SHEAR TESTING OF CABLE BOLTS USED

IN AUSTRALIAN MINES AND TUNNELS

N. Aziz, G. Wang, S. Khaleghparast, H. Resekh, A Mirzaghorbanalli and J. Nemcik,

University of Wollongong, NSW, Australia

(*Corresponding author: naj @uow.edu.au)

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 SHEAR TESTING OF CABLE BOLTS USED IN AUSTRALIAN MINES AND TUNNELS

ABSTRACT

For decades cable bolt technology has been used for ground reinforcement in civil, mining and
other construction projects. The strength properties of cables, used as cable bolts, have been evaluated
mainly by their ultimate tensile strength as this kind of test can be carried out in the field as well as in
the laboratory. Only recently there has been a growing interest in cable bolt failures in shear, because
of documented field failure evidence. Shear testing of various cables bolts were made using different
shear testing methods using 40 MPa strength concrete as the composite medium for cable installation.
Single shear testing was carried out in cylindrically shaped concrete medium, while in double shear
method tests were made in rectangular blocks. Cables used for tests include plain and indented wire
cable strands as well as a combination of both types in one strand. Additional parameters considered
included cable pretension load, the influence of bulbing, concrete confinement and the effect of
sheared joint face contacts. It was found that the single shear testing rig produced consistent results in
comparison to double shear testing methods, that the effectiveness of concrete confinement by steel
clamps contributed to consistency in shear failure results, that increased pretention load resulted in
lower cable failure load and reduced shear displacement, indentation contributed to reduced failure
load in comparison to smooth wire strands, and bulbing appeared to have a significant bearing on the
anchorage capacity of the cable in the medium. Plain wire strand cables are prone to debonding in
comparison with indented cable strands.

KEYWORDS

Cable bolt, plain and indented strand wires, shear testing methods and cable pretension loads, concrete
confinement

INTRODUCTION

Cable bolting has been used world-wide as a solution for structural support and in ground
reinforcement in civil, mining, tunnelling and other structure projects. The strength properties of these
cables, used as cable bolts, have been evaluated mainly for their ultimate tensile strength, as this kind
of test could be carried out in the field as well as in the laboratory.

For the past several years, significant knowledge has been gained on tendon load transfer
mechanisms and strength characterisation mainly by pull testing (Aziz and Jalalifar, 2005, Hagan, et
al., 2015), however little has been known about the cable bolt shear behaviour, since the interest in
cable bolt failure in shear has been confined to small amount of work carried out based on the British
Standard of shear testing (BS 7861-part 2, 2009) and the work of Craig and Aziz, 2010, and Aziz, et
al.2015a). Also, no credible test results are available from the field and only pictorial evidence has
recently surfaced for both failed solid rock bolts and cable bolts. Typical signs of sheared tendons
recovered from the field and a borehole view shear displacement in rock layers is shown in Figure 1,
as reported by McCowan (2015), and Li (2017)

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 After Li After McCowan

Figure 1- Sheared tendons recovered from field and a hole view of sheared rock (McCowan, 2015 and
Li, 2017)

When a cable bolt is sheared to failure in a soft medium such as in soft rock and in weak
concrete, there is little chance of the wires in the cable strand failing fully or snap in shear, instead the
strand wires are likely to fail in a combination of both tensile and shear. Other influencing factors
include grout strength, applied pretension load, testing method and loading condition (Yang, et al.,
2017).

SHEAR TESTING OF CABLE BOLTS

Methodology
Shear testing of cable bolts has, for several recent years, been undertaken by using both the
single and double shear methods. A single shear test method, based on the British Standard BS 7861
Part 2 (2009), was used to determine the shear strength of cable bolts to failure (Aziz et al., 2015b).
Aziz, (2004) undertook double shear testing of 15.2 mm diameter resin coated, seven wire strand
cable bolts to examine the extent of plastic surface damage with respective to increased shearing
displacement. Testing of cable bolts to full failure in shear was subsequently carried out in a larger
double shear machine (DS-MKII) by Aziz and Craig (2010). Further studies on the cable bolt load
transfer mechanism have since been undertaken with emphasis directed solely on determining the load
transfer characteristics with particular reference to evaluating failure profiles of various wires in the
strand.

Currently, two types of testing rig are used for shear testing of various cable bolts, they are;
Megabolt Integrated Single Shear Test Rig (MISSTR) and Double Shear Test Rig (DSTR). Prior to
the construction of MISSTR, all studies in shear testing of tendons were undertaken using the
University of Wollongong DSTR.

