ISSN 1018-5593

* *

*
*

*
*

European Commission

technical coal research

Mining operations

Optimization of cable bolting

and rock bolting material properties

European Commission

technical coal research

Mining operations

Optimization of cable bolting

and rock bolting material properties
British Coal Corporation
British Coal Corporation
Stoke Orchard
Cheltenham
Gloucestershire GL52 4RZ
United Kingdom

Contract No 7220-AB/830
1 June 1990 to 31 August 1994

Final report

Directorate-General XVII
Energy

1996

EUR 17188 EN

A great deal of additional information on the European Union is available on the Internet.
It can be accessed through the Europa server (http://europa.eu.int)

LEGAL NOTICE
Neither the European Commission nor any person acting on
behalf of the Commission is responsible for the use which might be made of the
following information

Cataloguing data can be found at the end of this publication

Luxembourg: Office for Official Publications of the European Communities, 1997

ISBN 92-827-9395-8
European Communities, 1997
Reproduction is authorized, except for commercial purposes, provided the source is acknowledged
Printed in Luxembourg

CONTENTS
CHAPTER 1
1.1
1.2
1.3
1.4
1.5
1.6

INTRODUCTION AND OVERVIEW

INTRODUCTION
BIRDCAGE CABLE BOLTS
MECHANISM OF CABLE BOLT REINFORCEMENT
PERFORMANCE TESTING
SYSTEM CONTROL
CONSUMABLE DEVELOPMENT

11
11
11
12
13
14
14

CABLE BOLTS
CHAPTER 2
2.1 CABLE BOLT DESIGN
2.2 SYSTEM DESIGN
2.2.1 CABLE LENGTH
2.2.2 PLACEMENT
2.2.3 CABLE DENSITY
2.2.4 NUMERICAL MODELLING
RIB REINFORCEMENT
2
CUTTABLE TENDONS
2
ALTERNATIVE CABLE BOLT SYSTEMS
2
2.5.1 NUT CAGE CABLE BOLTS
2.5.2 FLEXIBLE BOLT
2.5.3 THE BULBED CABLE
2.5.4 WIRE ROPE
2.5.5 4 0 TON BIRDCAGED CABLE
APPLICATION
2.6
2.6.1 ROOF
2.6.2 RIBS

19
19
19
19
20
20
21
21
22
23
23
24
24
24
24
25
25
26

CHAPTER 3
3.1
3 2
3 3
3 4
3 5

GROUTS
EARLY EXPERIENCE
GROUT CHARACTERISTICS
GROUT MIXING
QUALITY CONTROL
FIELD EXPERIENCE

33
33
33
35
36
37

CHAPTER 4

LABORATORY TESTING - PREVIOUS RESEARCH

CABLE AND GROUT TESTING
AIM OF LABORATORY TESTING
LABORATORY TESTING OF REINFORCING TENDONS
4.2.1 SIMULATION OF ROCK MASS CONDITIONS
4.2.2 AXIAL TESTING OF CABLE BOLTS
4.2.3 SHEAR TESTING OF CABLE BOLTS
LABORATORY TESTING OF CEMENTITIOUS GROUTS
4.3.1 PHYSICAL PROPERTY TESTS ON GROUTS
4.3.2 EVALUATION OF GROUT PROPERTIES ON CABLE BOLT
PERFORMANCE
4.3.3 FIELD SAMPLING OF CABLE BOLT GROUTS

41

4.1
4.2

4.3

CHAPTER 5
5
5,

BRITISH COAL LABORATORY TESTING OF CABLE BOLT SYSTEMS

AIM OF BRITISH COAL LABORATORY TESTING
TEST MATERIALS
5.2.1 CABLES
5.2.2 GROUTS

41
41
41
42
45
46
46
47
47
49
49
49
49
50

5.3
5.4

5.5

CHAPTER 6
6.1
6.2

6.3

6.4

TEST PROGRAMME
5.3.1 CABLES
5.3.2 GROUTS
EXPERIMENT DESIGN
5.4.1 AXIAL TESTING
5.4.2 SHEAR TEST DESIGN
5.4.3 DETERMINATION OF GROUT PROPERTIES

53
53
54
55
55
57
57

EXPERIMENT PROCEDURE
5.5.1 PREPARATION OF DOUBLE EMBEDMENT SAMPLES FOR
FOR AXIAL AND SHEAR TESTING
5.5.2 PREPARATION OF GROUT SAMPLES FOR TESTING

59
59

RESULTS AND DISCUSSION OF BRITISH COAL EMBEDMENT TEST

PROGRAMME FOR CABLE PERFORMANCE
RESULTS FROM SINGLE EMBEDMENT TESTS
INTERPRETATION OF RESULTS FROM AXIAL DOUBLE EMBEDMENT
TESTING
6.2.1 SYSTEM STIFFNESS
6.2.2 FAILURE CHARACTERISTICS OF BIRDCAGED CABLE BOLTS
CABLE RESULTS AND DISCUSSION
6.3.1 2 X 7 STRAND DYFORM CABLE
6.3.2 DOUBLE AND SINGLE BIRDCAGES
6.3.3 ALTERNATIVE CABLE TYPES
6.3.4 REINFORCING TENDONS FOR 27mm HOLES
6.3.5 CUTTABLE CABLES
6.3.6 EFFECT OF ANTI-NODE/NODE JOINT AND REDUCED
EMBEDMENT
RESULTS FROM SHEAR TESTING
6.4.1 INTERPRETATION OF RESULTS
6.4.2 2 X 7 STRAND DYFORM CABLE
6.4.3 DOUBLE BIRDCAGED CABLES
6.4.4 COMPARISON OF ANTI-NODE/NODE AT JOINT
6.4.5 SHEAR BEHAVIOUR OF 24 HOUR CURED GROUT
6.4.6 SHEAR BEHAVIOUR OF SINGLE BIRDCAGED CABLE

71

CEMENTITIOUS GROUTS: RESULTS AND DISCUSSION

CHAPTER 7
7.1 GROUT PROPERTIES
7.1.1 STRENGTH PROPERTIES
7.1.2 DENSITY
7.1.3 MODULUS
7.1.4 TENSILE STRENGTH
7.1.5 VISCOSITY OF CABLE BOLTING GROUTS
7.2 GROUT PERFORMANCE IN THE DOUBLE EMBEDMENT TEST
7.2.1 GROUTS A,B,C,D
7.2.2 GROUTS E,F,G
7.3 GROUT PROPERTIES AND THEIR PERFORMANCE IN THE DOUBLE
EMBEDMENT TEST
7.3.1 IMPORTANCE OF STRENGTH AND STIFFNESS PROPERTIES
7.3.2 IMPORTANCE OF POST FAILURE PROPERTIES
DOUBLE
EMBEDMENT PERFORMANCE WITH CURE TIME
7
ORDINARY
PORTLAND CEMENT
7,
EFFECT
OF
GROUT SAMPLE ASPECT RATIO ON STRENGTH
7,
EFFECT
OF
ADDITIONAL
WATER CONTENT
7,
FIELD
SAMPLING
OF
GROUTS
7.8
7.9 GROUT QUALITY CONTROL

59

71
72
72
73
74
74
74
75
77
78
80
81
81
81
82
82
82
83
103
103
103
104
105
105
106
107
107
109
109
109
110
110
111
112
114
114
115

ROOFBOLT DEVELOPMENT
CHAPTER 8
LIFTING
AND SUSPENSION OF EQUIPMENT
8.1
8.1.1
INTRODUCTION
8.1.2 APPROVED LIFTING BOLTS
8.1.3 CODE OF PRACTICE
8.2 ALTERNATIVE THREAD
8.2.1 OBJECTIVES
8.2.2
INVESTIGATIONS
8.2.3
CONCLUSIONS
8.3 DIN THREAD TRIALS
8.4 HIGH STRENGTH BOLT
8.4.1 INTRODUCTION
8.4.2 BOLT SPECIFICATION
8.4.3 RESIN SPECIFICATION
8.4.4 INSTALLATION TRIALS
8.5 WAISTED/BENDABLE BOLTS
8.5.1 BOLT DESCRIPTION
8.5.2 INSTALLATION TRIALS AND TESTING
8.5.3
CONCLUSION
8.6 COUPLED BOLT
8.6.1 ORIGINAL METHOD
8.6.2 MODIFIED SYSTEM
8.6.3
OVERVIEW

131
131
131
131
131
132
132
132
132
133
134
134
134
134
134
135
135
135
136
136
136
137
137

CHAPTER 9 FIELD WORK

9.1 STILLINGFLEET MINE
9.1.1
BACKGROUND
9.1.2 GEOLOGY
9.1.3 CABLE BOLTING
9.1.4 MONITORING
9.1.5
CONCLUSION
9.2 RICCALL MINE
9.2.1 BACKGROUND
9.2.2 GEOTECHNICAL INFORMATION
9.2.3 GATE ROADS
9.2.4 FACE LINE DRIVAGES
9.2.5 FACE JUNCTIONS
9.2.6 MONITORING
9.2.7
CONCLUSION
9.3 CASTLEBRIDGE COLLIERY
9.3.1
BACKGROUND
9.3.2 GEOTECHNICAL FEATURES
9.3.3 SUPPORT CRITERIA
9.3.4 CABLE BOLTING - EARLY EXPERIENCE
9.3.5 CABLE BOLTING - LATER EXPERIENCE
9.4 KIVETN PARK COLLIERY
9.4.1 BACKGROUND
9.4.2 GEOTECHNICAL FEATURES
9.4.3 MONITORING
9.4.4 CABLE BOLTING
9.4.5
CONCLUSIONS
9.5 OLLERTON COLLIERY
9.5.1
INTRODUCTION
9.5.2 GEOTECHNICAL INFORMATION
9.5.3 ROADWAY SUPPORT
9.5.4 COUPLED BOLTS

143
143
143
143
143
144
144
149
149
149
149
150
150
151
151
160
160
160
160
161
161
170
170
170
170
171
171
180
180
180
180
181

9.5.5
9.5.6
9.5.7
9.5.8

CABLE BOLTING
ROUTINE MONITORING
RIB REINFORCEMENT
CONCLUSION

181
182
182
183

9.6

LITTLETON COLLIERY
9.6.1 INTRODUCTION
9.6.2 GEOTECHNICAL FEATURES
9.6.3 ROADWAY SUPPORT
9.6.4 CABLE BOLTING
9.6.5 CONCLUSION

191
191
191
191
192
192

9.7

THORESBY COLLIERY
9.7.1 MEDIUM SET RESIN CAPSULES
9.7.2 MONITORED TRIAL
9.7.3 OBSERVATIONS
9.7.4 CONCLUSIONS AND RECOMMENDATIONS

195
195
195
195
196

CHAPTER 10 CONCLUSIONS AND RECOMMENDATIONS

199

ILLUSTRATIONS
CHAPTER 1
FIGURE 1
FIGURE 2
FIGURE 3
FIGURE 4

BIRDCAGE CABLE
PERFORMANCE COMPARISON STANDARD AND BIRDCAGE CABLES
CONFINEMENT MECHANISM OF CABLE BOLTS
SUSPENSION MECHANISM OF CABLE BOLTS

16
12
17
18

CHAPTER 2
PHOTO 1
PHOTO 2
FIGURE 1
FIGURE 2
TABLE 1

TYPES OF CABLE BOLT

TYPES OF CABLE BOLT
WOMBAT CABLEBOLTER
MODULAR BOLTING SYSTEM
DOUBLE NUTCAGE DESIGN

27
28
29
30
31

CHAPTER 3
FIGURE 1 GROUT MIXER/PUMP (MANUFACTURER A)
FIGURE 2 GROUT MIXER/PUMP (MANUFACTURER G)

38
39

CHAPTER 4
FIGURE
SINGLE AND DOUBLE EMBEDMENT AXIAL TEST (WINDSOR)
FIGURE
SINGLE AND DOUBLE EMBEDMENT PULL TESTS (FULLER & COX)
FIGURE
MODIFIED PUSH TEST (HYETT)
FIGURE
TEST ARRANGEMENT USED BY STILLBORG
FIGURE
DOUBLE EMBEDMENT TEST ASSEMBLY (GALE & FABJANZCYK)
FIGURE
GUILLOTINE SHEAR FRAME DESIGN (GALE & FABJANZCYK)

42
43
44
44
45
46

CHAPTER 5
TABLE 1
TABLE 2
TABLE 3
FIGURE 1
FIGURE 2
PHOTO 1
PHOTO 2
PHOTO 3

51
53
54
60
62
61
61
62

CABLE BOLTING GROUTS AVAILABLE IN 1990

CABLE COMPARISON TEST PROGRAMME
DOUBLE EMBEDMENT GROUT TEST PROGRAMME
BIRDCAGED CABLES - SECTIONAL DIAGRAM OF TEST ASSEMBLY
SECTIONAL DIAGRAM OF SHEAR FRAME
AVERY DENI SON TEST MACHINE
DOUBLE EMBEDMENT SAMPLE WITH LVDT AT JOINT IN TUBE
GUILLOTINE SHEAR FRAME IN TEST MACHINE

FIGURE 3a
FIGURE 3b
PHOTO 4
PHOTO 5

GENERAL ARRANGEMENT OF GUILLOTINE TEST RIG

DETAILS OF GUILLOTINE TEST RIG
FLOW CHANNEL
GROUT MIXER/PUMP

63
65
68
69

3 00mm SINGLE EMBEDMENT PULL TEST RESULTS

CABLE BOLT DEFORMATION CHARACTERISTICS
CABLE BOLT DEFORMATION CHARACTERISTICS
DOUBLE BIRDCAGED CABLE BOLT FAILURE CHARACTERISTICS
CROSS SECTION OF NODAL/ NODAL REGIONS OF
DOUBLE BIRDCAGE SAMPLE SHOWING FAILED GROUT
DOUBLE BIRDCAGE WIRE FAILURE - ANTI NODE AT JOINT
PHOTO 1
DOUBLE BIRDCAGE WIRE FAILURE - NODE AT JOINT
PHOTO 2
BOREHOLE WALL FAILURE
PHOTO 3
GROUT FAILURE
PHOTO 4
FIGURE 5 2 x 7 STRAND DYFORM CABLE IN TEST ASSEMBLY
FIGURE 6 DOUBLE EMBEDMENT TEST RESULTS ON 2 X 7 STRAND DYFORM
CABLE
FIGURE 7 DOUBLE EMBEDMENT TEST RESULTS: MANUFACTURERS A &
TABLE 2
DOUBLE BIRDCAGE CABLE PERFORMANCE WITH TIME
FIGURE 8 BULBED CABLE IN TEST ASSEMBLY
FIGURE 9 DOUBLE NUTCAGES IN TEST ASSEMBLY
FIGURE 10 DOUBLE EMBEDMENT TEST RESULTS: ALTERNATIVE CABLES
TABLE 3
COMPARISON INITIAL & WORKING STIFFNESS OF ALTERNATIVE
CABLE SYSTEMS
FIGURE 11 WIRE ROPE IN TEST ASSEMBLY
FIGURE 12 DOUBLE EMBEDMENT TEST RESULTS: WIRE ROPE
TABLE 4
COMPARISON INITIAL & WORKING STIFFNESS OF WIRE ROPE
FIGURE 13 DOUBLE EMBEDMENT TEST RESULTS: 40 TONNE & SINGLE
BIRDCAGE CABLES
FIGURE 14 250mm DOUBLE EMBEDMENT TESTS ON ROOFBOLTS
FIGURE 15 COMPARISON OF ROCKBOLTING SYSTEMS
FIGURE 16 SINGLE NUTCAGE IN TEST ASSEMBLY
FIGURE 17 DOUBLE EMBEDMENT TEST RESULTS: REINFORCING TENDONS FOR
27mm HOLES
FIGURE 18 FIBREGLASS CABLES IN TEST ASSEMBLY
FIGURE 19 DOUBLE EMBEDMENT TEST RESULTS: FIBREGLASS BIRDCAGED
CABLES
FIGURE 20 DOUBLE BIRDCAGED CABLES IN TEST ASSEMBLY:
ANTINODE AT SPLIT/NODE AT SPLIT
FIGURE 21 3 50mm & 450mm DOUBLE EMBEDMENT TEST RESULTS: EFFECT OF
NODE/ANTINODE AT SPLIT IN TUBE
TABLE 5
SHEAR TEST RESULTS
FIGURE 22 SHEAR BEHAVIOUR OF DOUBLE BIRDCAGE CABLE BOLT
FIGURE 23 SHEAR CHARACTERISTICS OF 2 X 7 STRAND DYFORM CABLE
FIGURE 24 DOUBLE BIRDCAGE ANTINODE SHEAR CHARACTERISTICS
FIGURE 25 DOUBLE BIRDCAGE NODE SHEAR CHARACTERISTICS
FIGURE
26
CABLE
MANUFACTURER
A
ANTINODE/NODE
SHEAR
CHARACTERISTICS
FIGURE
27
CABLE
MANUFACTURER

ANTINODE/NODE
SHEAR
CHARACTERISTICS
FIGURE
28
CABLE
MANUFACTURER
A
DOUBLE
BIRDCAGE
SHEAR
CHARACTERISTICS 1 & 14 DAYS
FIGURE 29 CABLE MANUFACTURER A SINGLE BIRDCAGE ANTINODE/NODE
SHEAR CHARACTERISTICS

71
85
85
86
86

CHAPTER 6
TABLE 1
FIGURE 1
FIGURE 2
FIGURE 3
FIGURE 4

87
87
88
88
89
89
90
90
91
91
92
92
93
93
94
94
95
95
96
96
97
97
98
98
84
99
99
100
100
101
101
102
102

CHAPTER 7
TABLE 1
FIGURE 1
FIGURE 2
TABLE 2
TABLE 3
TABLE 4

COMPRESSIVE STRENGTH DATA FOR 3 00mm PULL TEST GROUTS

CABLE BOLT GROUT COMPARISON: GROUTS A - D
CABLE BOLT GROUT COMPARISON: GROUTS E - G
CABLE BOLT GROUTS: UNIAXIAL COMPRESSIVE STRENGTHS
CABLE BOLT GROUTS: WSR. DENSITIES & YIELDS
BRAZILIAN TENSILE STRENGTHS OF GROUTS A,B,C & D

103
116
116
117
117
106

GROUTS A & B: SYSTEM PERFORMANCE WITH DOUBLE BIRDCAGE

CABLE
TABLE 6
GROUTS C & D: SYSTEM PERFORMANCE WITH DOUBLE BIRDCAGE
CABLE
TABLE 7 STRENGTH, MODULUS & SYSTEM WORKING STIFFNESS PROPERTIES
OF CABLE BOLT GROUTS AT 14 DAYS
FIGURE 3 DOUBLE EMBEDMENT TEST: COMPARISON OF CABLE BOLT GROUTS
A - D
FIGURE 4 DOUBLE EMBEDMENT TEST: COMPARISON OF CABLE BOLT GROUTS
E - F
FIGURE
5
DOUBLE
EMBEDMENT
TEST:
UNACCEPTABLE
GROUT
CHARACTERISTICS
FIGURE 6 SYSTEM PERFORMANCE WITH TIME DOUBLE BIRDCAGE CABLE
MANUFACTURER A WITH GROUT A
FIGURE 7 24 HOUR & 14 DAY GROUT CURE CHARACTERISTICS: GROUT A
& GROUT D
TABLE 8
GROUT A SYSTEM PERFORMANCE WITH TIME: WIRE ROPE &
BULBED CABLE
FIGURE 8 GROUT COMPARISON: B.C. APPROVED GROUT & OPC
FIGURE 9 DOUBLE EMBEDMENT TEST DOUBLE BIRDCAGE: B.C. APPROVED
GROUT & OPC
FIGURE 10 GROUT STRENGTH EFFECT OF SAMPLE GEOMETRY; BOTTLE AND
SUB-CORE SAMPLES: GROUT A
FIGURE 11 GROUT STRENGTH EFFECT OF SAMPLE GEOMETRY; BOTTLE AND
SUB-CORE SAMPLES: OPC
12
GROUT UCS: EFFECT OF SAMPLE GEOMETRY; BOTTLES AND
FIGURE
CUBES: GROUT A
FIGURE 13 GROUT UCS: EFFECT OF SAMPLE GEOMETRY; BOTTLES AND
CUBES: GROUT F
FIGURE 14 UCS & DENSITY OF GROUT WITH ADDED WATER: GROUT
FIGURE 15 UCS & DENSITY OF GROUT WITH ADDED WATER: GROUT D
FIGURE 16 FIELD & LAB GROUT STRENGTHS GROUT A - 7 DAYS
FIGURE 17 FIELD & LAB GROUT STRENGTHS GROUT A - 14 DAYS
FIGURE 18 UCS OF GROUT WITH VARIABLE WATER CONTENT: GROUT A
FIGURE 19 MODULUS OF GROUT WITH VARIABLE WATER CONTENT: GROUT A
FIGURE 20 DENSITY OF GROUT WITH VARIABLE WATER CONTENT: GROUT A
FIGURE 21 FIELD AND LABORATORY GROUT STRENGTHS: GROUT A
FIGURE 22 ROUTINE LABORATORY GROUT TESTING: GROUT A
FIGURE 23 QUALITY CONTROL EFFECT OF UNDERWEIGHT BAGS

118

125
125
126
126
127
127
128
128
129
129

CHAPTER 8
FIGURE 1
FIGURE 2
FIGURE 3
TABLE 1

138
139
140
140

TABLE 5

TENSILE TEST IN BENDING

VARIATION IN BENDING PERFORMANCE
INSTALLING COUPLED BOLT
FORGED/BENDABLE ROCKBOLTS (MANUFACTURER A)

CHAPTER 9.1
FIGURE 1 LAYOUT PLAN STILLINGFLEET MINE

118
109
119
119
120
120
121
121
122
122
123
123
124
124

145

FIGURE 2 TOTAL ROOF DISPLACEMENT 203's TAIL GATE

FIGURE 3 PRORAM PORTABLE CABLEBOLTER
TABLE 1
ROOF STRATA ASSESSMENT 203's
CHAPTER 9 .2
FIGURE 1 LAYOUT PLAN RICCALL MINE
FIGURE 2 BARNSLEY SEAM (DEEP) CHARACTERISTICS
FIGURE 3 504's MAINGATE/FACE HEADING JUNCTION PLAN
FIGURE 4 504's TAILGATE/FACE HEADING JUNCTION PLAN
FIGURE 5 TELL TALE PLOT 503's FACE HEAD
FIGURE 6 HEIGHT OF SOFTENING 503's FACE LINE
TABLE 1
ROOF STRATA- ASSESSMENT 430's
TABLE 2
ROOF STRATA ASSESSMENT & HEIGHT OF SOFTENING 473'S
CHAPTER 9 .3
FIGURE 1 LAYOUT PLAN CASTLEBRIDGE
FIGURE 2 EFFECT OF ROADWAY WIDTH ON ROOF STABILITY
FIGURE 3 TELL TALE PLOTS B05's
FIGURE 4 SONIC EXTENSOMETER PLOT B15's
FIGURE 5 MID ROOF EXTENSOMETER ANALYSIS B06's MAIN GATE
FIGURE 6 TELL TALE/HEIGHT OF SOFTENING ANALYSIS B06's
TABLE 1
ROOF STRATA ASSESSMENT
CHAPTER 9 .4
FIGURE 1 LAYOUT PLAN KIVETN PARK
FIGURE 2 STRESS MAP 36's MAIN GATE
FIGURE 3 ROOF FAILURE CHARACTERISTIC 36's LOADER GATE
FIGURE 4
TELL TALE PLOTS 36's LOADER GATE
FIGURE 5
SONIC EXTENSOMETER PLOTS 36's L/GATE
FIGURE
6 SONIC EXTENSOMETER PLOTS 36's L/GATE
TABLE 1
ROOF STRATA ASSESSMENT
CHAPTER 9
.5
FIGURE 1
FIGURE 2 LAYOUT PLAN PARKGATE SEAM
FIGURE 3 COUPLED BOLT PATTERN 19's LOADER GATE
FIGURE 4 SONIC EXTENSOMETER PLOTS 19's L/GATE
CABLE ANCHOR PLAN 19'S L/GATE
FIGURE 5 TELL TALE PLOT 19's L/GATE
FIGURE 6 RIB CABLE PATTERN 19'S L/GATE
CHAPTER 9.6
FIGURE 1 LAYOUT PLAN LITTLETON COLLIERY
CHAPTER 9.7
FIGURE 1 PHOTOGRAPH OF MBS MOUNTED ON CONTINUOUS MINER
REFERENCES

146
147
148
152
153
154
155
156
157
158
159
163
164
165
166
167
168
169
173
174
175
176
177
178
179
185
186
187
188
189
190
193
198
201

APPENDICES
APPENDIX I
CODE OF PRACTICE AND NOTES OF GUIDANCE
CABLE BOLTING FOR ROOF SUPPORT
APPENDIX II
STRATA REINFORCEMENT ACCEPTANCE SCHEME
APPENDIX III

203
203
206
217
217
221

CABLE BOLT TRAINING REQUIREMENTS

APPENDIX IV

221
225

UNIAXIAL COMPRESSIVE STRENGTH AND DENSITIES OF CABLE

BOLTING GROUTS
APPENDIX V

225
235

TECHNICAL GUIDANCE ON SPECIAL PURPOSE RESIN BONDED

ANCHOR BOLTS FOR THE PURPOSE OF LIFTING AND SUSPENSION
OF EQUIPMENT

10

237

CHAPTER 1
INTRODUCTION AND OVERVIEW
1.1 INTRODUCTION
Cable bolting is a post drivage reinforcement system primarily
used as a supplementary support where deformation is occurring
above the bolted height. Typical applications are in wide
excavations and roadways that are subject to large stress values.
The flexible nature of the cables, before installation, means
that lengths far greater than standard roofbolts can be installed
into mine roofs to reinforce the softening ground.
Research has previously been undertaken internationally in
rececent years to determine the behaviour of cable bolts by
laboratory testing and underground in-situ monitoring. The object
of this project is to extend and develop this work to suit the
UK mining situation.
A comparative study by laboratory investigation to determine the
important mechanical characteristics of the cables and grouts has
been carried out. These tests have included further variations
to the standard birdcage cable bolt and included products
developed within the roofbolting technology field.
In addition information gained from cable bolting practice at
collieries by monitoring a wide range of conditions and
circumstances has been used to optimise the reinforcement design
of subsequent roadway excavations. System and product design have
been developed from the experience gained and the analysis of
derived results.
1.2 BIRDCAGE CABLE BOLTS
The birdcaged strand (figure 1) was developed in the underground
metalliferous mines in Australia. It is achieved by altering the
basic seven wire strand such that six of the wires are opened out
around the central king wire in an open-weave form. At equal
intervals along the cable the strands form well defined nodes and
anti-nodes. This allows the grout to penetrate the weave of the
strand and to fully surround or encapsulate each individual wire
in the open-weave portion.
Development of the birdcaged cable was the result of identified
problems of anchor failure due to ineffective transfer of load
at the strand/grout interface. Work conducted by Nguyen et al.,
(1986) showed that greatly enhanced load transfer characteristics
could be achieved by the birdcaged cable. A comparison of the
performance between standard cable and birdcage cable is shown
in figure 2.

