising at least one of a staircase, a ramp, and a ladder. 
     
     
         8 . The overcast system of  claim 1 , wherein each of the one or more prefabricated panels includes a tongue at one end thereof and defines a groove at another end thereof for receiving a tongue of another panel. 
     
     
         9 . The overcast system of  claim 1 , further comprising a wire mesh applied to at least a portion of a surface of the first sidewall, the second sidewall, or the top member. 
     
     
         10 . The overcast system of  claim 1 , further comprising a brace secured to the first sidewall and the top member. 
     
     
         11 . The overcast system of  claim 1 , further comprising a bracket secured to a sidewall, the bracket being configured for attachment to a mine floor. 
     
     
         12 . A method of forming an overcast system for mine ventilation, the method comprising:
 forming a first sidewall using one or more prefabricated panels;   forming a second sidewall using one or more prefabricated panels, the second sidewall spaced apart from the first sidewall;   forming a top member using one or more prefabricated panels, the top wall spanning the distance between the first sidewall and the second sidewall; and   applying a flame-resistant coating to at least a portion of the first sidewall, the second sidewall, or the top member;   wherein each of the one or more prefabricated panels is formed from a composite material having one or more structural studs embedded at least partially therein.   
     
     
         13 . The method of  claim 11 , further comprising securing the first and the second sidewalls into a bracket attached to a mine floor.