Plug for a void, system and method

1. A method for forming a plug in a mine comprising the steps of:

adding a catalyst to a single component material;

providing the single component material with the catalyst to a pump which pumps only the single component material with the catalyst;

supplying air to the pump at a minimum of 90 psi while the pump is pumping the single component material with the catalyst through a first hose attached to a first port of a y fitting;

supplying water at a minimum of 60 psi through a second hose to a second port of the y fitting so the water and single component material with the catalyst merge in the y fitting to create a product, the catalyst used being a function of ambient temperature about the void and temperature of the water;

placing a plurality of pipes throughout the void; and

placing the product with a third hose that extends from the y fitting on outer most areas of the void and moving the product to a middle of the void, where the product expands when the product releases into the void from the third hose and cures to a rigid closed cell foam to form a plug in the void, the placing the product step includes the steps of connecting the third hose to a first pipe of the plurality of pipes and flowing the product to the first pipe so the product flows out of the first pipe into the void, after which the product foams and hardens, the third hose having a mixing stick across which the product flows in the first pipe.

2. The method of claim 1 including the step of connecting the third hose to a second pipe of the plurality of pipes and flowing the product through the second pipe so the product flows out of the second pipe into the void, after which the product foams and hardens.

3. The method of claim 2 including the steps of disconnecting the third hose on the first pipe, closing a material valve to stop flow of material to the Y fitting and flushing the third hose clean with water flowing from the water inlet of the Y fitting.

4. The method of claim 3 wherein the placing the pipes step includes the step of placing pipes in the void at least about every 10 feet apart lengthwise across the void and about at least every 5 feet apart depth wise across the void.

5. The method of claim 4 wherein the placing the product step includes the steps of creating pockets in the plug being formed when the product cures and hardens and then placing the product from the third hose into the pockets through pipes disposed in the pockets to strengthen the plug against forces.

6. The method of claim 5 wherein the placing the pipes step includes the step of placing a false floor at the void with a long wall shield, the pipes extending from the false floor into the void.

7. A plug for a void in a mine comprising:

a rigid closed cell foam which fills the void having a plurality of pipes disposed within the foam, the pipes distributed throughout the void, the pipes are positioned in the foam so the pipes are staggered in length vertically with respect to various heights in the void, and the pipes are positioned in the foam every 4′ to 6′ horizontally with respect to the void, each pipe has a mixing stick.

8. The plug of claim 7 wherein the pipes are disposed in the plug at least about every 10 feet apart lengthwise across the plug and about at least every 5 feet apart depth wise across the plug.

9. The plug of claim 8 including a false floor from which the pipes extends into the hardened foam.

10. A system for making a plug in a void of a mine a pressurized air source and pressurized water source comprising:

a material source of a single component material;

a pump having an air pump inlet to receive air from the air source and a material pump inlet to receive the material from the material source which pumps the material with the air at a minimum pressure of 90 psi out a pump outlet;

a first hose attached to the pump outlet through which the air and material is pumped from the pump;

a second hose attached to the water source which receives water from the water source at least at a pressure of 60 psi;

a y fitting having a first port to which the first hose is attached which receives the air and material from the first hose, a second port to which the second hose is attached to receive water from the second hose, and a third port from which a product formed from the water from the second hose and the material and air from the first hose flows out;

a third hose attached to the third port which receives the product from the y fitting, the third hose having a mixing stick disposed in the third hose; and

a plurality of pipes to be disposed in the void which are configured to be connected sequentially with the third hose through which product from the third hose flows into and through and out the pipes to foam and form the plug.