Double Shear Testing Method

Two types of double shear testing methods were available for evaluating the shear characteristics of
cable bolts; (a) The DSTR-MKII with opposing concrete joint faces being in contact with each other,
where the resultant shearing force is a combination of the shear failure load and friction force of the
sheared host medium faces, (b) A modified DSTR (MKIII), with opposing concrete joint faces not in
contact with each other and the measured shear resistance force is spent on shearing the cable wires.
Determining the level of shear force spent on overcoming the friction force can be determined using
the following equation based on the mathematical model based on the combination of Mohr Coulomb
criterion and Fourier series scheme (Aziz et al., 2015).

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  T   4a  16 a  48 a a  144 a 2  
 2 n cos 1 
2 2 1 3 3
 
a 3  2  24 a  
 p  ( 0   a n cos(
3
) ) tan( )  c
2 n 1  T 
 
 
 

where, ,is the shear stress, S is the shear load, C is cohesion, is Fourier Coefficient, is the
number of Fourier Coefficient, which is considered between 0 and 3, is the shear displacement and
is the shearing length. Aziz, et al., 2016 verified the effect of the equation with experimental test
results.

Both the DSTR- MKII and MKIII rig as shown in Figure 2 were used in this study. The basic
frame was the same and consisted of two 300 mm long outer cubic boxes and a 450 mm long middle
central cuboid box with 300×300 mm2 cross- sectional area. A conduit wrapped with 8 mm PVC hose,
was laid horizontally along the mould to precast a rifled hole through the centre of concrete blocks.
Once the concrete was poured it was left to set.

MKII MKIII

a b
Figure 2- Double shear test rigs (a) MKII and (b) MKIII.

Prior to the apparatus being assembled, the hollow central tube of each cable was filled with
grout and left to harden prior to encapsulation in the concrete blocks for at least one week. During
assembling, three concrete blocks were all mounted on the horizontal steel base. When assembling the
DS apparatus the blocks were pressed against each other and the cable was pretensioned and then the
cable was grouted as show in Figure 2 a. While in the MKIII set up the assembly was held together
using a truss system/braces around the double shear assembly as shown in Figure 2 b. The truss
system consisted of four 1100 mm long steel braces connected between two 30 mm thick side steel
plates. The brace system impedes subjecting lateral axial load on concrete blocks during shearing.
When assembled, gaps of almost 5 mm were left between concrete blocks, thus the adjacent sheared
concrete faces are kept apart eliminating contact between the sheared faces and hence no friction
force. Next the cable bolt was inserted into the central axial hole and was followed by mounting.a100 t
load cell on each protruding side of the cable in the assembled concrete blocks and tensioned to the
predetermined axial pretension load, using a “Blue Healer” tensioner. Tensioning of the cable was
retained by the barrel and wedge retainers. This was followed by the injection of grout into the central
concrete blocks hole for bolt encapsulation. Grouting of the cable in the concrete block was achieved
via 20 mm diameter holes cast on top of each concrete block Once the cable was pretensioned,
cement grout mortar was injected into the hole annulus space around the cable strand, from the
vertically pre-cast radial hole on top of each concrete block. After seven days of grout/resin curing

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time, the double shear assembly was then placed on the carrier base frame consisting of a parallel pair
of rail track sections welded to a 30 mm thick steel plate. The outer 300 mm side cube blocks of the
double shear apparatus was mounted on 100 mm steel blocks, leaving the central 450 mm long block
free to be vertically sheared down using a 500 t capacity hydraulic universal testing machine at the
rate of 1 mm/min for the maximum 100 mm vertical displacement. A hydraulic universal testing
machine with a capacity of 500 t was used to compress the middle block for shearing the cable strand
at the rate of 1 mm/min for the maximum 100 mm vertical displacement. Table 1 shows the peaks
shear loads and axial forces of SUMO cable bolts with with joint faces in contact with each other
The load displacement profiles are shown in Figures 3. Table 2 and Figure 4 show test results and
load profiles with joints in contact.

Table 1 Double shear test results of cable bolts with joints face in contact with each other

Test Cable type Nominal pre- Shear displacement Maximum Friction Shear load
NO. tension at maximum shear shear load load 30% pre side
(t) load (kN) (kN)
(mm)
1 Plain 25 58.8 1424 427 499
SUMO
2 10 78.9 1318 395 462
3 25 32.6 829 249 290
4 ID SUMO 10 46.0 933 280 327

Figure 3: Double shear load-displacement results of with concrete joints surface in contact with each
other contacts

Table 2: Double shear load-displacement results with no concrete joints face surface contact

Test Cable type Nominal pre- Shear Maximum shear Maximum

No tension displacement force shear force per
(t) (mm) (kN) side
(kN)

5 Plain SUMO 15 88.2 852 426

6 0 105 886 443
7 ID-SUMO 15 85.7 767 384

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 8 0 93.4 815 406

Figure 4: Double shear load-displacement results of with concrete joints surface in no contact with
each other.

