Ground Support Installation

Refresher Training

May 2017
Contents
• Why do we Bolt?

• Strata Bolt Installation (friction bolt / split set)

• Secura Bolt Installation (resin bolt)

• Thanks and Questions

Why Do We Bolt?
Why we bolt?

4
Why we bolt?

5
Why we bolt?

6
How rock bolts work
Transfer forces from unstable region to stable region via rock bolt

• Suspension of unstable rock

• Clamping to stop rock moving apart axially
• Shear restraint to stop rock sliding horizontally 7
Strata Bolt Installation
(friction bolt)
STRATA BOLT INSTALLATION

Strata Bolt 47 x 2400 Gal

47 200 x 200 x4
Dome Plat
Hole Diameter

• Hole diameter recommended for the Strata Bolt

47 x 2400 is approximately 45mm

• The bit size range of 43.0 – 44.5mm which is

the general range across the industry in hard
rock

• Either spherical button bits or cross bits are

best suited.
HOLE LENGTH

• Is not as critical as resin bolting but obviously

cannot be drilled too short

• For a 2.4m Strata Bolt a hole length of 2450 –

2500mm is recommended
HOLE ANGLE

• Most bolting designs the angle of installation

should be + / - 10 deg or as instructed by
Geotechnical Engineers

• Sometimes the ground conditions dictate the

angle, so to optimize the bolt’s effectiveness
there may need to be some interpretation from
Geotechnical Engineers & Operators to best
suit the situation
BOLT ANGLE

Bad angled bolts

( looking back from a heading )
BOLT INSTALLATION

• Always use the correct size Strata Bolt Driver

for the particular bolt that is being installed.
Using a smaller driver e.g. 40mm can cause
problems and bolt damage

• The 47mm driver is both suited to the 2.4m

Strata Bolt and also the 900mm Mesh Pin
( used for meshing )
BOLT INSTALLATION

• The drive time relating to pushing the bolt fully

in is the best indicator of the bolts effectiveness

• Drive times of 15 – 20 seconds is a good guide

for 2.4m bolts, any less than 15 seconds may
indicate an oversized bit or some indifferent
ground conditions ( faults / shears / excessively
broken rock etc )
BOLT INSTALLATION

• To complete the installation the bolt should only

be driven till the plate shows initial signs of
deformation

• Over driving the bolt with excessive percussion

will result in damaging the end of the bolt and
potentially effecting the integrity of the welded
bolt ring
Secura Bolt Installation
(resin bolt)
R27X2400 SECURA BOLT
DRILL BIT

• Bit type – 33mm or 35mm Cross or

Button Bit
• Generally drills a straighter / cleaner hole
• Maintains gauge during it’s life
• 33mm cross bit / 33mm drill hole is a
perfect match with the 26mm diameter
resin anchor, 35mm with 30mm resin
HOLE DEPTH
• Recommended hole depth for the R27x2400
Secura Bolts is 2300 – 2350 ( definitely no
longer! )
• This hole length will ensure full encapsulation
(should see some resin return at the hole
collar)
• A hole only 400mm too long can waste 25 –
30% of the resin in the toe of the hole. This will
mean non encapsulated sections of the bolt!
• Try and leave a clean as possible hole
HOLE ANGLE

• In general pattern bolting the angle of bolt

installation is normally set at + / - 10 deg or as
instructed by Geotechnical Engineers

• The pattern bolting design also normally

includes a ring spacing. This means that each
ring should be drilled from it’s own setup to
maintain the right installation angle
HOLE ANGLE !

+ 30 deg
Badly seated Domeball
Washer & Dome Plate
HOLE ANGLE

• When a 4.5 x 4.5m development heading is

blasted it will usually create approx. 1 – 1.5m
“ loosen zone” around the back, shoulder and wall
area’s depending on the blasting parameters

• The principle behind having a bolt installed as

close to perpendicular to the drive profile is to
ensure the bolt protrudes through the “loosen
zone” and has at least 1.0 – 1.4m anchored in
solid rock that has not been affected by blasting
HOLE ANGLE – LOOSEN ZONE

Loosen Zone
( Blast effected rock )

Development Drive
e.g. 4.5x4.5m
HOLE ANGLE – LOOSEN ZONE

Effect of installation angle on competent embedment

1350mm
2350mm
1000mm Solid Rock
675mm

1000mm Loosen Zone

Dev Drive 4.5x4.5m

INSERTING RESIN
• Using LOKSET ADVANCE 30x1200x2 Fast / Slow Resin
capsules, place inside the insertion tube ( fast set capsule
with cap at the end of tube )
• Locate hole and align to correct angle
• Insert tube fully to the back of the hole ( This is important
so as little resin as possible can be cut off )
• Pull insertion tube back out of the hole, the clear insertion
tube will indicate whether the resin is secured at the toe of
the hole
• Approximately 100mm of resin should protrude from the
hole
INSERTING R27 SECURA BOLT

• Locate hole and align the bolt to the correct angle

• Insert the bolt approximately 200 – 300mm then apply

rotation and steady feed that will fully mix the resin as the
bolt feeds to the back of the hole. From previous testing the
typical spin / feed time is approx. 20 seconds ( 15 sec. spin
& feed to the back of the hole then a further 5 sec spin to
complete the mixing

• The bolt is then held in position without moving off to

another bolt. A typical hold time of approx 20 - 40 seconds is
usually is sufficient for the fast set resin to set but may vary
depending on the resin and rock temperature.
COMPLETING INSTALLATION

• The correct method of installing the Secura

Bolt with a 2 speed resin is to stay on the one
bolt from insertion to tensioning. This is the
only effective way to create a correctly
tensioned bolt
COMPLETING INSTALLATION
• The correct method of tensioning the bolt is to break out the nut
and tighten when the fast resin has set, but before the slow set
resin has.
COMPLETING INSTALLATION

• Rotation breaks the nut’s locking pin and continues

to thread the nut up to the plate. Correctly applied
rotation should be enough to tension the nut up to
actually deform the plate slightly or till stall. The
jumbo’s torque should normally be set at approx.
400Nm.
• No percussion should be needed / used provided
the rotation torque is sufficient
• The tensioning process is carried out whilst the
slow set resin is still “going off”. Therefore once the
bolt is tensioned and the slow set resin has set you
have a correctly tensioned Secura Bolt
 LOAD DISPLACEMENT TESTS
R27 SECURA BOLT

Test Bolt No 1 Test Bolt No 2

Nom inal 35.0m m Bit Nom inal 35.0m m Bit
300 300
280 280
260 260
240 240
Load applied (kN)

Load applied (kN)

220 220
200 200
180 180
160 160
140 140
120 120
100 100
80 80
60 60
40 40
20 20
0 0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100

A c t u a l D i sp l a c e m e n t ( m m ) A c t u a l D i sp l a c e m e n t ( m m )

Test Bolt No 3 Test Bolt No 4

Nominal 35.0mm Bit Nom inal 35.0m m Bit
300
300
280
280
260
260
240
240
220 220
Load applied (kN)
Load applied (kN)

200 200
180 180
160 160
140 140
120 120
100 100
80 80
60 60

40 40

20 20

0 0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100

A c t u a l D i sp l a c e m e n t ( m m ) A c t u a l D i sp l a c e m e n t ( m m )
Feedback is Important
Example of improvement made to swage gap
after feedback from operators
 Thanks for your time.

Questions?

THE EARTH. UNDER CONTROL.™