11

Figure 2

30-

Tcnstt J.lu'e

8>'dc9e Cable

L O A D lionnes)

SO

D E F O R M A T I O N (mm)

Due to the much larger load capacity gained by the use of the
birdcage cables they have become the most commonly used long
tendon in coal mines.
1.3 MECHANISM OF CABLE BOLT REINFORCEMENT
The strength and stability of cable bolt systems depends upon
many factors, all of which have a bearing on the ultimate design
of the system. All these factors need to be considered in
optimising the support design and the materials used. These
factors include:
* Cable Characteristics (UTS, Modulus and Load/deformation)
* Grout characteristics (UCS, Modulus and Water solids ratio)
* Bond strength between cable grout - rock
* Rock Mass Characteristics (Confinement and Shear strength)
* Physical situation (Excavation dimensions and Stress regime)
Birdcaged cables provide a high capacity high stiffness system.
The effect of the formation of a birdcage is illustrated in
figures 3 and 4. They show a cross section at the node and antinodal points. It can be seen how the strands of the cable are

12

embedded in grout and the birdcage configuration provides both

confinement and suspension resisting further movement.
These characteristics have been investigated by means of the
double
embedment
pull
test
method.
Many
long
tendon
configurations have been tested, in the laboratory, by this
method, results of which are described later in the report. The
test method consists of embedment of candidate tendons with grout
into a twin-tube assembly. Loading and displacements are
accurately measured during a tensile test.
Development of grouts has progressed over the period of the
project. Initial emphasis was given to the candidate grouts
achieving acceptable values of compressive strength and strength
development within specific time parameters, from cube samples.
Later work has been conducted to include assessment of modulus
characteristics by the testing of sub cores of the grouts. It has
been established that the water solids ratio of grouts requires
careful control in the field. To assist this control all grout
companies have been advised to produce products requiring
uniformity in the volume of water addition.
System performance depends upon the achievable bond between
cable, grout and rock. The system requires a high quality of load
transfer. No in-situ measurements have been undertaken with
cables to determine typical load characteristics. This is due to
practical measurement difficulties which require further work to
be overcome. Methods of measuring loading characteristics in the
field roofbolts in the form of instrumented bolts and short
encapsulation pull tests. Over the period of this project work
has been undertaken to develop the laboratory push test for
roofbolts.
A
good
geotechnical
knowledge
of
the
rock
strength
characteristics around a roadway is important in order to
confidently interpret monitoring data and evaluate the nature and
cause of any deformation. At all sites where rockbolting is used
this is a fundamental part of the design procedure. Underground
cores are taken at all such sites from which are determined the
mechanical properties of the strata within 5 metres of the seam
(minimum) and the presence of potentially weak features. A
particularly good indicator of rock failure potential is the
strength to stiffness ratio, which is also identified. Stiffer
rock will attract greater stress values and the lower the
strength/stiffness ratio the lower will be the failure strain of
a stratum.
1.4 PERFORMANCE TESTING
The aim of the test programme has been to use the double
embedment technique to evaluate cable bolting and grout systems.
This enables a comparative study of alternative types of both
cables and grouts.
The chapter on laboratory testing work gives the background to
the establishment of this testing method and details the current
13

work in analysing the various types of reinforcement systems.

A variety of cable forms have recently been submitted for testing
by different manufacturers. In the detailed testing analysis no
reference is given to the manufacturers name, in order to protect
commercial confidentiality. Likewise a number of grouts have been
submitted from various companies, their identity is obscured
within the individual tests. The data obtained from these test
results is used in the optimisation of reinforcement requirements
within the field.
Performance testing of the grouts has been aimed at establishing
the two main characteristics influencing the bond strength of the
system, compressive strength (UCS) and modulus. Similarly the
results obtained are used to determine system design. A routine
sampling procedure has been established for cable bolting sites.
The samples are tested in the laboratory for density strength and
stiffness to check that quality control is being maintained.
1.5 SYSTEM CONTROL
To achieve the system design parameters, cable bolts need to be
installed to high standards. During the process of this project
a Code of Practice for Cable Bolting together with Notes of
Guidance, issued in August 1993, was prepared and issued to
ensure uniformity in standards is achieved. This document is
attached in Appendix I. The main areas covered are design,
installation practices, training, monitoring
and quality
assurance.
In accordance with this document a performance based training
package has been implemented for all personnel involved with the
installation of cable bolts. Classroom instruction is followed
up by underground assessment. British Coal have established rules
to ensure that no installation work can be conducted without the
personnel having received the appropriate safety and operational
training provided by the course. Details of the training aspects
are listed in Appendix II.
All consumables used, both in roof bolting and with cable bolting,
have to satisfy the requirements of British Coal's Strata
Reinforcement Materials and Equipment Acceptance Scheme (SRME),
Appendix III. Products are tested to satisfy their technical
suitability for use in British Coal
mines. Dependant on the
nature of the product it will also have to satisfy either the
Acceptance Scheme for Mechanical Equipment and/or the Acceptance
Scheme for the use of Non-Metallic Materials and Substances. A
number of new products have, during the period of this project,
been approved under these schemes.
1.6 CONSUMABLE DEVELOPMENT
Development of the laboratory testing procedure and establishment
of the required characteristics has enabled parameters to be set
for new consumables to be compared.

14

Consumables have been developed during the period of this project

to satisfy necessary requirements within the field. One important
development has been the introduction of cuttable reinforcement
tendons. These have been developed to satisfy the requirement of
reinforcing the face side of a roadway allowing the face shearer
to remove them as it cuts into the roadside. They have been
comprehensively tested within the laboratory to ensure their
characteristics compare with established parameters of birdcaged
cables. Their introduction underground is included within this
report.
Other varying forms of cable reinforcement are being analysed to
assess their reinforcement capabilities in the same way. This
includes nut cage cables and the flexible bolt. Both systems have
been used in international mines and work needs to continue to
evaluate their suitability in UK mining conditions.
Progressive improvement in grout technology has been accomplished
during the period. This has been as a result of the laboratory
testing work and from feedback on underground experience. Work
is ongoing in developing thixotropic grouts in an attempt to
improve the cable installation technique and improve the
consistent quality of the product.
Roofbolt development has progressed to produce a higher capacity
bolt and attempts to develop a dual purpose bolt for lifting and
support. The coupled bolt technique has been improved to provide
a fully encapsulated system. Work has started in evaluating the
potential in low height situations of the waisted/bendable bolt.
Another important development has been the introduction of medium
set resin capsules for the reinforcement of coal ribs. Initial
trials have established its capabilities and further work is
ongoing before it is introduced into the field as an approved
product.
Further development of consumables field is continuing which will
allow further optimisation of reinforcement techniques.

15

BIRD CAGING

Figure 1

16

CONFINEMENT
Extension
resisted by
stiff cage

Section A-A

Section B-B
Figure 3

17

SUSPENSION
Bird cage 'bulb'
is secured
by grout wedges

Figure 4
18

CHAPTER 2
CABLE BOLTS
2.1 CABLE BOLT DESIGN
Cable bolts used in British Coal Mines are formed from 15.2mm
diameter dyform strand manufactured to BS5896. The choice of this
strand was based on its success in the ground anchoring industry
and its ready availability in the UK. It contains 20% more steel
than standard steel wires. They are formed into a birdcage
configuration, with equally spaced nodes and anti-nodes (spaced
at approximately 240mm intervals) to improve load transfer
between the grout and the cable and to improve support stiffness
once installed.
Cable bolts provide a stiff support similar to that provided by
AT roofbolts.
In the single birdcaged configuration they have a yield capacity
of 300kN (30 tonne) providing a system stiffness of between 65 70kN/mm. This capacity is doubled when using them in the twin
form i.e. double birdcaged cable bolts (600kN and 130-140 kN/mm).
Since the initial use of cables in the late 1980s great emphasis
has been placed by TSRE on using the twin form due to improved
strength and stiffness characteristics.
Single cables are designed to be used in a 43mm nominal size
hole, whereas the twin birdcaged cable should be installed within
a 55mm hole. Initially many sites, where single cables were
installed, received them as plain rope and the cables were hand
formed on site into the birdcaged configuration. This was done
for simplification of transport and costs but in many cases led
to poor standards being achieved. Influenced by the technical
argument this practice has been discontinued. All twin cables are
supplied birdcaged, either hand formed or machine wound by the
manufacturers. There are currently two suppliers of birdcaged
cables in the U.K.
2.2 SYSTEM DESIGN
2.2.1 CABLE LENGTH
The length of cable required can be determined from the height
and style of displacements occurring in the roof. This can be
judged from available monitoring information which, if it is a
roofbolted roadway, will be routine monitoring in the form of
tell tales and in many cases a multi-horizon extensometer,
usually sonic within the proximity of the area requiring
reinforcement. The required length of cable bolts under changing
stress conditions can also be predicted by the numerical
modelling method. It has been determined that at least lm of
embedment length should be provided above the top strain horizon.
If this information is not known then the cable length is usually
chosen to be at least 1.5 times the roadway width.

19

The accepted standard length of cable bolts in practice in the

U.K. however is normally 8 metres. This gives an insurance that
the system is not under designed and suits a variety of
circumstances ensuring adequate embedment length is achieved. In
wide excavations and in situations where there is known strain
occurring higher into the roof than would be normal then cable
bolts of 10 metres in length are used. The parameters have been
set as principle guide lines laid down within the Code of
Practice,"Cable bolting for Roof Support" (Appendix I).
Several examples of differing lengths of cable design to suit a
variety of situations are detailed within the field work in
chapter 9.
2.2.2 PLACEMENT
Experience has shown that installing long tendon reinforcement
before significant displacement in the roof has occurred will
increase the support performance achieved. When displacement has
already occurred the load bearing capacity of the system is
reduced. Where long tendons are installed to provide additional
reinforcement against anticipated increases in stress levels
during face retreat the placement in certain cases can be delayed
until shortly before the increase occurs. This would be in a
situation where displacement within the roadway was stabilised
by the existing roofbolting support and the effect of stress on
the roadway could be accurately predicted.
From previous work conducted by Fabjanczyk and Gale (1987c) it
has been found that it is not always prudent to install cables
immediately after excavation. A short time period should prevail
between the roadway support system, whether it be standing
supports or roofbolts, and cable installation. In practice this
is generally the case due to the operational constraints of cable
bolt installation.
2.2.3. CABLE DENSITY
Previously no guide lines existed in the U.K. on required cable
bolt densities to stabilise an excavation. Guide lines have been
used from the work and recommendations of Fabjanczyk and Gale
(1987c) to determine design parameters. This together with the
experience from
field work has culminated
in design
recommendations being included in the Notes of Guidance within
the Cable bolt Code of Practice. Confirmation of design can be
determined by placement of sonic extensometers to a similar
height as the cables. From this, displacement and strains
developed within the roof can be identified and the effect of the
reinforcement design determined.
In a deforming roof axial stresses are concentrated at the centre
of a roadway whereas shear stresses are concentrated in the
ribsides. As cable bolts have a greater axial capacity they are
placed around the centre of the roadway where the vertical
displacement is greater.

20

An alternative approach is to calculate the maximum possible

weight of rock that a cable might be expected to carry after
deformation has occurred. The unit weight of rock and the amount
of rock below the highest expected strain zone will give an
indication of the load on the support system. This can be
determined from the following equation: L = HxWxSxQ
where L = the load on the support system
H = height to the highest expected strain zone
W = width of roadway
S = cable spacing along length of roadway
Q = unit weight of rock
This type of calculation should be treated with caution as it
does not account for the additional loads imposed on the support
system by roof deforming under horizontal stresses.
2.2.4 NUMERICAL MODELLING
Recent work has been undertaken under ECSC projects to
numerically model rock failure and deformation in underground
situations. This has been done using the computer programme
entitled FLAC. The package has been extensively used for pillar
design, but can additionally be used for roadway design.
However the model requires a large amount of detailed information
for it to be used as a predictive design tool. Such detail
includes pre
and
post
failure
triaxial
rock
strength
characteristics, underground stress measurements and monitoring
information from extensometry. These are very expensive to
collect and input. Rigorous validation of the output information
is required before it can be used for mine design.
2.3 RIB REINFORCEMENT
Besides the work on long tendon reinforcement of mine roadway
roofs, extensive work has been conducted on control of the
movement of ribs. In many cases it has been found that the two
cannot be divorced. The driving force in promoting roof failure
at some sites has been caused initially by the movement of the
ribs. At other sites ribs may detach themselves and slide along
pertinent parting planes at the roof of the roadway a process
termed as de-coupling.
Different
modes
of rib
failure
due
to
varying
seam
characteristics and the consequential reinforcement applied are
detailed in the colliery field work in Chapter 9. Ribs are most
susceptible to large amounts of movement from high increases in
vertical stress within the front abutment of retreat faces.
Adequate reinforcement is necessary to ensure passage of face
21

equipment is not inhibited. Placement of cables is best done well

before such movements are likely to occur and the same design
parameters can be applied as have already been outlined for roof
cables.
Cables used in rib reinforcement are usually identical to those
used in roofs. It is normal to use lengths of 5 metres, in most
situations this gives satisfactory reinforcement to contain rib
movement. It has been normal practice in the U.K. to use the
single birdcaged type placed within 43mm diameter holes. In
certain sites where ribs have been particularly difficult twin
cables in 50mm diameter holes have been necessary e.g. 19's
Loader Gate Ollerton Colliery (Chapter 9.5).
However, methods and results in general to control ribs have been
less satisfactory than with roofs and further work is ongoing
within this field to optimise the reinforcement systems.
2.4 CTTABLE TENDONS
A major development in the reinforcement field has been the
introduction of non-metallic tendons i.e. fibreglass cables. They
are cuttable such that they can be used to reinforce the face
side of a roadway and be removed by the face machine. They have
been designed to give similar characteristics to steel cables.
Fibreglass cables consist of fibre reinforced glass strands
formed into a birdcage mode by forming the strands around
uniformly placed plastic spacers and tying the nodal points by
wire wraps.
Initially two manufacturers were granted approval for underground
trials with their respective design of tendon. Both were designed
to be installed within a 50mm hole size. One design of cable
consisted of 14 strands each of 5mm thickness. Each fibreglass
strand is externally cross hatched to aid the load transfer
characteristics of the cable. The strands are coated in an antistatic graphite based lacquer. From tests undertaken under the
Project they were found to exhibit an ultimate strength of 29
tonnes and provide a stiffness comparable with single birdcaged
cables.
The end arrangement has the fibre strands fixed into a threaded
bar which accommodates a nut and standard domed washer plate.
Initially the cable was designed to accommodate a 5mm breather
tube, this was modified to 10mm, following unsatisfactory field
experience. The design was changed to incorporate a 10mm breather
tube along the centre of the cable. The grout tube is attached
to the cable in a similar manner to a standard cable bolt.
Experience with the use of this form of cable is included within
the field work report at Ollerton Colliery (Chapter 9.5). Similar
initial experience was gained at Daw Mill Colliery.
The other company produced a fibreglass cable which was
introduced at about the same time. These consisted of 10 strands
22

each of 7mm thickness. Their configuration had less nodal and

anti-nodal points due to their thicker strand size. This design
incorporated the accommodation of a breather tube running up the
centre of the cable. The end arrangement consisted of a barrel
and wedge which was forced onto the cable following grouting
operations. Experience has shown this to be a weakness in the
design especially where rib movements have been high.
Two other companies are in the process of submitting designs of
fibreglass cables for approval.
2.5

ALTERNATIVE CABLE BOLT SYSTEMS

2.5.1 NUT CAGE CABLE BOLTS

Nut cage cable bolts have a birdcage configuration that has a
tighter weave than standard cable bolts as shown in photograph
2.1. This is achieved in those currently commercially available
by the placement of a 15.8mm nut within the strands at the antinodal points. This reduces the overall diameter of the cable such
that single nutcage cables can be installed in a 27mm nominal
hole and double nutcage cables in a 43mm hole.
Each cable is formed of 7 strand dyform cable, one central
kingwire around which the nut is placed and six peripheral wires
which rest on the flats of the hexagonal nut. Nuts are spaced at
approximately 300mm intervals on each cable length and as an
overlap is created on the double nutcage version, nut spacing is
halved. The overall UTS of these cables is similar to standard
birdcaged
cables however the stiffness has been found to be
reduced by 50%. Actual nut spacing on the cables submitted by the
suppliers is shown in Table 1.
Following the double embedment tests conducted in the laboratory
(see Chapter 6) it has been recommended that single nutcage
cables would not be appropriate as a roof support but only
suitable to use for rib reinforcement. Monitored underground
trials are presently ongoing to compare the suitability of the
nutcage cable with existing cable reinforcement at Daw Mill
Colliery and Riccall Mine.
A big advantage with this mode of reinforcement is that the
cables are designed to be installed within smaller diameter holes
than standard cables. Depending on the outcome of the two trial
sites nutcage cables could be of considerable benefit in certain
applications especially where drilling hole sizes of 55mm for
double birdcaged cables is problematic. To compensate for the
reduction in stiffness obtained from the nutcage cables would
require additional smaller size holes (43mm) being drilled,
however.

23

2.5.2 FLEXIBLE BOLT

Two manufacturers have developed a rope strand formed by a number
of profiled steel wires which is designed as a reinforcement
system to be used in conjunction with encapsulated polyester
resin. It is called the flexible strand rope (FSR). The system
is designed to be installed within 27mm diameter holes up to a
height of approximately 4 metres. An end termination is provided
with the 'cable' to facilitate its insertion by a roofbolt
machine in a similar manner to roofbolt installation.
Comparative tests have showed that its average ultimate strength
was less than an AT roof bo It (287kN as compared to 315kN) .
However from the slope obtained on the load/displacement curves
the stiffness is less than half of the AT bolt. The FSR does have
a higher shear strength capacity in the region of 40% greater
than the AT bolt.
It would appear from these tests that although it could not be
used as a substitute for a roofbolting system it could provide
supplementary reinforcement in certain circumstances. Further
investigations are required to further test this application.
2.5.3 THE BULBED CABLE
This type of cable known as the 'Garford Bulb Anchor' is used
within Australian Coal Mines. A photograph of a single bulb is
shown in 2.2. It is manufactured from round steel wire and the
bulbs are formed by gripping the strand at two points and forcing
them together. Variable sized bulbs may be placed at varying
intervals along a strand. This design of open weave cable bolt
provides a tendon of similar properties to the birdcaged type but
due to the type of wires used its performance is inferior.
2.5.4 WIRE ROPE
This form of tendon is mine haulage rope which has had the centre
core removed to facilitate grout injection, see photograph 2.1.
It comprises clusters of small diameter rope strands wound in
right hand langs lay to form a rope, one type being 28mm diameter
the other 32mm diameter. It is designed to be used in smaller
diameter holes as an alternative to double birdcaged cables.
Satisfactory results were achieved from double embedment tests
with the 32mm rope used in a 38mm hole. But this is a non
standard hole size. The 28mm rope designed to be used in a 35mm
hole gave unsatisfactory results in the laboratory.
2.5.5 40 TONNE BIRDCAGED CABLE
This is of the same design as a single birdcaged cable but with
additional strands to give an increase in capacity. It is also
designed to be used within a 43mm diameter hole. It could have
a limited application more likely as a form of rib reinforcement.