Single Shear Test

To replicate as closely as possible field conditions for installed cable bolts, the Megabolt
Integrated Single Shear Test Rig (MISSTR) shown in Figure 5 was used to evaluate the behaviour of
cable strand in shear (McKenzie, & King, 2015). . Based on the principle of British Standard 7862-
part 2 (2009) the whole length of the 250 mm diameter concrete cylinder used in MISSTR is 3600
mm (1800 mm on each side) with central hole diameter of 28-55 mm. The diameter of the central
axial hole in the concrete was dependent on the diameter of tested cable bolt.

Figure 5- Megabolt integrated single shear rig (MISSTR)

The MISSTR is a horizontally aligned integrated system consisting of a shearing rig and an
integrated 120 t capacity compression machine. The 3.6 m long concrete shearing cylinder consists of

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two sections, each containing 1.8 m long concrete cylinders. The concrete cylinders are covered by
steel clamps, which provide confinement during the shearing process. Either a hand pump or a power
pack of a suitable capacity applies the hydraulic pressure for the compression machine legs. The
pressure in the manifold was monitored with a digital pressure transducer (Type Measure X, range 0-
800 Bar) in conjunction with an analogue pressure gauge (0-700 bar). The rate of loading was applied
manually, which was not constant, however the aim was to apply a constant load at the rate of around
1 mm/min (0.018 mm/sec), in line with BS7861-2 standards. The displacement at the shearing plane
was measured using a Linear Variable Differential Transformer (LVDT) as shown in Figure 5. Two
other LVDTs were also mounted on the cable ends to enable monitoring of cable debonding. A data
taker recorder was used to collect data during the tests.

When preparing, two 1800 mm concrete cylinders, two 900 mm cylinders were butt-glued
together in a specially built tensioning frame. The cable bolt is then inserted through the centre rifled
hole of the concrete cylinder. The cable bolt was pre-tensioned. The whole concrete cylinder loaded
frame with cylinder was then tilted for 65 degree and grout was pumped from the bottom up the hole
to remove any air bubbles remaining inside the grout annulus area and to ensure full cable
encapsulation. Stratabinder HS grout was used to encapsulate all tested cables in this programme of
study. The strength properties of the grout have been reported by Majoor et al. (2017), and Mirza, et
al,. (2016).

After a grout curing, each concrete sample with encapsulated cable bolt was disassembled from
the frame and lifted out to be mounted on to the shearing rig. Once the concrete cylinder was correctly
placed in the shearing machine, steel clamps were placed around the concrete blocks to provide a
confining pressure to the sample. When sheared one side of 1.8 m of the 3.6 m concrete column
remains fixed on the rig, while the other half is subjected to shearing. The applied shear load was
recorded in a data taker and the displacement of cable ends and sheared cable strand wires were
monitored by LVDTs, which were all logged by computer. Initially 16 single shear tests were conducted
on the 3.6 m concrete blocks to study the effect of cable type, surface profile type, pre-tension load, birdcage
structure, bonding and debonding, and the failure mode of cable bolts as shown in Table 3.

Plain wire cable bolts were found to have higher peak shear load compared with indented cable bolts.
Figure 6 shows the cross section views of both MW9 Spiral and MW10 Plain wires, with both wires of equal
diameter of 7 mm. However some minor strength reduction may occur because of the rifling or spiralling
process during manufacture, but no weight loss. Figures 7 (a and b) show the load-displacement profile
variations of other manufactures cables strand wires, where up to 10 % weight and strength loss can occur
during indentation process.

Figure 6: MW10 plain and MW 9 spiral wires, with both wires of 7 mm in diameter (McKenzie and King, 2014)

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 Table 3- Table 3: Summary of single shear test results
Test Product Name Cable UTS (t) Cable Pt Peak Shear Peak shear
No. dia. geometry (t) Shear Displacement load /UTS
(mm) load (t) (t) (%)
1 MW 10-P 31 70 Un-bulbed 15 68.3 68.2 97.6
2 MW 10-P 31 70 6 bulbs 0 63.8 62.6 91.1
3 MW 10-P 31 70 6 bulbs 15 60.4 56.0 86.3
4 MW9-S 31 62 6 bulbs 0 47.7 43.5 76.9
5 MW9-S 31 62 6 bulbs 15 43.9 47.4 69.9
6 MW9-S 31 62 Un-bulbed 15 49.7 41.7 67.3
7 Secura HGC 31 68 6 bulbs 0 64.7 51.8 95.2
8 Secura HGC 31 68 6 bulbs 15 55.9 45.9 82.2
9 SUMO-P 28 65 6 bulbs 0 55.8 71.8 86.8
10 SUMO-P 28 65 6 bulbs 15 68.4 78.2 106.5
11 ID -SUMO 28 63 6 bulbs 0 40.4 40.9 73.7
12 ID- SUMO 28 63 6 bulbs 15 37.4 30.9 59.4
13 ID-TG 28 60 Un-bulbed 0 44.9 51.3 69.8
14 ID- TG 28 60 Un-bulbed 15 36.3 30.9 57.6
15 Superstrand-P 21.7 60 Un-bulbed 15 52.4 90.2 85.7
16 Garford-P 2 *15 54** Bulbed 0 44.6 46.8 80.9

Figure 7 a: Tensile load / elongation profiles of both MW plain and MW indented 7 mm wires of
equal length

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 Figure 7 b: Tensile load / elongation profiles of both plain and indented 5.5 mm wires of the 21.7
mm cable bolts (Aziz et al., 2015a)

COMPARISON OF THE TESTING RESULTS BETWEEN SINGLE AND DOUBLE SHEAR TESTING
METHODS

Realistically, the methodology of tendon shear testing should not influence the test outcome, as long as various
parameters are the same. Factors of particular interest include:

1) Cable ends anchorage: In the single shear test, reliance is made on securing the optimum cable length
encapsulation in the concrete cylinder. The optimum length of encapsulation was found to vary
between indented surface and plain/smooth wires. In double shear testing methods the Barrel and
Wedge (B&W) system provides positive anchorage irrespective of cable strand wire surface. Cable
debonding in single shear testing may occur if the encapsulated cable length is insufficient; resulting in
increased cable wire failure mostly in tension rather the tensile /shear, because of the increased shear
load displacement.

2) Competence of concrete medium confinement: Poor medium confinement may result in premature
concrete radial cracking causing a reduction in cable stiffness with higher shear load travel. The
increased cable shear displacement would cause the cable to fail with an increased number of cable
wires failing in tension rather than in tensile/shear. In other words the cable strand shear failure load
will be closer to failure in tension rather than is shear. Thus effective confinement of the concrete
reduces the chances of radial crack occurrence, with less vertical shear travel. This is clearly observed
when testing samples in cylindrical concrete with effective and high torqued steel clamps.

3) Similar situation as in point 2 can also occur in single shear testing of cables and particularly plain
cables that have failed with increased debonding, because of the lack of effective encapsulation length.
All plain wired cables were found to debond readily in comparison with indented and cables with
increased shear displacement with strand wire failure occurring in tensile shear combination as reported
by Yang et al., (2018).
4) Pure shear in cable wires occurs when the cable is guillotined, with wires being squeezed with lower
shear load as reported by McTyre and Evans (2017). In double shear testing it is impossible to observe
cable debonding because of barrel and wedge influence.

5) It should be recognised that a realistic way of evaluating cable debonding per encapsulated length can
best be determined by pull-out testing and not by shearing. As various tests demonstrated excessive
displacement of a cable during the shearing process makes it behave as if the strand wires fail in tension
rather than in shear. This is demonstrated by the fact that most wires fail in tension with snapped
surfaces typically characterised by cone and cup failure, as shown in Figure 8.

6) The rate of shear loading should be at less than 4 mm /min that will produce consistent results
irrespective of the methodology of testing with other factors being the same.

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 Figure 8: Cross sectional view of debonded Plain MW10. Note the extent of wire failure in tension with failed
wires surface being mostly in cone and cup.

CONCLUSIONS

The choice of the method of testing cable bolts in shear is governed by the relevant factors that influence
the outcome of the testing, and irrespective of the methodology of testing. Effective medium confinement in
shear testing would prevent radial cracking of the concrete and effective confinement of the concrete reduces
the chances of radial crack occurrence, with less vertical shear load travel resulting in cable failures closer to
shear rather than failure in tensile. Under the same testing conditions, plain cable bolts appears to debond much
more readily than indented cable bolts when tested in the single shear testing machine with equal length of
encapsulation. Pure shearing of cable bolt wires is possible if the cable strand confinement is strong enough so
that the cable bolt is shear in pseudo- guillotined, with the with wires being squeezed surface area with lower
shear load. Finally, the use of the single shear test rig method in not appropriate for evaluating true cable
debonding for a given encapsulation length, rather the pull-out test method should be used.

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