24

2.6 APPLICATION
2.6.1 ROOF
Twin birdcaged cables are designed to be used in a 55mm hole
which was a non-standard size within British Coal. This presented
problems with earlier installations which used either equipment
compatible with the nearest bit size, 60mm or attempted to use
these bits with hand operated machines. Using large rig type
machines was not successful as they were not easy to manoeuvre,
required large volumes of water and were expensive to purchase.
Experience of one installation is detailed in Chapter 9.1,
Stillingfleet Mine. Hand operated machines proved to be
inadequate when drilling this large hole size. This was
aggravated when hard abrasive strata was encountered.
These problems inhibited the progression to twin birdcaged
cables. Most collieries were prepared to continue using the
single birdcage type. Development of 55mm bits therefore in the
early part of this programme became a priority. Initially winged
carbide bits were manufactured by stepping out the wings on 50mm
bits, keeping the body size the same. This was an interim measure
and in certain less abrasive strata was reasonably successful.
As the geotechnical requirement to use the higher capacity cable
became more apparent drill bits were developed as a standard both
for carbide types as well as poly crystalline diamond bits for
hard strata applications.
In most situations the rig type of bolting machine is impractical
due to its size, poor manoeuvrability, and cost. In the majority
of cable bolting applications it is more practical to use hand
operated pneumatic machines as used for roofbolting such as the
Wombat or Gopher. Cable installation has been made easier using
these machines by the bit development and the use of integral
drill steels using a rope thread for ease of coupling and
releasing.
High thrust types of machine have been developed recently which
are more suited to cable bolting. The low pressure Wombat and
Gopher machines are modified standard machines. They are designed
to perform satisfactorily at pressures down to 4 bar and give
increased thrust and torque to the standard machines when
operating pressures are higher. This has been achieved by
increasing the piston sizes in the air motors to improve the low
pressure performance and enable an increase in the leg thrust of
around 30%.
The other development is the Wombat Cablebolter, figure 1,
another modification of the standard machine which is twin legged
and provides high thrust (12kN 6.2 bar on the first leg stage,
9.4kN on the second) and reduced torque reaction. Several sites
are now using this type of machine resulting in speedier drilling
times and improved cable installation performance.

25

2.6.2 RIBS
Installation of rib reinforcement can be arduous if hand held
bolting machines are used. The thrust capabilities of these
machines have been improved by modifying them to incorporate an
air leg. Development of the Modular Bolting System (MBS), see
figure 2, has further improved side cable installation. Although
originally designed for rib bolt installation it has found favour
as a machine used for long tendon side reinforcement. The design
concept allows for the feed unit drill rig to be rotated around
a stinger leg capable of drilling through 360 degrees. The
operator controls the machine operations via an umbilical chord
which connects the feed and stinger units and allows him to stand
in a remote position from the machine. The stinger leg can be
rapidly set and retracted. The feed unit has powered retraction
enabling quick assembly of the drill rod extensions. It is a
lightweight machine that is mobile and capable of being advanced
and operated by one man. This machine has found to be most
beneficial in restricted areas such as when installing
reinforcement tendons on the conveyor side of excavations.

26

Photograph 2.1
TYPES OF CABLE BOLT (from left to right)
Double Nutcage, Wire Rope, Double Birdcage,
27

Photograph 2.2
TYPES OF CABLE BOLT (from left to right):
Conventional 15mm 7-strand Dyform Cable, Single Nutcage,
Single Bulbed, Single Birdcage.
28

WOMBAT CABLEBOLTER

Figure 1

29

More Twist
More Power

Pull Out
Feed Forward.

Figure 2

30

DOUBLE NUTCAGE DESIGN

d.

DISTANCE (mm)

CABLE
a

220

270

270

330

300

160

270

280

310

270

19 0

270

280

300

270

230

280

270

360

270

Table 1

31

CHAPTER 3
GROUTS
3.1 EARLY EXPERIENCE
Due to the operational similarities between cable bolting and the
well established long hole resin injection technique early
installations of long tendon cable bolts in the UK used the same
pumping equipment and resin. The resin approved by British Coal
for long hole injection is a gypsum plaster based material known
as M100. M100 exhibits a rapid strength build up reaching 75% of
its ultimate compressive strength within two hours. However its
strength is relatively low (UCS 25Mpa) and the mechanical
characteristics
exhibited
by
cementituous
grouts
are
significantly more suitable for cable bolting. Once suitable
grouts were developed for cable bolting its use was curtailed.
Some of the initial reinforcement work carried out within the
timescale of this project used products imported from Australia
(see Chapter 9.1) prior to the introduction of suitable UK
manufactured consumables.
3.2 GROUT CHARACTERISTICS
UK manufactured grouts have been developed from ordinary Portland
Cement with the addition of fine aggregates and expanding agents.
They have been designed to give the following characteristics:
a)

High strength

and high stiffness

b)

Rapid cure time

c)

Suitable pumping/setting characteristic

d)

Expansive properties (to enhance bond and anchorage)

e)

Non corrosive properties

To achieve the required strength development cable bolting grouts

have been designed to a low water/solids ratio of between 0.3 and
0.4. It is critical that the designed mix ratios are observed as
the addition of extra quantities of water can have a dramatic
effect on the strength of the product. Tests carried out to
establish the effect of additional water on both density and
uniaxial compressive strength are evaluated in Chapter 7.
The potential problems which can occur if under strength grout
is used in a cable array has been previously identified by
Fabjanczyk and Gale (1987c) . A reduction in grout strength will
give a proportionally greater reduction in the reinforcement
capability of a tendon. In a cable bolting array the lower
capacity of just one tendon can significantly affect the overall
stability.
Cable bolt grouts normally attain something near their maximum
strength after about 7 days. It is important that a high

33

percentage of this strength is developed rapidly

movement during the curing period is kept to a
have shown that generally providing the correct
are adhered to grouts attain 50% of their final
1 day and 75% after 3 days.

so that strata
minimum. Tests
mix parameters
strength after

From previous work carried out by Gale and Fabjanczyk (1987a) to

establish the effects of grout parameters on the load capacity
of birdcage cables the following was established:
a) Ultimate system capacity is more strongly controlled by
the grout compressive strength than modulus.
b) Maximising compressive strength increases the ultimate
capacity of the system.
c) System stiffness is a function of grout modulus.
d) Neither compressive strength or modulus can be isolated
as controlling the ultimate tensile capacity of the
system.
Grouts have been developed over the period taking these findings
into consideration. The bulk of long tendon cable bolt
reinforcement installations have used two specific grouts both
of which have displayed the desired characteristics (referred to
as grout A and grout in the test programme in Chapter 7) . These
have exhibited a designed U.C.S. of around 80Mpa and a Youngs
modulus of 25Gpa after a period of 28 days, achieving a high
proportion of these strengths within 7 days.
Cable bolting grouts are designed to be pumped for short
distances in relatively small diameter tubes. They need to be of
a suitable viscosity such that when mixed the product flows
freely to enable ease of pumping. In addition they require to gel
speedily so that following placement they are contained within
the strata. They need to achieve a high percentage of their
ultimate strength in a short period of time. Change of viscosity
by the addition of water greatly reduces their strength. A
Quality Assurance routine testing programme,(see 3.5 and Chapter
7) was implemented in order that a means of control was
established thus preventing poor quality products being used and
providing some consistency in the field.
More recently grouts have been developed exhibiting thixotropic
properties whilst retaining their strength characteristics. These
are now being introduced in the field with the intention of
replacing the well established grouts but further testing and
field work needs to continue to ensure that they satisfy the
design criteria of a cable bolting grout. Development of systems
whereby this type of grout is directly pumped into a drilled
hole, the grout being sufficiently thixotropic to remain in-situ,
and allowing a cable bolt to be inserted through it have been
attempted. Further work is required to perfect this system and
further develop its potential before it can be used in the field.

34

3.3 GROUT MIXING

Suitably designed pumps capable of developing a high shear
homogeneous mix should be used when mixing cable bolt grouts in
order that the designed strength characteristics are achieved.
Under mixing can result in a strength reduction of 50% The type
of pumps and mixers that were used with the pumping of long hole
injection resin were initially used for pumping grout and were
found to be inadequate.
The essential features required for grout pumps are:
i)

Capability of providing a high shear mix.

ii) Capable of pumping fine aggregates.

iii)Continuous and simultaneous mixing and pumping.
iv) Capable of high volume pumping, for batch grouting.
v)

Robust and portable.

Two pump/mixers have been introduced which satisfy the above

criteria.
1.

Grout mixer/pump (Manufacturer A)

This is a machine which is used in Australian Coal Mines and has

been adapted for use in British Coal mines by replacing certain
non-approved components. It is a self contained unit comprising
a mixing tank, a removable agitator and motor assembly and a
chamber to house a piston pump see figure 1. Both the mixer motor
and grout pump are air driven designed to work at similar air
pressures to standard roofbolting machinery. The pump is a
reciprocating single piston type which by its inherent action
draws the grout into the piston and dispels it to the outlet side
and attached hose. It has a capacity (150 litre tank) suitable
for batch grouting of cables. It is ideally robust and
transportable, the dry weight of the mixer assembly being 65kg.
Its removable motor assembly and agitator can be detached from
the tank. The pump unit is an independent assembly.
2.

Grout mixer/pump (Manufacturer G)

This unit, see figure 2, has been developed with an input from
staff employed on this project. It has an integral mixing unit
which can be detached for easy transportation. The unit is driven
by two air motors, one drives the mixer the other drives the pump
through a reduction gearbox. Grout slurry is mixed in a hopper
which has a capacity of 30 litres and delivered by opening a
valve and operating the pump. It satisfies the criterion already
outlined above but operators need to be well disciplined in
flushing the unit through with water at the end of each shift due
to inherent problems with this type of pump.
Grouts are delivered in bag sizes suitable for mixing with 5
litres of water. To ensure that precise mixes are obtained and
35

the designed water/solids ratio achieved operators need to use

appropriate measuring cylinders to meter the water content.
3.4 QUALITY CONTROL
In order to ensure quality control, performance procedures have
been developed and incorporated within the Code of Practice for
Cable bolting, (Appendix I). For cable bolts to provide optimum
performance the installation must be carried out to the highest
standard. At some of the early cable bolt installations the
effectiveness of the reinforcement was reduced when not adhering
to the parameters established within the Code.
To ensure grouts meet the required characteristics with relation
to U.C.S, modulus and density a set of routine sampling and
testing procedures has been devised. A data base has been
established using a standard grout. All candidate grouts can be
compared with this to establish their suitability. Details of the
procedure for testing and the background of the establishment of
the programme are fully discussed within Chapters 5 and 7.
The routine sampling procedure specifies that a minimum of three
grout samples are obtained from a batch mix and then random
samples are taken during the cable bolting operations, by
colliery staff.
A system has been established to identify quickly the density and
hence water/ solids ratio and the uni-axial compressive strength
of any grout sample. Limits of the range of acceptability of any
grout have been established from information supplied by the
manufacturer. Results are transmitted rapidly back to the
collieries. The main reason for poor quality samples is the
addition of surplus water to the grout, when the mix ratio has
not been adhered to.
Besides identifying poor working practices from cable bolting
sites this routine sampling procedure gives an additional check
to the quality of the product and would identify any change in
the chemical nature of the grout.
Testing the quality of work at underground sites is the duty of
the Colliery Roofbolting Engineer. After cables are pumped each
should be checked to determine a full column of grout has been
achieved. This is done by a visual inspection to determine
whether grout has flowed into the breather tube or by air
pressure testing. Once they have satisfied this inspection cables
are ready for end plating.
A training package has been devised to ensure key factors of the
cable bolt operations are understood, emphasis is put on the
grouting procedures and quality of work. This is dealt with in
Appendix III.

36

3.5 FIELD EXPERIENCE

Emphasis has been placed in the preceding chapter on the correct
timing of cable placement for the best effects. Work by
Fabjanczyk and Gale (1987c) established that grout should have
enough time to develop at least 75% of its maximum strength prior
to an increase in load on the reinforcement member. Early
placement of tendons minimises the problems encountered during
grouting. If minimal dilation of the strata has occurred grout
losses will be less as the grout can be targeted within the
confines of the cable bolt hole.
Optimum cable bolt performance is achieved by full column
grouting. The more developed fractures are in the rock beds, then
the more difficult it is to achieve effective grouting. In highly
fissured ground where grout losses can be high and the standard
method of grouting is not very effective two stage grouting may
be necessary. This is achieved by positioning the grout tube at
a higher position in the cable bolted hole than normal, or
alternatively introducing a secondary grout tube. Pre-injection
of the cable bolt can be achieved by pumping a small quantity of
grout into the hole. Once this grout has consolidated final
grouting operations can continue. Care has to be taken to ensure
the grout tube is kept free from grout between the two stages.
It is important that at all times during grouting operations a
small vessel containing water is attached to the breather tube
of the cable. This will indicate by the appearance of air bubbles
when the grout column is full. It can also be an indicator in
broken rock conditions if grout is passing between cables prior
to the holes being filled. Modifications to the sequence of
grouting may be required to overcome this eventuality.
Another method which is used where grout losses are considerably
high in ground that has well developed fractures involves
sleeving. In practice this would be used in situations where
cable bolts have been installed into ground not previously
reinforced by rockbolts. The object is to sleeve the length of
the badly fissured ground with a fibre sock. This area of the
cable is then pumped using an additional grout tube. However this
reduces the potential effectiveness of the system by reducing the
strength of the bond between the grout column and the rock where
the hole is sleeved.
An alternative method in this situation is to pre-grout the
affected area. This will involve pumping a grout more suited to
strata injection through standpipes inserted into strategically
placed holes. It will prevent the unnecessary pumping of large
volumes of more expensive cable bolt grout and is a more
effective way to achieve full grout encapsulation in difficult
conditions.

37

];( 6 00 ! _ S . .
AIR
S IL F. c
VA ivr
l i l . H O V A M l . t' I D fl AS

R E M O V A B L E MOTOR A S S Y .

Figure 1
Grout Mixer/Pump
(Manufacturer A)

Figure 2
Grout Mixer/Pump
(Manufacturer G)

UJ

CHAPTER 4
LABORATORY TESTING OF LONG TENDON REINFORCEMENT CONSUMABLES
PREVIOUS RESEARCH ON CABLE AND CEMENTITIOUS GROUTS TESTING
4.1

AIM OF LABORATORY TESTING

CABLES
The aim of performance testing cable bolts is to define the
mechanical response to the loading conditions that are likely to
arise when they are in service and to enable the most appropriate
device to be chosen for the predicted rock mass response.
Performance testing is conducted for two basic reasons:
(i)
to provide information on the response of the
different variant devices such that comparisons can be
made,
(ii) to provide data for use in the design stage of
reinforcement systems.
CEMENTITIOUS GROUTS
The effectiveness of any cable/grout system is governed by
properties of the grout used. The two main characteristics that
will influence the properties of the bonded cable are the grout
compressive strength (UCS) and Modulus (E).
Performance testing is conducted for three reasons:
(i)
to provide information on the properties of the different
grout types and their effect on placement in the field
and cable bolt/grout system stiffness such that
comparisons can be made,
(ii) to provide data for the use at the design stage of the
reinforcement system,
(iii) to monitor the characteristics of grouts sampled from the
field in order maintain quality control.

4.2
4.2.1

LABORATORY TESTING OF REINFORCING TENDONS

SIMULATION OF ROCK MASS CONDITIONS

The complex nature of the conditions of confinement within the

rock mass and the complicated . arrangement on in situ loadings
render artificial simulation virtually impossible. The basic
discontinuity displacements and the resulting cable bolt loads
are:
(i)
Dilation - Axial
(ii)
Shear - Shear
(iii) Rotation - Bending
(iv)
Combined - Combination
All of these tests need to be conducted with various embedment
lengths and in different grout and rock mass conditions.

41

In reality very few of these tests are actually conducted either

in the field or the laboratory. The in situ mechanisms are so
difficult to simulate that only the axial pull-out test is
conducted in the field.
A greater number of simulations can be conducted in
laboratory but these are often gross over simplifications
reality and require complementary analyses to account
additional effects that are ignored in testing but may
encountered in the field.
Axial testing is commonly reported and less frequently
testing.
4.2.2

the
of
for
be

shear

AXIAL TESTING OF CABLE BOLTS

Axial testing conducted in the laboratory is usually in a Single

or Double Embedment format as shown in Figure 4.1.

Load
Pom

$/*,

in

>x\v.

>m.

r 1

IJ

t\
]

>
:

i' h
w

Sr/Xt-

a) Single Embedment
Figure 4.1

?
. j

b) Double Embedment

The Single and Double Embedment Axial Test

(Windsor 1992)

The single axial test is used to simulate the loading of a

partially decoupled cable bolt by a face restraint system. The
Double Embedment axial test is used to simulate the loading of
a fully bonded cable at a dilating discontinuity. The embedment
can be varied to produce both slip and rupture of the cable in
order to determine the rate of load transfer and the minimum
embedment length sufficient to cause rupture.
Both testing
methods require samples of cables to be grouted into thick walled
steel tubes which are then loaded by a universal testing machine.
The Single and Double Embedment testing of rock reinforcement
consumables was first reported by F uller and Cox 1975. Their
Double Embedment test technique is shown in Figure 4.2. At the
time in the field of reinforced concrete the philosophy had, in
general, been to gear the investigations towards the improvement
in load carrying capacity of the reinforcing members with, very
42

often, only passing reference to reinforcement-matrix bonding.

The test program was devised to investigate the failure
mechanisms in the region on the reinforcement-matrix interface
of wire and conventional 15mm 7-strand cable and to identify the
effect of variables (embedment length, surface condition of wire
and surface shape of reinforcing member) on the reinforcement
system.
7 m m wirr

t2mm 7vire rond

IO turn Potentiometer

Grout IwmerAementO-'Sr

LVOT

10 turn Poienticnttr

.'' - ' -
veiohu.jnrrn

Rubber stopper

iJ 7

-BT

Suoporl
lenqth

'Jt'i d hivot

Embedment
lenqth

~SCraent
frtih

H*y>w;

Plue-

S S J F ^

Test M/C JOW5-7

1*1

Test specimen for pullout of strand

Test specimen, for pullout of wires

Figure 4.2

Single and Double Embedment Pull Tests after

Fuller and Cox 1975.
Grouting for the double embedment took place in two stages,
filling of the lower tube followed by the upper tube.
The above test method was adopted, with some modifications by
Goris 1990 for research on cable bolts by the U.S. Bureau of
Mines. The test program assessed cable bolt material and support
properties in order to provide design criteria for their use as
roof control under various types of underground mining
conditions.
The laboratory tests included evaluation of
conventional 15.2mm 7-strand cables and birdcaged cables along
with studies of the effect of embedment length, water-cement
ratios and the presence of empty or grout filled breather tubes.
The test confinement in the above test programs is somewhat
artificial as the steel tubes provide a relatively high radial
confinement as compared with what would be expected in the field.
Hyett et. al. 1992 conducted Double Embedment tests on
conventional 15mm 7-strand cable using variable confining mediums
in order to simulate variable confinement generated by different
rock masses. The confining mediums comprised steel, aluminium
and PVC and the conventional Double Embedment pull test was
modified as shown below in Figure 4.3. This push test overcomes
the excess confinement in the vicinity of the pulling threads
that can occur in the conventional pull test, Point A.

43

(A) Conventional pull test

(B) Modified push test

MTS stationary
head
125mm of constant
cible embedment

Steel pulling heads

Free end of tesis section

Variable confining medium
P V C Aluminum, Steel

' 250mm test section

Maximun of 25nun
of unbonded cable

Fixed end of test section

500mm fixed section

of grouted cable

MTS actuator head

Pull Rate = 03mm/s

Comparison between the: (A) conventional Dull test; and (B) modified push test.

Figure 4.3

Modified Push test (Hyett et. al. 1992)

An alternative to installing the test samples in steel tubes is

to install them in large concrete blocks and then to jack or pull
the blocks apart. Tests of this type have been conducted by
Stillborg 1990 on grouted rock bolts, grouted cable bolts and
friction anchored rockbolts (Swellex), as shown in Figure 4.4.

Figure 4.4

Schematic illustration of Test Arrangement used

by Stillborg 1990.

44

High strength reinforced concrete with a compressive strength of

60MPa was used for the two 1.5m concrete blocks separated by a
joint. The blocks were separated by pulling them apart on low
friction rollers. The joint opening was measured by two LVDT
gauges, one on each side of the mated blocks. At the free ends
of the two blocks, any rockbolt slip was measured by LVDT gauges.
Double Embedment tests have also been conducted by Gale and
Fabjanczyk 1987b and it was from this technique that the British
Coal test program was developed.
The majority of the tests were carried out on 10 strand birdcaged
cables which was the most commonly used tendon within the
Australian coal mines at the time. The Double Embedment test
configuration is shown below in Figure 4.5.

, CHUCK

tiptco

, ( lKSt0C D S U = : S I S "

we coot xtiea
/IVSE DWTtti o (MB )

Figure 4.5

Double Embedment Test Assembly (Gale

and Fabjanzyck 1987b)

Considerations in the design of the experimental system were:

(i) No significant premature bond failure to occur on the
borehole wall, therefore the internal surface of the tubes
were threaded.
(ii) To enable comparison of effective stiffness on the
reinforcement, no significant deformation of the tube must
occur and secondly, no section of the test assembly must
exceed its yield capacity; therefore the cross-sectional
area of the tube was made significantly greater than the
cross-sectional area of the strand itself.
The samples were tested on a long bed servo controlled testing
machine.
4.2.3

SHEAR TESTING OF CABLE BOLTS

Shear testing of cable bolts is much more difficult to perform

45

than axial testing and is consequently less common.

Shear testing of reinforcing tendons has been reported by Gale
and Fabjanzyck 1987b. The aim of these tests were to quantify
the effectiveness of various commonly used reinforcing tendons
in providing effective shear restraint. The tendons included
roof bolts and 10 strand birdcaged cable and investigated the
effect of hole size, embedment length and grout properties.
The experimental system comprised a guillotine shear frame as
shown in Figure 4.6. All samples were pregrouted into two steel
tubes, of the required internal diameter, jointed at the point
of shear. The guillotine shear frame was then placed in a servo
controlled testing machine.

loun.LQ'n .
c r o c . " I itwrff I M D..O'
l.t*r c'**. '*<* . < . '

* * v*H r a * ]

r'M

1"

Ovio
v i e ;/*o to
K u l Vt TM*<
100 COI

I.S.

| n o to o*4 \oc I
7 * * WO O ***" 1

CiiO viCw

COOSS

StCIiO"

IttltCr* A

Figure 4.6 Direct Shear Frame as used by Gale & Fabjanzyck

1987b.

4.3 LABORATORY TESTING OF CEMENTITIOUS GROUTS

4.3.1

PHYSIC AL PROPERTY TESTS ON GROUTS

Physical properties of grouts that are most important to cable

reinforcement are:
(i)
Uniaxial compressive Strength
(ii) Modulus
(iii) Viscosity
Tests on the physical properties of cementitious materials vary
according to the specific investigations but usually are
conducted where possible to National Standards.
In the UK laboratory tests are conducted according to BSI
1881:1983, the British Standards Institution method for testing
46

concrete, the standard describes the method for making, curing,

preparing and testing compressive strength and modulus of cores
and cubes.

4.3.2

EVALUATION OF GROUT PROPERTIES ON CABLE BOLT PERFORMANCE

The evolution of the Single and Double Embedment tests to

evaluate cable bolt performance has allowed the tendon type to
remain constant in order that the effect of grout properties on
system performance can be evaluated.
WATER-CEMENT RATIOS
Goris 1990 conducted tests to evaluate the effect of grouts with
water-cement ratios
between
0.30-0.45 on the
pull out
characteristics of conventional 15mm 7-strand cable using 300mm
embedment. Similar tests were conducted by Hyett et.al. 1992 on
conventional 7-strand cable using water-cement ratios of 0.3, 0.4
and 0.5 using 250mm embedment. Both report a reduction in cable
bolt system performance with increased water-cement ratios.
GROUT STRENGTH AND MODULUS
Double Embedment tests have been conducted by Gale and Fabjanzyck
1987b using 10 strand birdcaged cable at 38 0mm embedment in order
to evaluate the effect of grout strength and modulus. In one
test series the modulus of the grout/resin remained constant
while the UCS was varied and the second test series the UCS
remained constant while the modulus was varied. The tests showed
that both grout strength and stiffness have an effect on cable
bolt system performance.

4.3.3

FIELD SAMPLING OF CABLE BOLT GROUTS

In order that each tendon functions successfully to give optimum

interaction in any reinforcement pattern a high level of quality
control is required. In order to assess the quality of grouts
placed at long tendon reinforced sites routine grout sampling
should be carried out.
Gale and Fabjanzyck 1987a report a suggested method. In order
to allow for high volume sample preparation both in the field and
the laboratory a standard PVC mould was used. The sample moulds
were standard 50mm I.D. PVC tube 105mm long with 27mm long PVC
end caps. For easy release of the samples the tube is split along
its length, prior to use this split and the end caps are taped
and the cylinders mould released. In the field the grout samples
are collected at random from the grouting tube and once poured
are lightly tamped to minimise air entrapment, capped and left
to gel on site for a minimum of 24 hours. Once returned to the
laboratory the samples are wet cured.
Field sampling for quality of control of grout used in the
installation of cable bolts has also been reported by Gendron
47

et.al. 1992, for the Noranda Group mines and other sites in
Canada. Field sampling kits consisting of an aluminum sample
case with six PVC tubes 50mm in diameter and 200mm long were
supplied to mines along with silicone spray for application to
the tubes for easy mould release.
Both parties report that the average field strengths are lower
than equivalent strengths obtained in the laboratory.

48

CHAPTER 5
BRITISH COAL LABORATORY TESTING OF CABLE BOLT SYSTEMS
5.1

AIM OF BRITISH COAL LABORATORY TESTING

The British Coal laboratory test programme using the DOUBLE

EMBEDMENT TECHNIQUE has two main aims:
(i)

Evaluation of current cable bolt consumables (cables and

grouts) including the evaluation of rockbolt systems
(ii) Evaluation of alternative cable and grout types
The nature of the Double Embedment test means that the evaluation
of these tendons and grouts is by COMPARATIVE study.
5.2 TEST MATERIALS
5.2.1

CABLES

CONVENTIONAL 7-STRAND DYFORM CABLE

This conventional cable conforms to BS5896/3, having an ultimate
strength of 3 0 0kN (30tonnes) and elongation of approximately 6%.
The cable diameter is 15.2mm, and is made of 6 strands wound
around a king wire. The wires are multifaceted as opposed to
round as a result of being dieformed in order to improve load
transfer through greater surface area. It is this cable that is
supplied for the manufacture of birdcaged cables and is shown in
Photograph 2.2.
SINGLE BIRDCAGED CABLES
Single birdcaged cables are formed from the above Dyform cable
by unwinding the wires and allowing the natural twist to form
nodal points where the wires come together and antinodal
birdcages where the wires naturally remain parted.
The
wavelength between the nodal points is governed by the twist in
the wire and for UK formed cable it gives a wavelength of
approximately 240mm.
Single birdcages are supplied to British Coal by two
manufacturers :
1.
Manufacturer A (Man.A) whose cables are machine
formed, and the cable ends secured by steel ferrules.
2.
Manufacturer (Man.) whose cables are hand formed
and the cable ends secured by plastic end caps.
A single birdcaged cable is shown in Photograph 2.2.
DOUBLE BIRDCAGED CABLES
Double birdcaged cables are formed in the same manner as single
birdcages but consist of two 7-strand Dyform cables unwound and
brought back together to form the nodal and antinodal regions.
The resulting cable has 14 strands and an ultimate tensile
strength of 600kN (60tonnes) and a wavelength of approximately

49

2 60mm.
The double birdcages are supplied to British Coal by the same two
manufacturers, A and B, who supply the single birdcages and they
are formed by the same two respective methods.
A double birdcaged cable is shown in Photograph 2.1.
ALTERNATIVE CABLE TYPES
The following alternative cables have been tested to evaluate
their performance and the suitability of their use in British
Coal mines; the details of the cables can be found in section
6.3.3 with the test results and discussion:
1.

BULBED CABLE - This type of 14 strand cable was

supplied by Manufacturer C from Australia and is shown
in Photograph 2.2.

2.

NUTCAGED CABLE - This type of cable was supplied in both

the single and double capacity by Manufacturer
and are shown in Photographs 2.2 and 2.1
respectively.

3.

WIRE ROPE - Manufacturer D supplied a type of mine haulage

cable that has potential use as a cable bolt and
is shown in Photograph 2.1.

CUTTABLE CABLES
The Double Embedment technique has been used to evaluate the
performance of cuttable fibreglass birdcaged cables for long
tendon reinforcement of coal mine ribs on the face side.
The test has been used extensively by two manufacturers in the
design of their products in order to produce a cable with optimum
performance for use in the field. The tests have been used to
evaluate the effect of the following:
(i)
the number of strands used (varying from 10 -14)
(ii) the positioning of the strands relative to one
another
(iii) surface profile of the strands.
The initial tests conducted on this type of cable are given in
section 6.3.5, the final design of the two cables and their
system performance will be given in a later ECSC report (Project
Number 7220-AB/838); the cables are supplied by Manufacturer A
and Manufacturer E.

5.2.2

CEMENTITIOUS GROUTS

At the commencement of the cable bolt test programme in 1990

seven grouts were listed for test purposes as shown in Table 5.1.
Of these only four had full underground approval and only grouts

50

1, 2 and 3 were in use for cable bolting at the time,

of the grouts in use contained an aggregate filler.

All three

Of the grouts listed in Table l, only grouts 1, 2, 6 and 7 were

evaluated in the 3 00mm Single Embedment test prior to the
development of the Double Embedment test technique.
TABLE 5.1
CABLE BOLTING GROUTS AVAILABLE IN 1990

GROUT
1
2
3
4
5
6
7

W.S.R.

STRENGTH MPa *1

TIME Days

28

STATUS
*2

0.18

30

40

55

65

FULL
*3

0.18

20

44

64

FULL

0.18

24

44

59

FULL
*4

0.20

15

25

46

0.31

40

50

60

80

PROVISIONAL

0.16

20

^m

64

75

NOT

0.33

20

60

70

NOT

FULL

NOTES
*1

Compressive strengths quoted by manufactures

*2

A product may be either:

a. Fully approved for underground use. This means that
British Coal know the materials chemistry and a hazard
card is in existence.
b. Subject to provisional operational approval, indicating
that its use and thus its experience within British
Coal is still limited. Its chemistry would be known to
British Coal and a hazard card exists.
c. Not approved for use underground. Generally this means
that the product has not been formally submitted for
underground acceptance. (The manufacturer has this
responsibility.)

*3

The manufacturer of this grout at the time was revising the

claimed technical specification for this product. A new
data sheet will quote the following time/strength
development: lday - 40MPa, 3day - 60MPa, 7day - 75MPa,
51

2 8day - 8 0MPa.
*4

Grout 3 is essentially the same material as Grout 2. The

main difference is that Grout 3 contains a finer aggregate
which should be of advantage regarding cable bolting,
easier mixing with hand mixer and less solids residue
remaining when pumped.

Subsequently by 1992 when the testing commenced using the optimum

Double Embedment test design the grouts available for test had
changed.
The four grouts used in the main test program were:
GROUT A (Grout 5)
The grout gained full underground approval and became the most
commonly used grout for cable bolting. The grout is flowable
with a fly ash filler, so making it less gritty and more amenable
to pumping.
This grout was to be used as the 'Standard' for
cable comparison purposes.
GROUT (Grout 1)
A flowable grout with a aggregate filler.
GROUT C (Grout 3)
A flowable grout with an aggregate filler.
GROUT D ( a developmental grout)
Supplied in two separate formulations, F and U.
Both
formulations have an aggregate filler, formulation F was flowable
while formulation U is a of a slightly thicker consistency.
(Neither formulation was approved for underground use at that
time.)
Subsequent to this main test program other grouts
available and their performance assessed using the
Embedment technique.

became
Double

GROUT E
A THIXOTROPIC grout with an aggregate filler.
GROUT F
Produced by the same manufacturer as Grout in order to replace
Grout B, Grout F is THIXOTROPIC with a fly ash filler and of a
far higher yield than its predecessor.
GROUT G
GROUT H
Developmental.
THIXOTROPIC GROUTS
Thixotropic grouts are grouts that have been developed for
specific applications, once energy is no longer applied to them
they will not flow therefore they can be used in heavily broken
ground conditions and the amount of grout loss to the surrounding
52

5.3

TEST PROGRAMME

5.3.1

CABLES

30 0mm SINGLE EMBEDMENT PROGRAMME

This involved testing of Grouts 1, 2 , 6 and 7. These were cast
into 50mm cubes, two samples of each tested at 24Hours, 3 Days
and 14 Days for Uniaxial Compressive Strength.
The same four grouts were also cast with Manufacturer single
birdcage cable, 1 sample of each was tested at 24Hours, 3 Days
and 14 Days.
MAIN DOUBLE EMBEDMENT TEST PROGRAMME
The main test programme involved a comprehensive evaluation and
comparison of:
Manufacturer
Manufacturer
Manufacturer
Manufacturer

A
A
C
D

and Manufacturer SINGLE BIRDCAGED CABLES

and Manufacturer DOUBLE BIRDCAGED CABLES
BULBED CABLE
WIRE ROPE

The main test program for the cables is shown in Table

below:

5.2

TABLE 5.2
MAIN CABLE COMPARISON TEST PROGRAM

CABLE
TYPE

GROUT
TYPE

HOLE
SIZE
(mm)

NO.
Samples
per day

TESTING
TIME
(Days)

Man. A
Double Bird.

52

1,

3, 7,
14, 28,

Man. A
Single Bird.

43

1,

3, 7,
14, 28,

Man.
Double Bird

52

If

Man..
Single Bird.

43

Man. C
Bulbed Cab.

52

If 3, 7,
14, 28,

Man. D
Wire Rope

35

1, 3, 7,
14, 28,

3, 7,
14, 28,
1, 3, 7,
14, 28,

Subsequent cable types tested were also cast with Grout A, 2

samples were tested after 7 and 14 days cure.

53

SHEAR TESTS
Shear tests were conducted on 2 samples of each cable type after
14 days cure. However at the time of writing shear tests had not
been conducted on Man. single birdcage, Wire Rope or Bulbed
cable.

5.3.2 MAIN GROUT PROPERTIES TEST PROGRAMME

For each grout A, B, C, D, FIFTEEN bottle samples were taken to
give
three
density,
compressive
strength
and
modulus
determinations at 1, 3, 7, 14 and 28 days.
Once these results were completed any further testing using the
any of the grouts for Double Embedment testing involved casting
SIX samples for compressive strength analysis at 7 and 14 days
in order to ensure grout quality.
Each Grout A, B, C and D was to be evaluated in the Double
Embedment test as shown in Table 5.3 below.
TABLE 5.3
MAIN DOUBLE EMBEDMENT GROUT TEST PROGRAMME
CABLE
TYPE

GROUT
TYPE

HOLE
SIZE
(mm)

NO.
Samples
per day

Man. A
Double Bird.

52

I, 3, 7,
14, 28,

Man. A
Double Bird.

52

1, 3, 7,
14, 28,

Man. A
Double Bird.

52

1, 3, 7,
14, 28,

Man. A
Single Bird

43

1, 3, 7,
14, 28,

Man. A
Single Bird.

43

1, 3, 7,
14, 28,

Man. A
Single Bird.

43

1, 3, 7,
14, 28,

TEST
TIME
(Days)

CABLE BOLTING GROUTS E, F, G AND H.

Subsequent candidate cable bolting Grouts, E, F, G and H seeking
recommendation for underground use had fifteen 57mm diameter
bottles cast for testing at 1, 3, 7, 14 and 28 days as above.
In addition six BSI 50mm or 100mm cubes moulds were cast
(depending upon which the manufacturer based their data on) for
testing at 3, 7 and 14 days. Two Double Embedment tubes were
54

cast for evaluation of system performance after 14 days cure.

5.4 EXPERIMENT DESIGN

5.4.1

AXIAL TESTING

The basic design of the test method used is taken from Gale and
Fabjanzyck 1987b as already described in section 4.2.2.
300mm SINGLE EMBEDMENT
The first axial pull tests conducted by British Coal were Single
Embedment. Single birdcaged cables were grouted into 3 00mm long
steel tubes with an internal diameter of 4 5mm.
A length of
unbirdcaged cable was left protruding for the jaws of the test
machine to grip.
However the tests were not satisfactory because:
1.

2.

The pull on the protruding tendon caused distortion and

premature break up of the grout initially at the mouth of
the hole, which can then propagate up the hole.
This
failure mode is unlikely to occur in situ.
The stiffness of the system must be determined by
compensation for the stretch of the un-encapsulated section
of tendon.

DOUBLE EMBEDMENT TEST DESIGN

Figure 5.1 shows a sectional diagram of the test assembly
illustrating the set up used for double and single birdcaged
cables.
TUBES
STEEL QUALITY
The steel tubes used are
to DIN 1629/84 ST 52.0.
Yield stress
Tensile Strength
Elongation
Modulus

hot rolled, seamless and conform

Min. 355N/mm2
Min. 500-650N/mm2
Min. 21%
2 05GPa

TUBE WALL THICKNESS

The thickness of the tube walls were designed so that the
yield capacity of the tube was not exceeded and therefore
no significant deformation should occur.
Therefore the
cross sectional area of the tube was made significantly
greater than the cross sectional area of the cable. In the
case of tubes for double birdcaged cables the wall
thickness is 12. 1mm giving a 9:1 ratio in area to the cable
and a factor of safety of 1.4:1 over exceeding its yield
capacity. For single bird cages 10.3mm thick walled tubes
were used giving a 6:1 ratio in area to the cable and a
factor of safety of 2:1 over exceeding its yield capacity.
55

INTERNAL TUBE SURFACE

The internal tube surface needed to be such that no
premature failure occurred between this surface and the
grout. The surface also needed to be such that repeatable
results could be obtained through the virtual reduction of
the effect of factors such as rust and grease.
To meet
these criteria the internal tube surface was threaded with
a 2.0mm pitch and 0.5mm deep thread.
HOLE SIZE
The hole size was chosen such as to represent that used in the
field. Single birdcaged cables are installed in holes drilled
with a 43mm bit, and double birdcages in holes drilled with a
55mm bit. Single birdcaged cables are therefore tested in tubes
with 43mm internal diameter, however double birdcages are tested
in 52mm internal diameter tubes.
The reason being double
birdcaged cables can be installed in 52mm holes in the laboratory
set up but not in the field due to hole length and addition of
grout and breather tubes. As the test is purely comparative the
hole size is not critical.
EMBEDMENT LENGTH
The embedment length needed to be such that repeatable results
could be obtained. In order to meet this requirement at least
1.5 birdcages needed to be fall within the embedment length.
As the wavelength of the UK single birdcage is approximately
240mm a length of 450mm allows for embedment of 1.9 birdcages
(3.8cages in 900mm) .
In the case of a double birdcage the
wavelength is approximately 2 60mm so embedding 1.7 cages per
450mm (3.5 cages in 900mm). Figure 5.1 shows a sectional diagram
of the tested cables.
CHUCK ADAPTORS
The chuck adaptors were designed as a means for the jaws of the
test rig to grip the test assembly without directly gripping the
tube ends which can deform the tube and cause excess confinement
to the test specimen in that region.
The adaptors were
manufactured from 4 60MPa mild steel.
TESTING MACHINE
The testing machine used was a lOOOkN Avery Denison hydraulic
testing machine.
Photograph 5.1 shows the experimental set up in the test machine.
TEST RESULTS
Two load-displacement graphs are generated for each test:
1.
The first graph comes from a LVDT placed directly on the
test assembly at the split in the tube.
This is shown in
Photograph 5.2. The load-displacement characteristic is plotted
56

on a chart recorder, which is shown in Photograph 5.1, to the

left of the testing machine. The transducer originally used had
a calibrated travel distance of 10mm. This was later replaced
with a transducer with a calibrated travel of 20mm due to a
significant number of failures occurring at displacements greater
than 10mm; however all the significant
load-displacement
characteristics (initial and working stiffnesses) were found to
occur within the first 10mm displacement.
2.
A second graph comes directly from the Avery machine itself.
However this load-displacement graph is not a true record of the
system stiffness within the double embedment assembly due to
addition of the deformation of the chuck adaptors as the jaws of
the test machine bite into the mild steel.

5.4.2

GUILLOTINE SHEAR TEST DESIGN

TEST RIG DESIGN

The design of the guillotine shear rig was adopted from that used
by Gale and Fabjanzyck 1987b.
Figures 5.2 and 5.3a/b show the design of the rig manufactured
for the testing of UK Double Embedment test assembly.
Photograph 5.3 shows the rig set up in the testing machine.
The main design considerations were:
1.
The
together
shoulder
2.
The
could be
tubes of

two halves of the shear rig could not be clamped

so as to provide shear resistance therefore spaced
bolts were manufactured.
bushes were press fitted in for removal in order they
replaced with bushes to accommodate Double Embedment
variable outer diameter.

SHEAR TEST RESULTS

As with the results from axial testing two load-displacement
graphs were acquired, one directly the LVDT and the other from
the Avery test machine. The set up of the LVDT can be seen in
Photograph 5.5, the bottom half of the shear frame moves upward
in relation to the top half.
Both sets of results give the same system performance except the
results from the LVDT are on an larger displacement scale.

5.4.3

DETERMINATION OF GROUT PROPERTIES

UNIAXIAL COMPRESSIVE STRENGTH

BSI 1881 details the method for the determination of the uniaxial
compressive strength of concrete, the recommended test samples
are steel cube moulds being either 50mm or 100mm and/or cores
150mm diameter.
57

50mm cubes were originally used to determine grout strengths

within the laboratory, however the method also needed to be
suitable for underground sampling of cable bolt grouts such that
laboratory and field samples were of the same type. Clearly the
use of steel moulds is not feasible for the collection of field
samples. As a result 57mm I.D. 95mm long PVC bottles were
introduced. It was originally intended that the bottles samples
would not need any sample preparation other than lapping of face
ends.
The samples are tested in 500kN hydraulic testing machine. The
recorded compressive strength in kN is converted to MPa using
Hobb's Formula given below:
Hobb's Formula:
Load (

-*"*

"\

0.304(^)+0.848

where:
D = sample diameter
L = sample length
YOUNGS MODULUS
The test method for determination of Young's Modulus used an LVDT
with a maximum gauge diameter of 50mm therefore subcoring of the
57mm diameter bottle samples was necessary. In the laboratory
one of the three samples prepared for test on each day is
subcored to 44mm diameter in order to save on time and cost.
Field samples are not subcored for Young's Modulus.
VISCOSITY
A grout flow channel as shown in Photograph 5.4 was used to
determine grout characteristics. This method was introduced to
replace the purely visual comparison made on the grout types with
regards to flowability and pumpability. The method assumes that
the more flowable the grout the more pumpable it will be.
The method for using the flow channel is given below:
1. Wet completely the channel and tun-dish in water and stand on
end for one minute to drain.
2. Set up level with aid of spirit level attached to channel.
3. Fit tun-dish to closed end of channel and insert plug.
4. Place one quart of sample in tun dish and withdraw plug.
5. Read off on the scale fitted to the channel the distance the
grout flows along it.
6. Wash out immediately.

58

5.5 EXPERIMENT PROCEDURE

5.5.1 PREPARATION OF DOUBLE EMBEDMENT SAMPLES FOR AXIAL AND SHEAR
TESTING
The tubes are butted together and secured at the joint with tape,
correspondingly one end is taped off.
The grout is mixed using a mixer/pump as used underground,
supplied by Manufacturer A, as shown in Photograph 5.7.
A
minimum of one bag is mixed following the manufacturers
instructions for water quantity and required mixing time.
The grout is then pumped into the tubes, once filled the cable
is then slowly inserted and the tubes tamped in order to reduce
air entrapment.
Air temperature and humidity are recorded as these are known to
affect grout properties.
The Double Embedment samples are then bagged and taped off in
order to ensure self curing. The samples are then stored and
allowed to cure for the desired time period.
AXIAL TESTING
For axial testing the tape is removed from the joint and either
end of the cable, the chuck adaptors are then fitted and the
assembly placed in the machine. The LVDT is attached as shown
in Photograph 5.2. Load is then applied at a controlled rate.
SHEAR TESTING
For shear testing the sample preparation tape is also removed.
The rig is split into its two halves and the bottom half bolted
to the bottom of the Avery bed. The test sample is inserted and
the joint aligned with the shear frame face and secured to
prevent movement when the top half of the rig is bolted into
place. The LVDT is attached as shown in Photograph 5.3. Load
is then applied at a controlled rate as used in axial testing.

5.5.2 PREPARATION OF GROUT SAMPLES FOR TESTING

Grouts are mixed in the same way as for preparation of Double
Embedment samples and then pumped into 57mm diameter PVC bottle
samples and either 50mm or 100mm cube samples. These are then
lightly tamped in order to minimise the amount of air trapped.
The bottle and cube samples are then allowed to cure for 24hours
before removal from their respective moulds and placed under
water for the remainder of the cure period.

59

BIRDCAGED CABLES
SECTIONAL DIAGRAM OF TEST ASS EM BLY
DOUBLE BIRDCAGE

MILD STEEL
CHUCKADAPTOR

SINGLE BIRDCAGE

STEEL TUBE

450mm DOUBLE
EMBEDMENT

^ J \
ANTINODE

INTERNALLY THREADED
SURFACE
2.0mm PITCH
0.5mm DEEP

CABLE
WAVELENGTH
260mm
JOINT

(3.5 cages
Per 900mm)

CABLE
WAVELENGTH
240mm

NODE

BRmSHCOAL
APPROVED GROUT

(3.9 Cages per

Per 900mm)
INTERNAL HOLE
DIAMETER 52mm
INTERNAL HOLE
DIAMETER 43mm

FIGURE 5.1

60

Photograph 5.1
Avery Denison Test Machine

Photograph 5.2
Double Embedment Sample with LVDT at Joint in Tube
61

SECTIONAL DIAGRAM OF SHEAR FRAME

DOUBLE EMBEDMENT
TUBE CONTAINING BIRDCAGED
CABLE IN GROUT

HARDENED STEEL
BUSHE9 INTERCHANGABUT
TO ACCOMODATE DIFFERENT
TUBE SIZES

LOAD APPLIED TO LOWER

SECTION OF SHEAR FRAME ONLY
UPPER SECTION REMAINS STATIC

FIGURE S2

62

NOT TO SCALE

J ^

HQT::20596

DO,NOT SCPL.E
REFER TO D-O

-^3-

fc^^A^^?
M&u&

NOTE:- FOR FftBRICfiTED DETAILS OF TEST RIG SEE DRG No HOT 2059?

OS

3%7

05

Ml 2 SOCKET HD CRP SCREU

04

Ml 6 SHOULDER BOLT

03
02

INSERT

8|7M40

SHEAR FRftME UPPER SECTION

BS4360/4i

SHEftR FRA ME LOUER SECTION

BS360/43A

ITEM No.
PRIfCIP. | , Y

REFERENCES
THIS ORG. ON
TEH LIST NO.

HOT -

OSSOCIOTED OND
SIMILOR DROUINSS

HOT

THIS DRPUING I S CONFIDENTIOL

OND I S THE PROPERTY OF
BRITISH COOL PNU KJST NOT
BE REPRODUCED EITHER UHOLLY
OR PORTLY. CLL RIGHTS IN
RESPECT OF POTENTS. OESIGNS
OND COPYRIGHT ORE RESERVED.

J . DIMENSIONS I N MILLIMETRES
I M . E S S OTHERWISE STO I E D.

REMOVE OU. BURRS STOMP. ENGRA VE OR ETCH DRPWNG "

OND SMORP EDGES NUMBER UHERE INDICA TED T H U S :
sj^p

T H I S DROUING I S TO BS SO

TOLETWCES TO BE OS SPECIFIED BELOU. UNLES OTHERWISE STBTED

500
looo 2000
OVER
30
100
MQCHIKD SURFA CES THUS
V
Ig'OJ ZOOQ
UP TO & INCLUDING 30
00
SYMBOLS TO BS .11 p. R.
I F INE
CLETE MOCHINING
o. :s o.2 i 0. I*
UELO STM3CLS TO SS ppftT ?
WELDS TO BE TO : SI SS OND TMS ONE
t
MEDIUM
tOTD HONJOL OF DP>.UIN;
RAM3E KOCHIN ING
2.0
0.
3
O. 5 .i 0. 5 1 C 1 1.5
OFFICE PROCTI.
OND

THE

H0NURL

OF

DSPUIM: O F F ; 3 PRA CTICE.

wro.iNrp

20

5.0

MOTERIOi.
SPEC.
PROTECTIVE.
FINISH

UPDATE CAD FILE ONLY

issu:
OHO No
DOTE
OPP'D

DRN:FH.
CH

" D 'y^
:

DOTE : 2 2 / l 1/93

HEX HD BOLT LENGH'

TO SUIT

3 5 LG

BS43B0/43A

MATERIAL SPEC. No. CFf

DESCRIPTION/SIZE

MATERIAL SCHEDULE FOR FABRICATED ASSEMBLIES

GENERAL ARRANGEMENT OF
G U I L L O T I N E TEST R I G

V^-2i/tr/9S_

D > ^ 7 DTET37^J
" > > >

B.S.W

TECHNICAL SERVICES AND RESEARCH EXECUTIVE

A1

ftz=>

63

"5 S'

DRG. No:- HOT 2 0 5 9 8 .

SHEET

NUMSER

I.

OF

KSRK + IF Trt!3 DRS H!

HOT -2.JS99. J %*&-?n.

' . 0 7 F C C E 0 2 5 1 S DEEP OT CENTRE

D R I L L S f O TOP M 1 2 THRO '

??o
21.87

SPOTFOCE 4 0 WIDE
OPPROX 1 DEEP

SPOTFOCE 8 3 5
O P P R O X I DEEP

"

"

2700
2:.S7
Vy
\ r V

^-.
.!?

"

"

di

123

SCROP S E C T I O N O N o o
(TrPICOL
.PLOCES)
t C 2 2 HOLES
N PLOTE

203

SCROP SECTION ON B-8

(TYPICOL t-PLOCES)

4 2 2 HOLES
I N PLOTE

J2.

28?

123
.S'

C"

IJ
;./?
3' "..-X L

45*

r.:>

g pilli ...

i l . ?

-Rl

g|g

-^2^feS23
^
/>.

;->
\

,1

1.017

2kL
*'^'

SPOTFOCE 0 3 5
N / S ONLY

r-

.baas

TT

1.-20 uIDE 6i CRS

LONG SLOTS IN Pi_T
SP0T--OCE '0 "IDE

_3

SECTION ON RRROw X-X

KOLES

THPO PLT

,> , C " O M F

N/S O N L Y

SECTION ONfiRROWY-Y

DETAIL OF ITEM 02 - SHEAR FRAME (UPPER SECTION)

DETAIL OF ITEM 01 - SHEAR FRAME (LOWER SECTION)

h ic, 2-e

15-

2 1 . 87
2 1 . 75

. 67

35LG

APPRQx

jrn
I

* I 0

DETAI1
K=Tt^IL

ONLY

(1000

1150 / '

TENSILE

U/CUT 1 UIDE
0 . S DEEP

ISOLO M . S B AR
M. S P L T

HEX

.MUT i.

FLOT

2STMK??0580LG

H.S PLT

?0TKK2?0285LG

M. S P L T

C i 50

UOSHER

DETAIL OF ITEM 04 - SHOULDER BOLT

S'RENCH)

OF TEST

R I G * SC^c

B5tJ60/Sa
BS560'^

2 0 T M K M S 0 I 7SLG M . S PLT

SUF?LY U I T H M16

INSERT

WROUGHT STEEL TO BS " 0 PORT I 1983 GRODE 8I7M10

ORRONGEMENT

S O L G M . S BA R

?0TMKX6SXISXG

C HA M F E R

CHQMFR

OF ITEM 03

DRG No HOT 2 0 S ? 8

TOTA L WEIGHT

0 1 SO

N/S

GENEROL

SEE

BStJCO.iSA

-pI

I I
I II

l45'

FOR

op

SSL

Tik

S O T E

30 O/F

ISOLG

BSSe*>/>

M . S BA R

2 O T H K X 6 S X I 5 0 L G M S PLT

SS360/.^

2 O T M K I S 0 ' I 7SLG M . S PLT

B530'>

2 S I W 2 0 3 8 0 L G

M. S PLT

?0TMK.2?028LG

M.S P L T

XSCRIPION'SIZE

8S*6D'
MfcTERlo. ' I C !:

MATERIAL SCHEDULE FOR FA BRICA TED

REFERENCES
" . IS S^ECI^IEO

LIS

NOTE
'~-SEe | " i

UELP

TO

BE

6 mm F I L L E T
U.O. S .

l H [ i amolde IS CO^IKNTie.
o is i< M(CPE*T' c*
BlWSn COt. M 3 ' *CT
K KtMtCDXCD E ) ' < WKXIT
0 *0*MLY. ft.L Kl&wtS I
E s t e : Df poit'i's. t s i o f t
COT-rtUCnl "C *ESEvE.

*,,. D M I i o ^ IM F[t.LKTS
L A c t ' < UBICO.

i . i l >"ne j j io
* ,"5*0 **. or

* * l I tC IO F> S>\\ t
, ' * , ar 9K<kii>c

iF"
65

KXEttrgfj f 0 ns S*tC:r IEP BEOW. 1M.ESS Oi<<BwiSf Steif

i j ^ TQ .
T

AO

tEKvt **.! BLR*S S T * . t O o v t o t o OKWI*C ()~

DNO S - EDGES fctrSCK wCftC JNOICA E3 i v S s ; Q r *

OQXTE
1

RA M*

E j a i t j J t

TECHNICAL

SERVICES

A SSEUEUES

A ND RESEA RCH

I SI:E
UPDATE

C A D R L E ONL"

130 1 0 0 0
I 0 0 0 00
'/'j

/3j

DETRILS OF GUILLO"!
TEST R I G
HOT 20E

EXECUTIVE

Photograph 5.3
Guillotine Shear Frame in Test Machine

67

Photograph 5.4
Flow Channel

68

Photograph 5.5
Grout Mixer/Pump

69

CHAPTER 6
RESULTS AND DISCUSSION OF BRITISH COAL DOUBLE EMBEDMENT TESTS FOR
CABLE PERFORMANCE

6.1

RESULTS FROM 300mm SINGLE EMBEDMENT TEST PROGRAMME

As already described the first pull tests were 3 00mm Single

Embedment using single birdcages. Maximum pull out loads and
failure mechanisms were recorded but not the system performance.
The results are shown in Table 6.1 below.
TABLE 6.1
3 0 0mm SINGLE EMBEDMENT PULL TEST RESULTS
CURING TIME
7 Days

1 Day
GROUT TYPE
*1 GROUT 1
(1)
GROUT 1
(2)
GROUT 2

GROUT 6

GROUT 7

14 Days

MAXIMUM FORCE (kN) / FAILURE MECHANISM

185

288

291

All Wires
Pulled Out

2 Wires Frac.
5 Wires P\Out

All Wires
Fractured

156

267

263

2 Wires Frac.
5 Wire P\Out

2 Wires Frac.
5 Wires P\Out

2 Wires Frac.
5 Wires P\Out

165

169

224

All Wires
Pulled Out

All Wires
Pulled Out

All Wires
Pulled Out

297

288

291

4 Wires Frac.
3 Wires P\Out

All Wires
Fractured

3 Wires Frac.
4 Wires P\Out

166

226

290

All Wires
Pulled Out

All Wires
Pulled Out

All Wires
Pulled Out

NOTES
*1 Grout 1(1) strength and density were low as compared to those
obtained by the manufacturer, therefore the grout was retested
(2).
MANUFACTURER SINGLE BIRDCAGE
45mm DIAMETER HOLE - INTERNALLY THREADED

71

The results are variable but the following conclusions can be

drawn:
1.
Grout 2 and 7 had complete wire pull outs even after 14 days
cure indicating that the grout had unsuitable load transfer
characteristics.
2.
Grouts 1 and 6 had suitable characteristics for effective
load transfer to cause cable failure.
For reasons already discussed in section 5.4.1 no further tests
were conducted using this method.

6.2

INTERPRETATION OF RESULTS FROM DOUBLE EMBEDMENT TESTS

Results plotted are from the LVDT, early tests used a 10mm LVDT
while results from later test used the 20mm LVDT. As a result
any lines terminating before 10mm or between 10mm - 20mm
represent cable rupture, lines terminating at 10mm or 2 0mm
represent termination of test results from the LVDT.

6.2.1

SYSTEM STIFFNESS

Figure 6.1 shows the deformation characteristics for a double

birdcaged cable and the alternative cable types. It can be seen
that three types of behaviour are occurring:
1.

2.

3.

INITIAL STIFFNESS This represents an essentially linear

response related to axial stiffness of the cable, elastic
properties of the grout and the properties of the
adhesional bond between the two. This occurs upto 200kN.
WORKING STIFFNESS This represents the crushing action of
the grout within the birdcages and the wedging action
against the borehole wall as the antinodal regions try to
pull through the grout at the nodal regions. For comparison
purposes this is calculated at loads from 200kN - 400kN
although the working stiffness is maintained upto loads of
500kN.
FINAL STIFFNESS This represents continued grout crushing,
some pulling of the wires through the grout and steel yield
upto failure, 500kN - 600kN.

For comparison purposes the initial and working stiffness are

quoted in order to compare the performances of the different
cable types as this is more accurate than visual comparison of
the graphs.
The stiffnesses are quoted in kN/mm and assume
linear deformation between 0 - 200kN and 200kN - 400kN therefore
it is an underestimate of the true system performance, however
as already stated the tests are purely for COMPARISON purposes.
For comparison purposes initial and working stiffness are quoted
for 14 day grout cure because at this time the grout will have

72

reached over 90% of its final strength.

Similar deformation characteristics are
birdcaged cables as shown in Figure 6.2.

6.2.2

defined

for

single

FAILURE CHARACTERISTICS OF BIRDCAGED CABLE BOLTS

WIRE FAILURE
Figure 6.3 shows the typical failure characteristics of a double
birdcaged cable bolt.
The number of wires that fail at any one given time will depend
on how evenly each wire is loaded which depends upon the exact
position of each wire within the borehole and how well grouted
that wire is. On continued loading the remaining unbroken wires
either fail and/or pull out of the grout.
Photograph 6.1 shows the complete wire failure of one particular
double birdcage sample with an antinode at the joint.
Similarly
Photograph 6.2 shows the failure of a double birdcaged cable with
a node at the joint, in this case one king wire was left unbroken
and on continued loading began to pull out of the grout.
After loading and failure of the wires at the joint a sample was
sectioned at various intervals along its length.
Figure 6.4
shows sections from a node and an antinode, the cracked grout
between the wires clearly shows that the grout has failed under
compression.
BOREHOLE WALL FAILURE
Photograph 6.3 shows a borehole wall failure.
The internal
surfaces of the tubes were threaded in order to prevent this type
of failure, but it was observed. It occurred very rarely on the
pull tests conducted after 24 hours cure when the grout has a
relatively low strength.
GROUT FAILURE
Photograph 6.4 shows grout failure which, as with borehole wall
failure, usually occurs at 24 hours grout cure when it has
relatively low strength. It is characterised by pull out of the
cable at very low loads.

73

6.3 CABLE RESULTS AND DISCUSSION

6.3.1

2X7-STRAND DYFORM CABLE

The testing of two 7-strand Dyform cables in a 52mm hole was

conducted in order to show the improvement in system performance
due to birdcaging the cables.
Figure 6.5 shows a sectional diagram of the test assembly and the
test results are shown in Figure 6.6.
The results clearly show the advantage of birdcaging the cable.
The 2x7-strand cable starts to pull out of the grout after 50kN
load. At continued loading upto the maximum loads for the two
samples, (584kN and 564kN), shear failure of the grout cusps
occurs as the wire is pulled through the grout. After this load
drops off as the cables pull out at a rate controlled by the
residual shear strength of the grout.

6.3.2 DOUBLE AND SINGLE BIRDCAGED CABLE BOLTS

COMPARISON OF DOUBLE BIRDCAGES SUPPLIED BY MANUFACTURERS A &
Figure 6.7 graphically compares the results for the two cables
after 14 days grout cure.
Table 6.2 shows the initial and working stiffnesses of both
manufacturers cables after 1, 3, 7, 14 and 28 days grout cure.
After 14 days cure the average initial stiffness for Manufacturer
A is 297kN/mm and the average working stiffness 138kN/mm,
correspondingly results for Manufacturer are 325kN/mm and
150kN/mm. This system performance will be also controlled by the
grout properties, in the case of the two sets of data separate
grout mixes were used, however, grout sampling showed that both
grout mixes were within acceptable limits. Given the effect of
the grout the results show no significant differences.
As a result of these tests a lower acceptable working stiffness
was of lOOkN/mm was adopted in order that future consumables
assessed were of a high standard.
COMPARISON OF SINGLE BIRDCAGES SUPPLIED BY MANUFACTURERS A &
Tests on single birdcages supplied by Manufacturers A and were
conducted with Grout A at 1, 3, 7, 14 and 28 day periods as for
the double birdcaged cables. However the results were lost in
the TSRE fire incident in December 1993.
Analysis of the results prior to the fire showed no significant
differences between Manufacturer A and and repeat tests were
only carried out on Manufacturer A single birdcage with Grout A
after a 14 day cure period. The system performance from these
tests is shown in Figure 6.7.
Calculation of the initial stiffness of a single birdcaged cable
gives 167 kN/mm and a working stiffness of 63kN/mm, therefore a
74

single birdcaged cable has half the ultimate strength and

correspondingly half the initial and working stiffness as
compared to double birdcaged cable.

6.3.3 ALTERNATIVE CABLE TYPES

BULBED CABLE
This double bulbed cable was supplied by Manufacturer C from
Australia.
Figure 6.8 shows a diagram of the double bulbed cable within the
Double Embedment test assembly. Photograph 2.2 shows a single
bulbed cable as used in the construction of a double bulbed
cable. The cable is manufactured from round wire which has a
lower cross sectional area and therefore a lower ultimate tensile
strength than UK Dyform wire. The bulbed cable is formed by
gripping a conventional 15mm diameter 7-strand cable and pushing
the wires apart.
The results
Table 6.3.
obtained by
is not much
compared to

for system performance are shown in Figure 6.10 and

The ultimate strength is 530kN compared to the 600kN
UK 14 wire cables. The working stiffness, however,
lower than that of a UK double birdcage, 122.9kN/mm
149.8kN/mm.

The bulbed cable design creates the same system performance as

birdcaging the cable. If the bulbing is applied to UK Dyform
cable there should be no reason why it would not perform as
adequately as a birdcaged cable.
NUTCAGED CABLE
The double nutcaged cable was supplied by Manufacturer in two
designs, Design A and Design B. These designs are shown in
diagrammatically as tested in the Double Embedment technique in
Figure 6.9 and Design is shown in Photograph 2.1.
The cable in its single form has been tested in the Double
Embedment test in the laboratory and by field pull tests in
Canada where in 1991 it was considered as a potential replacement
for the conventional 7-strand cable under certain mining
conditions (Hyett et.al. 1993). The design was assessed for use
in the UK as an alternative to double birdcages if its
performance could be shown to be acceptable. The major advantage
of this double cable is that it can be installed in a 43mm hole.
The results are shown in Figure 6.10 and Table 6.3.
Design A
The results clearly show that design A has insufficient
nutcages to create the necessary crushing and wedging
action responsible for high working stiffness.
Design
The results show a dramatic improvement in working
stiffness, however this is still half that of a
75

conventional birdcage, 69.0kN/mm as compared to 149.8kN/mm.

The working stiffness of the cable design could be improved by
the addition of further nuts, however the operational advantage
of installing it in a 43mm hole as opposed to a 55mm hole may
offset the reduced system performance.
WIRE ROPE
A type of mine haulage rope was supplied by Manufacturer D.
Figure 6.11 diagrammatically shows the type of coreless wire rope
supplied. Two sets of tests were conducted, firstly on a 28mm
diameter rope and subsequently on 32mm diameter rope. Photograph
2.1 shows the 32mm rope tested.
The rope was supplied as an alternative to the double birdcage,
the possible advantage of this cable was installation in a
smaller hole size, 35mm for the 28mm diameter rope, with the
grout being pumped up the centre core and thus eliminating the
need for a grout tube.
The results are shown in Figure 6.12 and Table 6.4.
28mm Diameter Rope
The results for the 28mm diameter rope, after 14 days cure,
gave an ultimate tensile strength of 550kN and a working
stiffness of 82kN/mm, both of which are inferior to those
of a double birdcage.
32mm Diameter Rope
The increase in diameter correspondingly gave an increase
in UTS to 660kN and the working stiffness reached an
acceptable value of 106kN/mm, however this was accompanied
by the need to increase the hole size from 35mm to 38mm.
The Double Embedment results show that the 32mm diameter rope has
acceptable system performance and could be used as an alternative
if cost competitive and easy to install in the field.
40TONNE BIRDCAGED CABLE
Manufacturer supplied a birdcaged cable for use in a 43mm hole
in place of a single birdcaged cable for specific applications.
The cable consisted of 14 wires manufactured from two 7 wire
strands, each being 12.7mm in diameter. This is compared to a
standard single birdcage with 7 wires manufactured from one
15.2mm diameter strand. The 40tonne birdcage wavelength is
comparable to a single birdcage, approximately 240mm.
Figure 6.13 shows the characteristic system performance of the
40tonne cable. The initial stiffness is 188kN/mm and the working
stiffness is 65kN/mm and is therefore comparable to a single
birdcage, with an initial stiffness of 167kN/mra and a working
stiffness of 63kN/mm.
Although the 40tonne cable or other UTS variants may be useful
for specific applications, there is however the possibility of
mistaking the 40tonne variant with the 60tonne birdcage. It is
76

thus imperative that if used the cable is clearly marked so that

its capacity
can be
identified both before
and
after
installation.

6.3.4 REINFORCING TENDONS FOR 27mm HOLES

ROOFBOLTS
The AT bolt, currently used in all UK coal mines replaced the
BS4449 bolt. Double embedment tests were carried out on these
two types of bolt to determine their system performance with
resin supplied by Manufacturer C.
The 32mm diameter high
strength 'Big Bolt' was also assessed. All tests were carried
out at 250mm embedment which was the embedment length used for
underground pull tests at the time.
BS4449 BOLT
The nominal 20.0mm diameter BS4449 bolt is made form steel
conforming to BS 4449 : 1988 (Carbon Steel Bars for the
Reinforcement of Concrete).
Steel Grade : 4 60N/mm2.
Elongation : min. 12%
Yield Strength : 15tonnes.
AT BOLT
The nominal 21.7mm diameter 'Australian Technology' AT bolt
is manufactured
from homogeneous microalloyed
steel
conforming to BS4449 : 1988 with the following exemptions:
Maximum Carbon content : 0.3%
Maximum Manganese content : 1.6%
Vanadium content : 0.2 - 0.25%
Steel Grade
: 680N/mm2
Elongation
: Min. 18%
Yield Strength : 25tonnes.
The Ultimate Tensile Strength (UTS) is not specified but is
expected to be 20% greater than the specified yield
strength.
The nominal core diameter is 21.7mm circular profile with
low profile (0.5 - 0.75mm) transverse ribs with a left hand
spiral on both sides of the bolt.
HIGH STRENGTH 'BIG BOLT'
The High Strength 'Big Bolt' is manufactured from the same
steel as an AT bolt but has a 30.5mm core diameter with low
profile ribs. The yield strength is Sltonnes.
The results are shown in Figure 6.14 and are compared with the
performance of a double and single birdcage in Figure 6.15.
The results in Figure 6.14 clearly shows the yield of each of the
three systems; 15tonnes, 27tonnes and 45tonnes for the BS4449,
AT and Big Bolt respectively for 250mm Double Embedment. The
results clearly show the enhanced performance of the AT bolt
compared to the BS4449.
77

Figure 6.15 compares the AT and Big Bolt with a single and double
birdcaged cable. The AT bolt and the single birdcaged cable both
have a similar UTS, AT bolt 31tonnes and a single birdcage
3 0tonnes, however the single birdcage has less than half the
system stiffness compared to an AT bolt. Upto loads of 20tonnes
the AT bolt provides 260kN/mm reinforcement while the single
birdcage provides lOOkN/mm.
The double birdcage and Big Bolt have an UTS of 60tonnes and
62tonnes respectively. Upto loads of 40tonnes they provide a
reinforcement of 220kN/mm and 330kN/mm respectively and therefore
both maintain high levels of system stiffness provided by the AT
bolt at higher loads.
ALTERNATIVE TENDONS FOR 27mm HOLES
It would be advantageous to find a long tendon reinforcement
system capable of being installed. in 27mm holes for specific
applications that was not restricted by roadway height as the
conventional roofbolts are.
Two types of tendon have been evaluated, both capable of being
installed in 27mm holes and can be coiled as with conventional
birdcages in order to supply lengths greater than 2.4m.
The two types evaluated are the single nutcage and
minesweeper cable, the results are shown in Figure 6.17

the

1.

SINGLE NUTCAGE
Figure 6.16 shows a sectional diagram of the tested cable
which is the same as that used in the double nutcage, it
therefore has a UTS of 300kN. The single nutcage was tested
resin bonded and grout bonded.
The results show that the performance characteristics
for resin bonded samples were extremely poor. Although the
performance of the grout bonded samples were better they
were still far inferior to that of an AT bolt.
The single nutcage in this form is not suitable for
roof reinforcement however it may have a potential use for
solid side rib support when grout bonded.

2.

MINESWEEPER
This 22mm diameter cable was supplied by Manufacturer F and
is similar in appearance to the wire rope. The cable was
resin bonded and the results are shown in Figure 6.17.
The results show a lower system performance and an UTS
only two thirds that of a conventional roof bolt, therefore
this would not be suitable for long tendon reinforcement.

6.3.5 CUTTABLE CABLES

Two types of cuttable cable made from fibreglass were supplied
at their design stage by Manufacturers A and E in order to meet
a requirement within British Coal for a non metallic tendon to
78

support the face side of roadways that would eventually be cut

by the shearer.
A considerable number of designs were supplied and tested for
both manufacturers, however results will not be fully discussed
at this stage but will be included in a more extensive study of
rib reinforcement materials under ECSC project number
7220AB/838.
Nearly all the results obtained from cuttable cables were lost
in the fire. The two designs used in the field are currently
being retested.
Figure 6.18 shows a sectional diagram of the tested cables and
Figure 6.19 shows the results from tests performed on initial
designs supplied.
Manufacturer E.
The company supplied two cable types both manufactured from
7mm diameter strands with an UTS of 30kN (3tonnes) . Both the
cables tested had the reinforcing strands centred around a spacer
with an integral breather tube running up the centre. The spacer
separated the strands to give a maximum cable diameter of 48mm.
The wavelength of each cage was 450mm so a node was placed at the
split in the tube with a full cage either side.
Type A
The cable had 10 strands, and was grey coloured due to
integral antistatic protection.
The UTS is 300kN
(3 0tonnes).
Type
This cable had 12 strands and was black in colour due
to an external antistatic coating that gave a rougher
textured finish which was hoped would aid load
transfer characteristics. The UTS is 360kN (36tonnes).
Manufacturer A.
This company supplied an initial cable type consisting of
14 strands 5mm in diameter with a nominal UTS of 20kN each,
therefore producing a cable with an UTS of 280kN (28tonnes) . The
strands were separated around an spacer to give a maximum cable
diameter of 45mm. The wavelength of each cage was 450mm so a
node was at the split with a full cage either side. The tested
cables were white in colour with a external cross hatch
reinforcing strands to aid load transfer characteristics.
Test results: Manufacturer A,
The initial results show that upto 284kN of reinforcement
can be obtained with a working stiffness that is comparable to
that of a single birdcaged cable bolt.
Test results: Manufacturer E,
The Type cable achieved upto 180kN reinforcement before
failure of the bond between the grout and cable interface.
Further designs from both Manufacturers were subsequently tested
79

and both now produce a cable type in underground use.

6.3.6 EFFECT OF ANTINODE/NODE AT JOINT AND REDUCED EMBEDMENT

LENGTH
EFFECT OF ANTINODE/NODE AT JOINT
Tests were conducted in order to assess the effect of either an
antinode or a node at the joint in the Double Embedment test.
In a underground situation there would be no easy method of
determining whether an anti-node or node were reinforcing a
dilating parting plane between strata.
Figure 6.20
results.

shows the test assemblies and Figure 6.21 the

The results for an average of 2 tests show that at 450mm Double

Embedment with an antinode at the joint the initial stiffness is
297kN/mm and the working stiffness is 138kN/mm while the initial
and working stiffnesses for a node at the joint are 250kN/mm and
141kN/mm respectively.
Theoretically the antinode would be
expected to give a lower system stiffness because as the wires
crush the grout within the antinode there is some grout loss
through the free surfaces allowing for reduced pull out
resistance.
However test results show that there is no
significant difference between the node and antinode at the joint
for 450mm embedment.
Given that there is no easy way in the field of telling whether
a node or antinode is reinforcing a dilating joint the laboratory
test results show that this knowledge is not critical.
EFFECT OF REDUCED EMBEDMENT LENGTH 350mm
In an under ground situation roof dilation may occur at multiple
points along the length of the cable bolt at any spacing,
consequently the embedment length was reduced to assess
reinforcement capacity with both an antinode and node at the
joint for 350mm Double Embedment.
At 350mm Double Embedment with a node at the joint one full
birdcage falls either side of the joint, in the case of an
antinode at the joint two half cages fall either side of the
joint.
The test results are shown in Figure 6.21.
Results for a node at the joint show no significant difference
to results for a node at the joint at 450mm embedment, the
initial stiffness is 292kN/mm and the working stiffness 163kN/mm.
With an antinode at the joint there is also no significant
difference in performance to an antinode at the joint for 450mm
embedment, the initial and working stiffnesses being 254kN/mm and
99kN/mm respectively.
80

However above 500kN with an antinode at the joint for 350mm

embedment there is a significant reduction in system stiffness.
This can be attributed to the lack of fully formed cages either
side of the joint.

6.4 RESULTS FOR SHEAR TESTING

6.4.1 INTERPRETATION OF RESULTS
Figure 6.22 shows the first set of results carried our using the
guillotine shear frame on double birdcaged cables and shows the
deformation
characteristics
of
sheared
tendons,
initial
stiffness, initial yield and working stiffness.
The INITIAL YIELD is defined by an inflection in the shear force
displacement curve after which a decrease in the rate of shear
force per unit displacement occurs.
The INITIAL STIFFNESS is the rate of increase of shear force per
unit increase in shear displacement up to the point of initial
yield.
The WORKING STIFFNESS is the rate of increase in shear force per
unit increase in shear displacement from the point of initial
yield.
The post peak load deformation is governed by the rate at which
the wires are broken, which is dependant upon their position
relative to the shear surface. This post peak deformation is not
shown on future results.
At the time of writing shear tests had not been conducted on
either the AT Bolt or high strength 'Big Bolt'.

6.4.2 2X7-STRAND DYFORM CABLE

2x7-Strand Dyform cable was embedded in 52mm diameter tubes in
order to compare the shear characteristics of an unbirdcaged
cable with a birdcaged cable.
Figure 6.23 shows the results of two tests which are compared to
a birdcage node at the tube joint and Table 6.5 shows the average
initial stiffness, initial yield and working stiffness.
The maximum load for the birdcage and the Dyform cable Test 2 are
similar, 456kN and 458kN respectively. The maximum load achieved
on Test 1 was 516kN, the exact maximum capacity will depend upon
the orientation of the cable respective to shear.
The initial stiffness and initial yields for the 7-strand Dyform
cable are very similar to a double birdcage node, however the
working stiffnesses are more variable, due to the exact
81

positioning of the wires in the hole relative to the direction

of load.

6.4.3 DOUBLE BIRDCAGED CABLES

COMPARISON OF MANUFACTURER A AND BIRDCAGES
Shear tests were carried out to evaluate the performance in shear
of double birdcaged cables supplied by Manufacturer A and B.
Figure 6.24 and 6.25, and Table 6.5 show the results.
Figure 6.25 shows the results when an antinode was placed at the
joint. Table 6.5 shows there is no significant differences in
initial stiffness, initial yield and working stiffness. Ultimate
loads varied between 424kN - 464kN depending upon the exact
positioning of the wires, in th case of Tests 1, 2 and 3 some
peripheral wires were sheared before peak load was reached.
Figure 6.24 shows the results when placing a node at the joint.
The results are more variable for two reasons:
1. the relative position of the node within the tube
relative to load direction
2. the positioning of the wires in the antinodes either side
of the node.
When taking these variables into account there is no significant
difference in performance between the two cable types.

6.4.4 COMPARISON OF NODE/ANTINODE AT JOINT

Figures 6.26 and 6.27 and Table 6.5 show the results of placing
a node or antinode at the joint for manufacturer A and
respectively.
The results show that:
1.
2.
3.

Initial stiffnesses for an antinode are higher than for a

node and maintained for higher loads.
Working stiffnesses are similar for both the antinode and
node.
Lower ultimate loads are obtained with an antinode at the
joint due to preferential working and failure of peripheral
wires.

6.4.5 SHEAR BEHAVIOUR OF 24HOUR CURED GROUT

Tests were conducted after a 24Hour cure period for Grout A to
obtain the shear reinforcement available on cable placement
before the grout has reached its full strength properties.

82

Figure 6.28 and Table 6.5 shows the results. At 24hours the
grout had a strength of 40MPa and a modulus of 14GPa, while after
14 days the strength reached 65MPa and 18GPa.
The results show a reduced initial stiffness and initial yield
due to the weaker grout, however working stiffness is comparable
to a grout with full strength characteristics. The peak load is
reduced as a result of the wires coming into contact with the
borehole wall sooner due to reduced initial stiffness and yield.

6.4.6 SHEAR BEHAVIOUR OF SINGLE BIRDCAGED CABLE

Tests were conducted to assess the shear performance of a single
birdcage cable with a node and antinode at the joint.
Results are shown in Figure 6.29 and Table 6.5
Two tests were carried out on the an antinode and a node at the
joint. However results needed careful interpretation due to some
shear of tube faces. Calculations of initial stiffness, initial
yield and working stiffness were taken from the least effected
samples and are given in Table 6.5 below.
The initial stiffnesses for a single birdcage are similar to
those for a double birdcage. The working stiffnesses are half
that of a double birdcage and correspondingly the maximum loads
are half.

83

TABLE 6.5
SHEAR TEST RESULTS
INITIAL STIFFNESS, INITIAL YIELD AND WORKING STIFFNESS AFTER 14
DAYS CURE

Cable
Type

2x7-Strand
Dyform
Cable

Initial
Stiffness
0 - lOOkN
(kN/mm)
1.
2.

50.0
50.0

Initial
Yield
(kN)
115
115

Working
Stiffness
200kN-30kN
(kN/mm)

Maximum
Load
(kN)

10.5
13.3

516
458

Man. A DOUBLE BIRDCAGE

Node

28.6
40.0

105
105

16.9
17.2

448
456

Antinode

66.7
76.9

140
150

17.5
16.1

448
438

Antinode
24 Hours

35.7
38.5

100
125

18.2
16.6

368
364

Man. DOUBLE BIR]DCAGE

Node

40.0
43.5

125
115

14.3
17.2

504
498

Antinode

62.5
62.5

150
150

19.6
17.5

424
464

Man. A SINGLE BIRI5CAGE

Node

35.7

100

9.6

238

Antinode

51.7

100

13.9

206

84

450mm DOUBLE EMBEDMENT TEST

CABLEBOLT DEFORMATION CHARACTERISTICS
700

450mm DOUBLE EMBEDMENT TEST

CABLEBOLT DEFORMATION CHARACTERISTICS
400

300
8TlfTNE89

co
Ln

10

DISPLACEMENT (mm)
DOUBLE BIRDCAGE DOUBLE NUTCAGE

DISPLACEMENT (mm)
BULBED CABLE

WIRE ROPE

CURETIME:14DAYS

SINGLE BIRDCAGE SINGLE NUT CAGE

CURE TIME: 14 DAYS

FIGURE t\

fiOUflE 62

10

450mm DOUBLE EMBEDMENT TEST

DOUBLE BIRDCAGED CABLEBOLT
FAILURE CHARACTERISTICS

CROSS SECTION OF NODAL & ANTI-NODAL REGIONS

OF DOUBLE BIRDCAGE SAMPLE SHOWING FAILED GROUT

700

ANTI-NODE

600 -

i\

: il

500
400

M
;|
M

: '1
: II

(3 300 -

'. ' \
: \
: \
T

00

200

; 1
' ' 1

'
1
' '1

100

NODE

/" "

*
I

1 \l

*>

8 10 12 14 1 18 20 22 24 28 28 30

DISPLACEMENT (mm)
FAILURE OF ALL WIRES FA ILURE OF WIRES

FAILURE OF 12 WIRES

N.B.
NOT TO SCALE
WIRE ARE MULTIPACETEO EXCEPT TWO CENTRAI. KJNQ WIRES

CURE TIME: 14 DA YS
GROUT A

FIOUAE &3

fiouRe a

Photograph 6.1
Double Birdcage Wire failure, Anti-node at Joint

jjtaAlii

SB

asai ...

<-\mt .*">'

.._
*

Photograph 6.2
Double Birdcage Wire failure, Node at Joint
87

Photograph 6.3
Borehole Wall Failure

Photograph 6.4
Grout Failure
88

2 7-STRAND DYFORM CABLE

SECTIONAL DIAGRAM OF TEST ASSEMBLY

450mm DOUBLE EMBEDMENT TEST

MNF.A 2 7-STRAND DYFORM CABLE &

DOUBLE BIRDCAGE CABLE
70.0

2 7-STRAND DYFORM
CABLES SECURED TOGETHER

CHUCK
ADAPTOR

CROSS SECTION
oo

JOINT

QROUTA

0
450mm DOUBLE
EMBEDMENT
INTERNAL HOLE
DIAMETER 52mm

8 10 12 14 16 18 20 22 24 2 28 30

DISPLACEMENT (mm)
DOUBLE BIRDCAGE
Max. Load 624kN Cable Failure

1. 2x7 STRAND DYFORM CABLE

Max. Load 574kN Bond Failure

2. 2x7 STRAND DYFORM CABLE

Max. Load 568kN Bond Failure
QROUTA
CURE TIME: 14 DAYS
HOLE SIZE : 52mm

FIOJfiE &5

FIOJAE

450mm DOUBLE EMBEDMENT TEST

TABLE

MAN.A & MAN.B DOUBLE BIRDCAGES

MAN.A SINGLE BIRDCAGE

S.2

DOUBLE PIRJPCAGED CABLES

SYSTEM

PERF ORMANCE

INITAL STIF F NESS ; 0 - 200kN

(kN/mm)
WORKING STIF F NESS : 200kN - 400kN
(kN/mm)
Manufacturer A DOUBLE BIRDCAGE + GROUT A
Cure
Time
(Days)

Max.
Load
(kN)

Inital
Stiffness
(kN/mm)

519
301

181.2
266.7

629
621

250.0

637
* 585

222.2
250.0

14

628
634

307.7
285.7

28

634
636

200.0
307.7

Average
INITAL
Stiffness
(kN/mm)

Working
Stiffness
(kN/mm)

Average
WORKING
Stiffness
(kN/mm)

29.0
224.0

29.0
117.6

250.0

117 .6

236.1

114 .3
125.0

119.7

296.7

142.9
133.3

138.1

253.9

129.0
125.0

127.0

VD
O

Grout F ailure
Borehole Wall F ailure
Node at Split
Manufa cturer DOUBLE BIRDCAGE GROUT A

8 10 12 14 16 18 20 22 24 2 28 30

DISPLACEMENT (mm)
MAN.B DOUBLE BIRDCAGE MAN.A SINGLE BIRDCAGE
Max. Load 618kN
Max. Load 302kN

Cure
Time
(Days)

Max.
Load
(kN)

304
335

160.0
133.3

146.7

621
518

266.7
235.3

251.0

619
623

307.6

617
620

285.7
363.6

625
623

333.3

3
7

DOUBLE BIRDCAGE
Max. Load 616kN

14
28

CURE TIME: 14 DA YB

Inital
Stiffness
(kN/mm)

AVERAGE
INITAL
Stiffness
(kN/mm)

(kN/mm)

Grout failure
Borehole wall failure

AVERAGE 1
WORKING
Stiffness 1

(kN/mm) II
119.8
114.3

117.1

117.6
307.6

GROUT A
FI OiRE 5 7

, Working
Stiffness

324.7

117.6
158.7
140.8

149.8

155.0
333.3

155.0

DOUBLE NUTCAGES

BULBED CABLE

SECTIONAL VIEW OF TEST ASSEMBLY

SECTIONAL DIAGRAM OF TEST ASSEMBLY

DESIGN A

TWO 7-STRAND
ROUND WIRED CABLES
SECURED TOGETHER AT
INTERVALS ALONG THEIR
LENGTH

450mm DOUBLE
EMBEDMENT

DESIGN

TWO 7-STRAND
DYFORMED
CABLES WITH
NUTONWNG / $
WIRE SECURED
TOGETHER AT
VARIOUS
INTERVALS ALONG
THEIR LENGTH

200mm
INTERNAL HOLE
DIAMETER : 62mm

NUTCAGED
LENGTH
150mm

INDIVIDUAL BULB
DIAMETER 35mm

INDIVIDUAL CAQE
DIAMETER Z*rm

QROUTA

BULBED LENGTH 100mm

UNBULBED LENGTH - 100mm

ROJRE &

0R0UTA

INTERNAL HOLE
DIAMETER 43mm

& g

450mm DOUBLE
EMBEDMENT

450mm DOUBLE EMBEDMENT TEST

MAN.B DOUBLE BIRDCAGE, DOUBLE NUTCAGE
BULBED CABLE
700

TABLE

6 3

ALTERNATIVE CABI.R ; SYSTEM PERF ORMANCI^

Mapu.pmrer , BIRDCAGE. Manufacturer DOUBLE NTCAGE 11
a&AmBLiajB
*
INITAL STIFFNESS : 0 - 200kN
(kN/mm)
WORKING STIF F NESS : 200kN - 400kN
(kN/mm)

DOUBLE BIRDCA GE
.DOUBLE NUTCA GE
DESIGN

Cure
Time
(Days)

Max.
Load
(kN)

DOUBLE NUTCA QE
DESIGNA

Inital
Stiffness
(kN/mm)

AVERAGE
INITAL
Stiffness
(kN/mm)

Working
Stiffness
(kN/mm)

AVERAGE
WORKING
Stiffness
(kN/mm)

M a n u f a c t u r e r D O U B L E BIRDCAGE + GROOT A
7
14

619
623

307.6

617
620

285.7
363.6

117.6
307.6
324.7

DOUBLE NUTCAGE
7
14

0 L_J

I ' l l

57.1
62.5

575
546

69.0
57.1
DOUBLE

DISPLACEMENT (mm)
MAN.B DOUBLE BIRDCAGE

DOUBLE NUTCAQE DESIGN A

Max. Load 618kN Cable Failure

Max. Load 546kN Pull Out

7
14

BULBED CABLE
Max. Load 530kN Cable Failure

CURE TIME: 14 DAY3

QROUTA

f I OURS ft IS

19.6
16.5

18.1

30.3
63.1

32.3

31.3

DESION GROOT A

606
606

166.7
153.

160.3

61.5
51.9

56.7

598
608

250.0
222.2

236.1

81.6
56.3

69.0

BULBED CABLE + GRODT A

7

DOUBLE NUTCAGE DESIGN

149.

D E S I G N A + GROOT A
59.8

ITOTCAOE

2 4 8 10 12 14 16 18 20 22 24 2 28 30

Max. Load 68 Wire Failure

519
528

117.6
158.7
140.8

14

531
531

160.0
166.6

163.3

96.2
88.9

92.6

530
526

235.3
25.7

260.5

133.3
112.4

122.9

HOLE S I Z E S :
D o u b l e Birdc ago
Bulbed C a b l e
D o u b l e Nutca ge

52mm
52mm
. 4 3 mm

450mm DOUBLE EMBEDMENT

WIRE ROPE
SECTIONAL DIAGRAM OF TESTED CABLE

DOUBLE BIRDCAGED CABLE & WIRE ROPE

28mm 6x7 (6/1) & 32mm 6x7 (6/1)
700
32mm WIRE ROPE
DOUBLE BIRDCAGE

600

_ 28mm WIRE ROPE

500

WIRE ROPE
32mm DIAMETER CABLE
38mm HOLE

400

28mm DIAMETER CABLE

35mm HOLE

O
to

300

6x7 (6/1) CORELESS

RIGHT HAND LANG'S LAY

200

100
GROUTA

KS
J

4 6 8 10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)
DOUBLE BIRDCAGED CABLE
WIRE ROPE 28mm Sx7 (8/1)
Max. Load 018kN Cable Failure Max. Load 553KN Cable Failure

WIRE ROPE 32mm 6x7 (6/1)

Max Load 06 Cable Failure
QROUTA
HOLE SIZE : 35fnm 38mm Respectively
28mm & 32mm 6x7 (6/1) Right hand Lang'e lay
FIGURE cU1

FIOURE &1?

TABLE

450mm DOUBLE EMBEDMENT

6.4

MAN.B 40TONNE BIRDCAGED CABLE

MAN.A SINGLE BIRDCAGED CABLE

ALTERNATIVE CABLES : SYSTEM PERF ORMANCE

MnaugftCtur B DOUBLE BIRDCAGE t. BRIDN ROPE
INITAL STIFFNESS : 0 - 200kN (kN/mm)
WORKING STIFFNESS : 200kN - 400kN (kN/mm)

Cure
Time
(Day)

Max.
Load
(kN)

Inital
Stiffness
(kN/mm)

AVERAGE
INITAL
Stiffness
(kN/mm)

Working
Stiffness
(kN/mm)

500
AVERAGE
WORKING
Stiffness
(kN/mm)

Manufacturer DOUBLE BIRDCAGE + GROUT A

7
14

619
623

307.6

617
620

285.7
363.6

117.6
307.6
324.7

117.6
158.7
140.8

149.8

28am HIRE ROPE +.GROUT A

7
-fe
14

554
550

250.0
210.5

230.3

85.1
69.2

77.2

553
548

250.0
285.7

267.9

75.2
88.5

81.9

32mm WIR]i ROPE OROUT

7
14

666
668

285.7
285.7

285.7

108.7
104 .2

106.5

666
665

285.7
285.7

285.7

110.5
106.4

108.5

140LB SIZE S :
Doukile Birdc age
28mn Hire Rope
32mnt Hire Ro ?e

52mm
35mm
38mm

J L
8 10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)
MAN.A SINGLE BIRDCAGE MAN.B 40TONNE BIRDCAGE
Max. Load 304kN
Max. Load 430kN
GROUTA
CURE TIME: 14DAY3
HOLE 8IZE : 43mm
FiOURE 0 13

250mm DOUBLE EMBEDMENT

ROOFBOLTS

COMPARISON OF ROCKBOLTING SYSTEMS

700

AT, 4449 & BIG BOLT

DOUBLE BIRDCA GE + GROUT

BIO BOLT + RE9IN

AT BOLT + RESIN
I

LH

B9 4449 BOLT + RESIN

8 10 12 14 18 18 20 22 24 26 28 30

DISPLACEMENT (mm)
AT 22mm Diameter
Max. Load 323kN

4449 20mm Diameter

Max. Load 184kN

BIG BOLT 30mm Diameter

Max. Load 562kN

6 8 10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)

RE8IN TYPE : Manufacturer C AT BLOW 8ET

HOLE BIZE8 : AT & 444 27mm
BIG. BOLT 35mm
FIGURE & n

FIOJAE a 15

DOUBLE EMBEDMENT TEST

REINFORCING TENDONS FOR 27mm HOLES

AT BOLT, SINGLE NUTCAGED CABLE, MINESWEEPER ROPE
500

SINGLE NUTCAGE
8ECTI0NAL VIEW OF TEST ASSEMBLY

400

AT BOLT + RESIN
SINGLE
NLfTCAGED CABLE

CHUCKADAPTOR

NUTCAQE + Q ROUT

7 STRAND DYFORMED
CABLE WITH NUT
ON KING WIRE

io

/ MINESWEEPER RESIN

JOINT
NUTCAOEO
LENQTH
100mm

NUTCAQE + RES|N

NUTCAQE
DIAMETER 23mm

QROUTA

0
450mm DOUBLE
EMBEDMENT

J
2

L
4

J
I L
J
I I I
8 10 12 14 16 18 20 22 24 26 28 30

DISPALCEMENT (mm)
AT BOLT RESIN BONDED
NUTCAGE GROUT BONDED
Max. Load 333kN Bond Failure Max. Load 318kN Cable Failure

INTERNAL HOLE
DIAMETER 27mm

NUTCAGE RESIN BONDED

MINESWEEPER RESIN BONDED

Max. Load 214kN Cable Failure

AT BOLT : 250mm DOUBLE EMBEDMENT

NUTCAGE. MINESWEEPER : 450mm DOUBLE EMBEDMENT
Fl QU RE &1<

FiouRE air

450mm DOUBLE EMBEDMENT TEST

FIBREGLASS CABLES
SECTIONAL DIAGRAM OF TEST ASSEMBLY

FIBREGLASS BIRDCAGED CABLES

Manufacturer A & Manufacturer E
400

450mm DOUBLE
EMBEDMENT

CHUCKADAPTOR

MULTIPLE STRAND
FIBREGLASS CABLE

QROUTA

ID

JOINT

NODE

INTERNALLY THREADED
SURFACE

0
ANTINODE

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)
MAN.A SINGLE BIRDCAGE
Manufacturer E
Max. Load 304kN Cable failure Max. Load 174kN Bond failure

8PACER

MAN.E Graphite Coated

Manufacturer A
Max. Load 180kN Bond failure Max. Load 284kN Cable failure
GROUTA
CURE TIME : 8TEEL BIRDCAGE 14 DAYS
FIBREGLASS CABLES 7 DAYS
FIGURE &18

FlOJRE

ftl

DOUBLE BIRDCAGBD CABLES

350mm & 450mm DOUBLE EMBEDMENT
EFFECT OF NODE/ANTINODE AT SPLIT IN TUBE

SECTIONAL DIAGRAM OF TEST ASSEMBLY

ANTINODE AT SPLIT

NODE AT SPLIT

MNF.A DOUBLE BIRDCAGE

700
....NOce

<$/

. DOUBLE
BIRDCAGED
CABLE
14 STRANDS

WTINOOE

WAVELENGTH
240mm

VD
00

INTERNAL HOLE
DIAMETER 52mm

450mm DOUBLE
EMBEDMENT

J
L
8 10 12 14 18 18 20 22 24 26 28 30

DISPLACEMENT (mm)

450mm DOUBLE EMBEDMENT 450mm DOUBLE EMBEDMENT

ANTINODE AT SPLIT
NODE AT SPUT
350mm DOUBLE EMBEDMENT 350mm DOUBLE EMBEDMENT
ANTINODE AT SPLIT
NODE AT SPUT
HOLE SIZE : 82mm
CURE TIME: M DAYS
QROUTA

FIGURE &S0

FlOURE &1

DOUBLE EMBEDMENT TEST

MAN.A DOUBLE BIRDCAGE + GROUT A

SHEAR BEHAVIOUR

DOUBLE EMBEDMENT TEST

M A N A DOUBLE BIRDCAGE & 2 7-STRAND DYFORM CABLE

SHEAR CHARACTERISTICS
700

700

600
INrTALWIRE
FAILURE

ID

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34

DISPLACEMENT (mm)
10

20

DISPLACEMENT (mm)
1. Max. Load 482kN 2. Max. Load 478kN
CURETIME-.ODAYB
ANTINODE AT SPLIT IN TUBE
7 DAY GROUT U.C.S.-BflMPa MODULUS 16.4GPa
FIGURE & 2 2

MAN.A DOUBLE BIRDCAGE NODE 1. 2x7 STRAND DYFORM CABLE

Max. Load 456kN
Max. Load 516kN
2. 2X7 STRAND DYFORM CABLE
Max. Load 458kN
CURE TIME: 14 DAYS
HOLE 8IZE : 52mm
GROUT A
FIGURE <V?3

DOUBLE EMBEDMENT TEST

DOUBLE EMBEDMENT TEST

MAN.A & MAN.B DOUBLE BIRDCAGES

ANTINODE SHEAR CHA RA CTERISTICS

MAN.A & MAN.B DOUBLE BIRDCAGES

NODE SHEAR CHARACTERISTICS

700

IU\J

600 -

600 -

500 -

500 -s
^ 400 **
Q
<
Q 300 _J
-

^-y

J2 400
Q
(3 300

'$%?
-

o
o

200 -

/
'

'

/'

f'

, ' / \ /
/

s/
/

200
y

'A

100

'

-fi

100

fi
9

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

1 ' I

DISPLACEMENT (mm)

1.Man. A
2. Man. A
Max. Load 448kN Max. Load 438kN

I.Man. A
2. Man. A
Max. Load 448kN Max. Load 456kN

3. Man.
4. Man.
Max. Load 424kN Max. Load 464kN

3. Man. B
4. Man. B
Max. Load 504kN Max. Load 498kN
CURE TIME :14 DAYS
HOLE 8IZE : 52mm
GROUTA

FIGURE & M

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)

CURETIME:14DAYB
HOLE 2 : 62mm
GROUTA

FIGURE &

DOUBLE EMBEDMENT TEST

DOUBLE EMBEDMENT TEST

MAN.A DOUBLE BIRDCAGE

ANTINODE-NODE SHEAR CHARACTERISTICS

MAN.B DOUBLE BIRDCAGE

ANTINODE - NODE SHEAR CHARACTERISTICS
700

700

0 2 4 8 10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)

0 2 4 8 10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)

1. ANTINODE
2. ANTINODE
Max. Load 448kN Max. Load 438kN

1. ANTINODE
2. ANTINODE
Max. Load 424kN Max. Load 464kN

3. NODE
4. NODE
Max. Load 448kN Max. Load 456kN

3. NODE
4. NODE
Max. Load 504kN Max. Load 408kN
CURETIME:14DAY3
HOLE SIZE : 52mm
GROUTA

CURETIME:14DAY3
HOLE 8IZE :62mm
QROUTA
FIGURE &2

FIGURE t St

DOUBLE EMBEDMENT TEST

DOUBLE EMBEDMENT TEST

MAN.A DOUBLE BIRDCAGE

SHEAR CHARACTERISTICS 1 & 14 DAYS

MAN. A SINGLE St DOUBLE BIRDCAGES

ANTINODE - NODE SHEAR CHARACTERISTICS

700

700

600

600

500

500

HOAYQFOUT:
KMPi
IMP

400

WHOuROROUT:
, < ^ y '

300

40 MP.
MOP.

<
O 300

3
o

400

/
y'

200

200

/
100

100

10

15

20

DISPLACEMENT (mm)
1. 1 DAY
2. 1 DAY
Max. Load 368kN Max. Load 364kN

3. 14 DAY
4. 14 DAY
Max. Load 448kN Max. Load 438kN
ANTINODE AT SPLIT
HOLE 8IZE :62mm
GROUTA

25

30

S'

/
/

/'

/'
y

y'

.\

hV

J
I
I
L_L
l

8 10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)

SINGLE BIRDCAGE ANTINODE

Max. Load 206kN Cable Failure

SINGLE BIRDCAGE NODE

Max. Load 238kN Cable Failure

DOUBLE BIRDCAGE ANTINODE

DOUBLE BIRDCAGE NODE
Max. Load 448kN Cable Failure Max. Load 456kN Cable Failure
CURE TIME: 14 DAYS
HOLE 8IZE : 43mm
GROUTA

FIGURE &
FIGURE t M

CHAPTER 7
CEMENTITOUS GROUTS ; RESULTS AND DISCUSSION
7.1 GROUT PROPERTIES
7.1.1.

STRENGTH PROPERTIES

Table 7.1 below shows the strength and densities of the grouts
cast with the 3 0Oram Single Embedment single birdcage samples.
Modulus data was not recorded.
TABLE 7.1
COMPRESSIVE STRENGTH DATA FOR 300mm PULLTEST GROUTS
50mm CUBES
TIME

1 DAY

7 DAY

14 DAY

GROUT

UCS
(MPa)

DENSITY
(g/cc)

UCS
(MPa)

DENSITY
(g/cc)

UCS
(MPa)

DENSTY
(g/cc)

GROUT
1
(1)

21.6
22.0
* 30

2.16
2.16

61.3
64.0
* 55

2.17
2.19

66.6
71.4

2.17
2.14

GROUT
1
(2)

19.3
17.6
* 30

2.18
2.21

60.3
59.7
* 55

2.15
2.18

67.7
68.7

2.14
2.19

GROUT
1
(3)

31.8
31.0
* 30

2.22
2.24

82.9
81.0
* 55

2.23
2.20

84.3
85.0

2.22
2.21

GROUT
2

14.0
13.7
* 20

2.17
2.14

48.0
54.2

2.14
2.14

59.3
60.4
* 44

2.13
2.13

GROUT
6

52.7
53.5
* 20

2.27
2.27

44.8
73.6

2.28
2.22

70.9
80.9
* 64

2.27
2.26

GROUT
7

29.6
29.5
* 20

1.98
1.99

57.8
51.0

1.98
1.96

57.2
61.8
* 60

1.98
1.97

NOTES

* 20 Manufacturers data
GROUT 1 (1) & (2) Compressive strengths and densities low for
both pull tests.
GROUT l (3) Compressive strengths and densities OK, no
corresponding pull tests conducted.
Grouts 1 and 6 have the better compressive strengths and
correspondingly had the better pull test results, however as will

103

be discussed in section 7.3.1 relatively low compressive strength

as shown by Grouts 2 and 7 (60MPa) compared to Grouts 1 and 6
(greater than 70MPa) does not always necessitate poorer pull test
results.
Figure 7.1 shows the strength development over 28 days of the
four main Grouts A, B, C and D. As a result of these tests a
lower compressive strength development curve was set so that
future evaluated grouts would meet the same standards.
Figure 7.2 shows the strength development curves for the two
grouts that subsequently became available for cable bolting,
grouts E and F.
Grout G, had at the time of writing, been
laboratory tested and found to be suitable for cable bolting
however it is not yet available for use in the field.
Table 7.2 shows the strengths obtained for 57mm bottle samples
used in Figures 7.1 and 7.2, along with the compressive strengths
obtained by the grout manufacturers for cube samples.
The
results obtained are comparable to those of the manufacturers,
a full discussion of any differences between cube and bottle
samples will be addressed in section 7.6.
The results show that for comparison purposes the grouts can be
split into two groups on the basis of their 14 day strengths, (14
day results are quoted for all comparison purposes because pull
tests are conducted at this time):
1.
2.

Relatively high compressive strength (greater than 75MPa):

Grouts A, B, F and G.
Relatively low compressive strength (less than 75MPa):
Grouts C, D and E.

Complete strength data for each grout at the given time periods
is given in Appendix IV.
7.1.2 DENSITY
Table 7.3 shows the densities for each grout. Also shown are the
bag size (Kgs.) that the grouts are supplied in, the recommended
amount of water to be added (Its.) and the Water Solids Ratios
(WSR) .
The densities of the Grouts A - F, as given by the manufacturers
are shown with those obtained by TSRE after a 14 day cure period.
The density can be used as an indicator for the addition of the
correct amount of water as will be discussed more fully in
section 7.8.
Table 7.3 also shows the price per 25Kg for each grout, the yield
per 25kg (Its.) and consequently the price for lOlts of grout.
Grout has one of the highest prices per litre and this was one
of the reasons why the manufacturer replaced it with Grout F.
Complete density data along with strength data for each grout is
104

given in Appendix IV,

7.1.3 MODULUS
A comprehensive set of modulus data for the grouts at all tested
time periods from 1 -28 days does not exist, however available
data for the grouts is given in Appendix IV. Shown below is a
summary of the available modulus data after 14 days cure period:
YOUNG MODULUS OF CABLE BOLTING GROUTS AFTER 14 DAYS CURE

GROUT
YOUNGS MODULUS
A
GPa
18

GPa
27
C
32 * GPa
D
GPa
E
GPa
25
F
17 * GPa
G
GPa
17
28 Day results

The grouts, on the basis of modulus can be split into two groups:
1.
2.

Relatively high modulus:

Relatively low modulus:

Grouts B, C, E.
Grouts A, F, G.

The significance of grout modulus will be discussed

detail in section 7.3.

in more

7.1.4 TENSILE STRENGTH

Brazilian tensile tests were conducted on Grouts A, B, C and D;
the results are shown in Table 7.4 below:

105

TABLE 7.4
BRAZILIAN TENSILE STRENGTHS OF GROUTS A. B. C & D
CURE TIME ; 7 DAYS
GROUT TYPE

GROUT A
GROUT

TENSILE STRENGTH

(MPa)

10.66
10.10

AVERAGE STRENGTH
(MPa)
10.38

9.18
12.08
10.17
10.13

10.39

GROUT C

7.15
9.24
10.46

8.95

GROUT D

7.73
7.53
11.20

8.82

The results show that Grouts A and which have higher

compressive strengths than Grouts C and D also have higher
tensile strengths. As the mode of reinforcement for a birdcaged
cable bolt system relies on compressive failure of the grout the
differences in tensile strength of the grouts is not significant.

7.1.5

VISCOSITY OF CABLE BOLTING GROUTS

One of the most important properties of cable bolting grouts

besides their strength characteristics is their viscosity. The
grout needs to be capable of being mixed and pumped to distances
upto 10m in small diameter tubing by equipment suitable for
underground use.
The viscosity of each cable bolting grout will be governed by its
chemical composition. The viscosity can, of course be directly
altered by the addition of excess water but at the expense of
density and strength reduction.
During the early stages of the laboratory investigation the
viscosity or flowability of a cable bolting grout was assessed
visually on pumping. Grouts , and C are all very fluid and
consequently easy to pump and place in the Double Embedment
tubes.
Grout D, as already stated was supplied in two formulations, U,
universal and F, flowable. As the name implied the flowable type
was fluid as easy to pump and place; however the universal
formulation was somewhat thicker and although pumpable and
capable of being placed in the Double Embedment tubes it was

106

difficult to ascertain whether there was any air entrapment and

consequently full encapsulation of all the strands of the
birdcage cable in grout over its entire length.
The flow channel is a method of assessing the flowability and
from tests carried out on Grout A the grout should flow to a
distance of at least 45cm (18-inches) , it is doubtful if Grout D
would have met this specification.
Grouts E and F were not subject to the flow channel as these are
thixotropic grouts.
Grout G like the universal formulation of Grout D was a thick
grout and did not reach the required flow distance.

7.2 GROUT PERFORMANCE IN THE DOUBLE EMBEDMENT TEST

7.2.1 GROUTS A, B, C AND D.
Figure 7.3 graphically shows the system performance of Grouts A,
B, C and D in the Double Embedment test. Tables 7.5 and 7.6 show
the working system stiffnesses of these grouts at 1, 3, 7, 14 and
28 days cure.
Tables 7.5 and 7.6 show that the results need
interpretation because the data set is not complete.

careful

Grout A
This grout has the most complete data set and clearly shows
the increase in working stiffness of the system as the
grout cures. One sample at 24hours exhibited grout failure
(due to the poor grout strength, 40MPa) and two others
exhibited borehole wall failure (probably due to poor grout
strength and/or poor quality of internal tube threading).
These failure mechanisms do not preclude the calculation of
working stiffness if the peak failure load is above 400kN
because up until the point of either grout, borehole wall
or cable failure the.entire system is being tested.
Grout
The data set for this grout is acceptable up until 14 days
cure. The 24 hour tests both showed grout failure which is
comparable to the relatively very poor strength of this
grout at 24 hours (20MPa). LVDT data is not available for
the 28 day cure periods, however comparison of Avery
results show very similar results as recorded for Grout A.
Grout C
Grout C has only two results from the LVDT available for
the calculation of system stiffness. The Avery results
show that the grout has lower stiffnesses than those
obtained for Grout A, however preliminary analysis and
comparison of this grout to Grout A in the single birdcaged
system prior to the loss of data in the fire, showed
similar system characteristics. Only a complete retest
would confirm the performance of this grout.
107

Grout D
As already stated this grout was supplied in two
formulations :
U = Universal
F = Flowable.
Five double embedment samples were cast of U, and four of
F for testing of one sample type at each time period.
Bottle samples of U were cast however no corresponding
samples of F were taken for grout strength analysis.
F
Formulation F performed extremely well attaining a
working stiffness at 24 hours that is comparable to
that attained by other grouts , and C at 14 days,
at 14 days a working stiffness of 18l.8kN/mm was
attained. These results would suggest a grout with
high strength and/or stiffness with a rapid cure time.
U
Formulation U also showed high working stiffness at 24
hours and 3 days, 122.0kN/mm which can be attributed
to the fast cure time and relatively high grout
strength at 24 Hours (57MPa).
However the system
performance then falls over the period from 3 to 28
Days, as shown by a drop in working stiffness to
77.3kN/mm. The corresponding grout results also show
a strength decrease over this period at 7 and 14 days.
There are three reasons that could explain this apparent
drop in system performance:
1.
Sampling error, only one Double Embedment sample
has been tested for each time period.
2.
The fall in grout strength and system performance
is real, this could be possible as some early
strength grouts cure in such a way that the
crystals formed are unstable/weak in the long
term.
3.
The characteristics are a result of the nature
of the specific composition of the sample mixed
that day under those specific conditions.
Only a complete retest could verify this, although there
are test results from an investigation into the effect of
added water on Grout D strength, the results for normal
water content at 3, 7 and 14 days are shown in Figure 7.15
and these show a normal strength increase.
From the interpretation of the data given in Tables 7.5 and 7.6
a system performance 'standard' was set with a minimum working
stiffness after 14 days cure of lOOkN/mm.
It needs to be stressed that although the available working
stiffnesses for Grouts B, C and D from the LVDT all fall below
this limit, interpretation of the Avery results and single
birdcage results prior to the TSRE fire incident indicate that
all are capable of attaining this standard. Only retesting would
prove this.

108

7.2.2

GROUTS E, F AND G

Figure 7.4 shows the Double Embedment results for these grouts,
all easily attain the required working stiffness of lOOkN/mm
after 14 days cure. The initial and working stiffnesses are
quoted in Table 7.7 in section 7.3.1 below.

7.3.

GROUT PROPERTIES AND THEIR PERFORMANCE IN THE DOUBLE

EMBEDMENT TEST

7.3.1 IMPORTANCE OF GROUT STRENGTH AND STIFFNESS

Gale and Fabjanczyk 1987b demonstrated that the performance of
a grout in the Double Embedment test is dependant on both the
strength and modulus of the grout. Table 7.7 below summarises
the 14 day strength, modulus and Double Embedment initial and
working stiffness properties of Grouts A-G.
TABLE 7.7
STRENGTH. MODULUS AND SYSTEM WORKING STIFFNESS PROPERTIES OF
CABLE BOLT GROUTS AT 14 DAYS
INITIAL
STIFFNESS

WORKING
STIFFNESS

18

296.7

138.1

87

27

246.7

88.5

61

* 32

160.0

91.3

64

98.5

57

25

363.6

166.7

** 63

17

285.7

135.1

78

17

363.6

133.3

GROUT
TYPE

UCS
(MPa)

MODULUS
(GPa)

70

**

(kN/mm)

(kN/mm)

28 Modulus
Manufacturers quoted 14 day strength = 80MPa

If it is considered that all grouts perform similarly in the

Double Embedment test then (given that the initial and working
stiffnesses of Grouts B, C and D are underestimates on true
stiffness) it is shown that:
Grouts A, F and G are relatively high strength, greater than
75MPa, and low modulus, less than 20GPa,
Grouts C, D and E are relatively low strength, less than 65MPa
and high modulus, greater than 23GPa, (assuming grout D has
109

a modulus above 23GPa).

The lower strength grouts therefore perform as well in the system
as high strength grouts because their strength is compensated for
by the relatively high modulus.
Grout has both high strength and modulus but does not perform
any better than the other grouts proving that there is a limit
to grout strength and stiffness properties above which no
increase in performance is attained for a given cable-grout
system, ie the nature of the cable configuration then becomes the
controlling factor.

7.3.2

IMPORTANCE OF POST FAILURE PROPERTIES OF GROUTS

Figure 7.5 shows the results from a developmental formulation of

Grout H, for possible future use in cable bolting whose current
properties are unacceptable.
The 14 day grout strength is 75MPa, the modulus is 19GPa and the
average working stiffness is 48kN/mm. A full tabulation of the
strength, stiffness and density is given in Appendix IV.
The results show that given the grout strength and stiffness
properties a good working stiffness would be expected. However
this is not the case and implies that grout strength and modulus
are not the only properties that affect system performance. The
system performance is affected by a third grout property, the
behaviour of the grout after compressive failure within the
birdcages, this is related to the angle of internal friction of
the grout.
The angle of internal friction can be determined through triaxial
testing.
Only this type of testing on a grout with 75MPa
strength and 19GPa modulus with poor performance and one with a
good performance would prove the probable effect of post failure
properties of grout.

7.4

DOUBLE EMBEDMENT PERFORMANCE WITH CURE TIME

Figure 7.6 graphically shows the increase in system stiffness of

Grout A from 24 Hours upto 28 days cure as taken from Table 6.2.
The graph clearly shows the effect of grout strength and
stiffness on system performance. The results at 24 hours show
the inadequate strength and stiffness of the grout at this time,
after 7 days the grout has sufficiently cured to give upto 80%
of the full system performance.
Tables 7.8 show the system performance for the 28mm wire rope and
the bulbed cable over the 24 hour - 28 day cure period with Grout
110

A.
Both show grout failure at 24 hours and the increase in
system performance upto 28 days.
These results clearly show the need for a fast curing grout after
24 hours cure. This is characteristic of Grout D as shown in
Table 7.6 and Figure 7.7. Although this is shown to have good
1 and 3 day characteristics as already discussed in section 7.2.1
there is doubt over its ability to perform as well after further
curing.
The strength characteristics of Grout G as shown in Figure 7.2
also show a fast cure time but without the strength reduction
after 3 days shown by Grout D. This would therefore suggest a
good system performance at 24 hours and 3 days, at 14 days the
Double Embedment tests give an average working stiffness of
166.7kN/mm.

7.5 ORDINARY PORTLAND CEMENT (OPC)

The strength and stiffness of OPC and its performance in the
Double Embedment test after 14 days cure were evaluated because
it is upto one fifth the price of some specially formulated cable
bolting grouts and could have use in specific applications if the
results are acceptable. The cement was tested at a WSR of 0.31
and 0.37.
Figure 7.8 shows the results for the strength development for the
WSR of 0.31 and 0.37, correspondingly Figure 7.9 shows the system
performance after 14 days cure. A full set of the strength,
stiffness and densities is given for both in Appendix IV.
WSR 0.31
The first mix was cast using a WSR of 0.31
strength and stiffness as high as possible,
it was a thick mix but still pumpable with
As OPC is thixotropic it was not evaluated

in order to keep the

the WSR was such that
the mixer /pump used.
in the flow channel.

The results showed a good strength and stiffness development,

after 14 days cure the strength was 79MPa and the stiffness
18GPa. The results from the Double Embedment test after 14 days
cure were disappointing, the working stiffness reaching 65kN/mm,
significantly lower than the required lOOkN/mm.
As already discussed in section 7.3.2 the post failure
characteristics have an important role in the performance of the
grout, these will be affected by the filler type, non-shrink
additives etc. that are used.
WSR 0.37
The second mix of OPC was cast at a WSR of 0.37, this was used
because at the WSR the cement when being mixed had the
consistency comparable to Grout A.
The results in Figure 7.8 clearly show the reduction in strength
111

due to the extra water, the strength at 14 days has reduced from
79MPa to 53MPa, but the stiffness remains similar, 18GPa for WSR
0.31 and 20GPa for WSR 0.37.
As would be expected with the increase in WSR as shown by Goris
1990 and Hyett et.al. 1992 the system performance in the Double
Embedment test is reduced, the initial stiffness falls from
200kN/mm at WSR 0.31 to l33kN/mm for a WSR of 0.37,
correspondingly the working stiffness falls from 65kN/mm at WSR
0.31 to 41kN/mm for the WSR of 0.37.
These results for OPC show that it has unsuitable characteristics
for use as a grout for roof cable bolting however the WSR 0.31
characteristics might be suitable for use in rib cabling.

7.6

EFFECT OF GROUT SAMPLE ASPECT RATIO ON STRENGTH

CYLINDRICAL SAMPLES
As already discussed in section 5.4.3 TSRE grout properties are
determined using samples from 57mm I.D. 90mm long PVC bottles.
These were chosen in order to provide a fast laboratory turnover
through the omission of sample subcoring and field samples
directly comparable to laboratory samples.
However the LVDT
available for the determination of Young's Modulus did not have
a long enough gauge length to accommodate the 57mm diameter of
the grout samples. Therefore samples needed subcoring to fit the
LVDT,
in order to reduce time and therefore costs only one
sample in three of the laboratory samples were subcored for each
time period.
Field samples were not subcored for modulus
determination, subcoring was only used for damaged samples or
those supplied in PVC bottles larger the 57mm diameter.
Subcoring originally was done to a 29mm diameter and more
recently to 44mm diameter, the corresponding length to diameter
ratios are:
57mm 1.6:1
44mm 2:1
29mm 3:1
Figure 7.10 shows clearly the effect of reduced diameter on Grout
A. The strength is greater for the smaller diameter samples.
The 44mm samples are on average 7% higher than the 57mm diameter
samples. The 29mm samples are on average 14% higher than the
57mm diameter samples, although is should be noted that the data
for the 29mm subcored samples comes from a different grout mix
with a slightly higher density which would imply slightly higher
strengths, however the strength is still significantly higher
than the 57mm samples.
Similar results are shown in Figure 7.11 for OPC with a WSR of
0.31, the strength of the 44mm subcored samples are 8% higher
than the strengths of the 57mm diameter bottle samples.
It should be noted that the recommended height to diameter (h/d)
112

for testing is at least 2:1 (Brady & Brown 1984) and the ISRM
1981 suggest a ratio of 2.5 - 3.0:1. This is due to the shear
stresses set up on the sample ends by the platens of the test
machine, these stresses in small h/d samples cause non uniform
stresses that elevate sample strength through confinement.
Theoretically therefore it is expected to get elevated strengths
in low h/d specimens, as shown by Neville 1963 and Vutukuri 1974.
The above test results show that the variation in samples
strength is not related to h/d ratio and therefore will be due
to the size effect. With an increase in sample size there is
correspondingly an increase in volume which can increase the
number of flaws and surface imperfections leading to lower
strengths.
CUBE SAMPLES
Either BSI 1881 50mm or 100mm cube samples were cast in the
laboratory with 57mm diameter bottle samples in order to gain
direct comparison with manufacturers data.
Figure 7.12 shows the comparison between the strength of Grout
A in 50mm and 100mm cubes. The smaller cubes would appear to
give higher strengths, the data is difficult to interpret due to
the apparent decrease in strength of the 100mm cubes; it would
be expected that the larger cubes would have lower strengths due
to the size effect.
COMPARISON OF CYLINDRICAL AND CUBE SAMPLES
Figure 7.13 shows the results of 50mm cubes strength results of
Grout F compared to the strength results of the 57mm diameter
bottle samples, on average the 50mm cube strengths are 17%
higher.
Figure 7.12 shows the comparison of 50mm cubes and 100mm cubes
as compared to the 57mm diameter bottles samples for Grout A.
In this case the 50mm cube samples are only 3% higher than the
57mm diameter bottle samples.
Cube strengths differ from bottle strengths due to the shape
effect. Vutukuri 1974 and Neville 1964 report that there are
conflicting results available regarding whether cube or
cylindrical samples have a greater strength for a given h/d
ratio.
Neville 19 64 discusses that the ratio of cylinder
strength/cube strength will depend upon the strength of the
material tested and the grind size of the aggregate filler of,
in this case, concrete.
It can therefore be concluded that the difference in strength
between the TSRE bottle samples and BSI cube moulds will be due
to the shape effect and the exact strength difference will also
be affected by grout type.

113

7.7

EFFECT OF ADDITIONAL WATER CONTENT

In order to assess the influence of additional water content on

the strength and density of Grout and D , 25%, 50%. 75% and
100% water was added to the normal specified amount.
The results for Grout are shown in Figure 7.14 and those for
Grout D are shown in Figure 7.15, in both cases the density data
is shown for 3 and 14 days cure.
Results for upto 50% water are probably the most important as it
is highly unlikely that in the field more than 50% excess water
would be added. After 14 days cure Grout has a UCS of 68MPa,
a strength decrease of 26%, and Grout D has a UCS 40MPa, a 29%
strength decrease.
The characteristics of Grout are more
favourable because it still maintains a good strength.

7.8 FIELD SAMPLING OF GROUTS

Routine field tests on 57mm diameter bottle samples of grout A
tested at 7 and 14 days cure have been collated from 1993. This
grout is the most commonly used and so represents the largest
database.
Field data on grouts B, C, D, E and F is not
sufficient for analysis.
The field results collated from 1993 for Grout A are compared at
7 and 14 days cure to results, from the laboratory from the same
time periods, these are shown in Figures 7.16 and 7.17
respectively.
The results from both cure periods show a large scatter in
strengths and densities; if results 15% lower than the average
laboratory results are unacceptable then the results show that
approximately 50% of the field results have inadequate strength
and density.
The reduction in grout strength and density could result from;
1.
2.
3.

Poor water quality

Underweight bags
Addition of too much water.

Addition of too much water is the most likely cause of reduced

field strengths and densities because in the field excess water
is likely to be added to a mix that appears too thick to pump and
water is added to give a grout that visually looks easy to pump.
In the laboratory tests were under taken using Grout A by adding
5%, 10% and 20% additional water to the mix. Grout A is supplied
in 25Kg bags which requires 7.75Litres of water therefore
addition of the above percentages represented the following:
1.
2.

5%
10%

WSR = 0 . 3 2 8
WSR = 0 . 3 4 4

8.201ts.
8.601ts.
114

(+0.451ts.)
(+0.851ts.)

3.

15%

WSR = 0.376

9.401ts.

(+1.651ts.)

57mm bottle samples were cast such that there were 6 bottles for
each water percentage for testing at 14 days cure; 3 samples for
57mm diameter UCS and 3 samples for subcoring to 44mm for
determination of Young's Modulus as well as UCS.
Figures 7.18, 7.19 and 7.20 show the reduction in strength,
modulus and density with additional water content respectively.
The strength drops relatively dramatically with the first 5%
added water by 24% (from 67MPa to 52MPa) but only a further 22%
between 5-20% added water (52MPa to 42MPa). At 2 0% added water
the strength and modulus is similar to that after a normal 24
hour cure which has already been shown to have a poor system
performance in the Double Embedment technigue.
Reduction in
density and modulus follows a similar trend.
Figure 7.21 plots the 14 day 57mm bottle samples with 5%, 10% and
20% added water with the corresponding 14 day results from the
field.
These results demonstrate the probability that upto 20% excess
water is added to some mixes, this representing an extra
1.651itres of water per bag. A possible explanation is that
usually 2-4 bags are mixed together which require a high shear
mix for several minutes. Excess water may be added prior to
complete mixing time when the grout appears too thick.

7.9 GROUT QUALITY CONTROL

Routine laboratory testing of Grout A used for cable comparison
purposes in 1994 were plotted against those obtained in 1993 when
the densities for the 1994 grouts were not reaching the expected
2.08-2.09g/cc. These results are plotted in Figure 7.22.
The data shows a reduction in density and grout strength after
14 days cure. These results lead to the weighing of the final
remaining bag in the batch supplied with lower results.
The last bag weighed only 24.50Kg gross weight, leaving a maximum
of 24.35Kg of grout when allowing for the weight of the bag. The
results from the routine 14 day strength and density test on this
grout are shown in Figure 7.23 compared to a bag weighed and
tested from a subsequent batch which was not underweight. The
results show a reduced density although in the case of this test
only one of the two samples tested had lower grout strength.
The results clearly show the effect of bag weight on grout
strength although other factors may be influencing this including
the exact physical and chemical nature of the batch supplied.

115

COMPARISON OF CABLBOLTING GROUTS

GROUTS A, B, C & D.
120

COMPARISON OF CABLBOLTING GROUTS

GROUTS E, F & G.
120

100 a

80

60 / ' " *

en

*" *

. '

ol

CO

'

40

20

ivy
7

"

^ *"

'lr"'x~"

;.'

"~

/ / " ^

it

'k
ili
!

12

18

20

(Days)
GROUT A

GROUT

GROUT D

BRITISH COAL LOWER

ACCEPTABLE LIMIT

T.8.RE. 67mm DIAMETER CYLINDICAL SAMPLES

FIGURE

11

GROUT C

24

28

12

16

20

24

TIME (Days)
GROUT E

GROUT G

GROUT F

BRITISH C 0 A L

LOWER ACCEPTABLE
LIMIT

T.S.R.E. 57mm DIAMETER CYLINDICAL SAMPLES

f icunE }

28

TABItB ?..2

CABLEBCLT aB0DT3

T.3.R.E. UNIAXIAL C0WPRES3IVK STRENGTH (MPa)

57mm DIAMETER BOTTLE SAMPLES
TIME
(Days)

TABLE

7 .3

CABLBOLTING GROOTS
1

14

28

GROUT
A

41.1

5B.1

63.9

70.3

82.5

GROUT

21.7

64.4

79.3

87.0

95.4

GROUT
C

47.3

52.1

59.3

60.7

67.1

GROUT
D

B6.9

66.0

65.2

63.5

71.1

GROUT
E

41.1

51.

57.1

57 .1

64 .4

GROUT

39.7

51.

55.0

62.9

74 .9

WATER SOLIDS RATIOS. DENSITIES & YIELDS

GROUT
A

GROUT

GROUT
C

GROUT
D

GROUT
E

GROUT
F

25.00

13.75

14.00

25.00

25.00

16.40

WATER
(Lt)

7 .7S

2.50

2.50

3 .90

5.00

5.00

W.S.R.

0.31

0. 18

0. 18

0. 16

0. 20

0.30

Average of 3 samples, S7mm diameter bottles, one sample subcored

for Youngs Modulus.

MANF.
DENS.
(g/cc)

2 .09

2.30

2.20

2 .00

MANFACTUERERS UNIAXIAL COMPRESSIVE STRENGTHS (MPa)

CUBE SAMPLES

TSRE
DENS,
(g/cc)

2.07

2 .27

2.22

2 .19

2 .13

2 .01

BAG
PRICE
(El

9.58

5.24

4 .20

9.00

6.38

5.74

9 .00 ,

6.38

0.75

approx.
14

16.3

4 .50

5.30

BAG
SIZE
(Kg)

TIMB

(Days)

14

28

GROUT A
100mm
CUBES

40

50

60

80

25Kg
PRICE
(E)

9.58

9.53

7 .50

GROUT
50mm
CUBBS

40

60

75

80

YIELD
25 Kg
(Lt)

15.6

12.7

approx.
13

20

42

53

57

PRICE
lOLt
(E)

6 . 10

7 .50

5.80

40

55

65

70

GROUT C
CUBBS
GROUT D
100mm
CUBES

GROUT ?
50mm
CUBBS

30

55

70

85
80

7 . 50

Prices June 1994, excluding VAT.

GROUT

approx.
12

Grout A is now available

5.OOLts.
TSRE Density = 14 day cure

in 16Kg bags, added water

TABLE

7 J

TABLE

GROUTS A t SYSTEM PERFORMANCE WITH DOUBLE BIRDCAOEP CABLE

INITAL STIFFNESS : 0 -200kN (kN/mm)

WORKING STIFFNESS : 200kN-400kN (kN/mm)

GROUT A

GROUT C

Max.
Load
(kN)

Inital
Stiffness
(kN/nm)

519
* 301

181.2
266.7

629
621

250.0

1
1 i4
28
CO

GROUTS C ft SYSTEM PERFORMANCE HITH DOUBLE BIRDCAGED CABLE

INITIAL STIFFNESS 0 - 200kN

(kN/mm)
WORKING STIF F NESS : 200kN-400kN (kN/mm)

Cure
Time
(Days)

7.6

AVERAGE
INITAL
Stiffnenn
(kN/nm)

Working
Stiffnees
(kN/mra>

AVERAGE
WORKING
Stiffness
(kN/nm)

29.0
224.0

Cure
Time
(Days)

2 9.0
3

117.6
250.0

117.6

637
585

222.2
250.0

263.1

114 .3
125.0

119.7

62
634

307.7
285.7

296.7

142.9
133.3

138.1

634
636

200.0
307.7

253.9

129.0
125.0

Max.
Load
(kN)

Inital
Stiffness
(kN/mm)

AVERAGE
INITAL
Stiffness
(kN/mm)

330
487

114.3

114.3

17 6
618

173 .9

173.9

620
627

80
620

160.0

160.0

28

604
590

Grout F ailure
Borehole Wall F ailure
Node at Split

AVERAGE
WORKINO
Stiffness
(kN/mm)

49.4

49.4

98 .5

98.5

14

127.0

working
Stiffness
(kN/mm)

Grout Failure
Borehole wall failure
GROOT D

GROUT
Cure
Time
(Daye)

Max.
Load
(kN)

Inital
Stiffness
(kN/mm)

293
* 518

166.7
111.1

3
7
14
28

620
626
629
630
620
** 363
598
623

AVERAGE
INITAL
Stiffness
(kN/mm)

250.0
222.2
307.6
142.9
160.0
333.3

138.9
236.1
225.3

Working
Stiffness
(kN/mm)

44.0
99.0
97.1
163.9
64.5

44.0
98.1

114.7 J

Cure
Time
(Days)

Max.
Load
(kN)

U 607
F 629

U 363.6
F 266.7

U 608
F 625

7
14

88.5
246.7

88.5

Grout failure
Borehole wall failure

AVERAGE
HORKING
Stiffness
(kN/mm)

28

Inital
St i C f ness
(kN/mm)

INITAL
Stiffness
U
(kN/mm)

Working
Stiffneos
(kN/mm)

WORKINO
Stiffness
U
(kN/mm)

363.6

U 122.0
F 118.3

122.0

U 333.3
F 210.5

333.3

U 122.0
F 127 .4

122.0

U 619
F 625

U 235.3
F 333.3

235.3

U 98.5
F 183 .5

98.5

U 607
F 619

U F 250.0

U 91.3
F 181.8

91.3

U 610

U 137.9

U 77.5
137.9

77.5

Grout D was supplied in two developmental formulations:

U Universal & F Flowable
Formulation U was subsequently approved for underground
use.

450mm DOUBLE EMBEDMENT TEST

COMPARISON OF CABLEBOLT GROUTS

GROUTS A, B, C, & D.

450mm DOUBLE EMBEDMENT TEST

COMPARISON OF CABLEBOLT GROUTS

GROUTS E, F, & G.
700

IO

QROUTA
Max. Load 628kN

8 10 12 14 1 18 20 22 24 26 28 30

DISPLACEMENT (mm)
GROUT
Max. Load 620kN

GROUT D
BRITISH COAL LOWER
Max. Load 607kN ACCEPTABLE LIMIT
CABLE TYPE : Manufacturer A DOUBLE BIRDCAGE
CURE TIME: 14 DAYB
HOLE 8IZE : 62mm
FIGURE 7.3

GROUT C
Max. Load 624kN

J L
J L
8 10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)

GROUT E
Max. Load 642kN

GROUT F
Max. Load 615kN

GROUT G
BRITISH COAL LOWER
Max. Load 644kN ACCEPTABLE LIMIT
CABLE TYPE : Manufacturer A DOUBLE BIRDCAGE
CURE TIME: 14 OAY3
HOLE SIZE : 52mm
FlOUBE 1

450mm DOUBLE EMBEDMENT TEST

UNACCEPTABLE GROUT CHARACTERISTICS

GROUT H
700

450mm DOUBLE EMBEDMENT

MNF.A DOUBLE BIRDCAGE + GROUTA

SYSTEM PERFORMANCE WITH TIME
700

-.r."'

600

J I
2 4

J
J
I I l
8 10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)
BRITISH COAL LOWER
ACCEPTABLE LIMIT

1. GROUT
Max. Load 640kN Cable Failure

2. GROUT
Max. Load 640kN Cable Failure
CABLE TYPE : Manufacturer A DOUBLE BIRDCA GE
CURETIME:14 0A Y8
HOLE SIZE ; 62mm

8 10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)
24 HOURS
Mx. Loud 518kN Q(out Fallute

3 DAYS
7 DAYS
Max. Load SBkN Cable Failure Max. Load e07kN Cable Failure

MDAY9
Max. Load fl26f<N Cable Failure

28 0AY9
Max. Load o34kN Cable Failure

HOLE SIZE : 52mm

ANTINODE AT SPLIT

Fioune r
fiQjRE r t

TABLE, 7 0
OROT A SYSTEM PERF ORMANCE WITH TIME WITH 2 8mm HIRE ROPE &

450mm DOUBLE EMBEDMENTT TEST

BBItBBB C ABLE

24HOUR & 14 DAY GROUT CURE CHARACTERISTICS

INITAL STIFFNESS
WORKING STIFFNESS

0 200kN (kN/mm)
200kN400kN (kN/mm)

GROUT A & GROUT D

700

WIRE ROPE 28mm 6x7 (6/1) GROUT A

J C ure
Time
(Days)

Max.
Load
(kN)
392
* 409

Inital
Stiffness
(kN/mm)

AVERAGE
INITAL
Stiffness
(kN/mm)

Working
Stiffness
(kN/mm)

AVERAGE
WORKING
Stiffness
(kN/mm)

114.3

37.4

547
555

160.0
160.0

160.0

58.8
74 .1

66.5

554
550

250.0
210.5

230.3

85.1
69.2

77.2

14

553
548

250.0
285.7

267.9

75.2
88.5

28

555
553

266.7
285.7

276.2

90.5
81.6

3
7

114.3

600 -

yC*

jf

il;

37.4

500 -

///
400

//.'

81.9
86.1

li
ii ;

O 300 / / . /
-I

F a i l u r e of Grout

li

BULBED CABLE + GROOT A

200 Cure
Time
(Days)

1
3

Max.
Load
(kN)
* 449
388

551

Inital
Stiffness
(kN/mm)
222.2
133.3

AVERAGE
INITAL
Stiffness
(KN/mm)

Working
Stiffness
(kN/mm)
29.2

177.8

29.2

!s
14

90.9

163 .3

96.2
88.9

92.6

235.3
255.7

260.5

133.3
112.4

122.9

250.0
285.7

267.8

121.2
111.1

116.2

531
531

160.0
166.6

530
526
530
529

100 |
/

90.9

250.0
250.0

I
I

AVERAGE
WORKING I
Stiffness
(kN/mm)

I
4

I
I I I I I I I I I
I I
6 8 10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)
QROUTA QROUTA GROUT D QROUTD
24 HOURS 14 DAYS 24 HOURS 14 DAYS

F a i l u r e of grout
CABLE TYPE : Manufacturer A DOUBLE BIRDCAGE
HOLE SIZE 52mm
FiOURE ?

CABLBOLTING A SSESSMENT: GROUT COMPA RISON

450mm DOUBLE EMBEDMENT TEST

ORDINARY PORTLAND CEMENT

WSR 0.31 & 0.37

ORDINARY PORTLA ND CEMENT

WSR 0.31 & 0.37

120

700

600

500 -

400

300

200

rvj

100

10

20

OPC WSR 0.37

57mm Bottles

OPC WSR 0.37

100mm Cubes

10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)

TIME (Days)
BRITISH COAL LOWER LIMIT OPC WSR 0.31
57mm Bottl89
57mm Bottles

OPC WSR 0.31

100mm Cubes

BRITISH COAL LOWER LIMIT

Max. Load 602kN

1. OPC WSR 0.31

Max. Load 636kN Cable Failure

2. OPC WSR 0.37

Max. Load 614kN Cable Failure
CABLE TYPE : Mabufectur A DOUBLE BIRDCAGE
CURE TIME: 14 0AY3
HOLE SIZE 52mm

Bone Data: 2x57mm 1x44mm Subcor

Cub Data: 100mm Av. 2 Sample
All Sampl Wet Curad
FIOURE

FIOJRE re

QROUT STRENGTH : EFFECT OF 8AMPLE GEOMETRY

GROUT STRENGTH : EFFECT OF SAMPLE GEOMETRY

57mm BOTTLES, 44mm &. 29mm SUBCORED SAMPLES

GROUTA

57mm BOTTLES, & 44mm SUBCORED SAMPLES

ORDINARY PORTLAND CEMENT WSR 0.31

IU

120

100

100

, . ' 'OOgrcc

80
,."'

OTeOc

.."ittfoo. '

^ ^ ^ " ^
^_^""^^

^ ^ ^ "

Qu

D_
60

Q
<
O

<

ISJ

_J
40

20

10
20
TIME (Days)

57mm Bottle samples 44mm Suboore 29mm Subcore

Av. 2 samples
1 sample A v. 3 samples
ALL SAMPLES WET CURED

10

20

TIME (Days)
57mm Bottle samples 44mm Subcore
Av. 2 samples
1 sample
ALL SAMPLES WET CURED

flOJBE M 0

FIOJRE 111

GROUT STRENGTH : EFFECT OF SA MPLE GEOMETRY

GROUT STRENGTH : EFFECT OF 8A MPLE GEOMETRY

57mm BOTTLES, 100mm & 50mm CUBES

GROUTA

57mm BOTTLE SAMPLES & 50mm CUBE SAMPLES

GROUT F
120

120
(0
CL

100

H 100
I

80

h
O

UJ

ltfce

or

2(<xyoc

\~

Ztltfcc

80

6 0 200tfoo

LU
>

<

ZCne/oa

2 0 2 : _ _ZCXffoc _ /-

60
Z20(ycc

LU

cr
L

40

o
10

20

TIME (Days)
57mm BOTTLE SAMPLES
100mm CUBES
Average of 3 Samples A verage of 2 Samples

20

D
5

50mm CUBES
Average of 2 Samples
A U 8AMPLES WET CURED

10

15

TIME (Days)
57mm Diameter Bottles 50mm Cubes
3 Samples
2 Samples
ALL SAMPLES WET CURED

firxjBE M J

20

FlOuRE 1 15

25

UCS & DENSITY OF GROUT WITH ADDED WATER

GROUT

UCS & DENSITY OF GROUT WITH ADDED WATER

GROUT D

13 s 100

I uu

rt
Q_

ajotfcc

<*.
* .
*

'0

'

.,' . .

%*

80
2IPOOC

217f>oo

'
%\

*,'.,

*^*^

\-

^
. . .
^\216tfcc

**

' 2<Woe

75

60
\^
>v

N.00(yoe\

40

2I7O/0C

>

'\

60

LU

S3
PfH

80 _

LU

'"

^V

00

(5

^*^*s*fc.

S
X

* \
\

i.iryoc

s ,t;ycc
N

v''

" " * .
' * .

OL

\\

'**.

''..,,
s

'S..t-5ota:

' " .

'S."

*> 2MO/0C

O
s

20 -

" ~ " " . . . ^ 2 21 ota:

CO
CO
LU
CC 40

' .

'.

1.87ofoc *

.,

<

Af>,^.

20

''.,
"^^i.eoo'oc
*" . _
'"s.;;

** *

.,
.900

1
20

1
40

1
60

I.OVcc
1

80

20

100

40

60

ADDED WATER (%)

ADDED WATER (%)

3 DAYS 7 DAYS

3 DAYS 7 DAYS 14 DAYS

Averag of 2 tempi

Average of 3 eample9

29mm 8UBCORED SAMPLES

57mm BOTTLE 8AMPLE3

FIGURE M A

14 DAYS

FiouflE n s

80

100

FIELD & LABORATORY GROUT STRENGTH

GROUTA
7 DAYS CURE

FIELD & LABORATORY GROUT STRENGTH

GROUTA
14 DAYS CURE

120

120

(0
Q2

1.0

2.1

2.2

DENSITY g/cc
LABORATORY FIELD

2.3

MANUFACTURERS DATA
100mm CUBES
D

LAB DATA : 57mm Diameter Botti Samplee

FIELD DATA : 67mm Botti S a m p l 6V 20mm 8uboor
SAMPLE DATES ; Jan-Dec 1993
FIGURE ?

2.4

2.1

2.2

DENSITY g/cc
LABORATORY FIELD

2.3

MANUFACTURERS DATA
100mm CUBES
D

LAB DATA : 57mm Dlameler Bottle Samples

FIELD DATA : 75mm BottJe Samples & 28mm SuDCore
SAMPLE DATES : Jan-Dec 1093
FIGURE 7 11

2.4

MODULUS OF GROUT WITH VARIABLE WATER CONTENT

QROUTA
20

UCS OF GROUT WITH VARIABLE WATER CONTENT

GROUTA
100

18 -

co .

a . 16

(3

CO

D
=J
D

NJ
^1

co

14

12

CU

10

10

15

20

ADDED WATER %
44mm Subcored Samples
CURETIME:14DAYS
AVERAGE OF 3 SAMPLES

10

ADDED WATER %
57mm Bottle Samples 44mm Subcore
CURE TIME: 14 DAY3
AVERAGE OF 3 SAMPLES

FIGURE 7.IS

15

FIGURE t IS

20

DENSITY OF GROUT WITH VARIABLE WATER CONTENT

FIELD & LABORATORY GROUT STRENGTH

GROUTA

GROUTA
2.12

14 DAYS CURE

1.

2.1

2.2

DENSITY g/cc
LABORATORY
5

10

15

ADDED WATER %
57mm Bottle Samples 44mm Subcore

FIELD

20
MANUFACTURERS DATA ADDED WATER CONTENTS
100mm CUBES
57mm Bottle Samples
D
A
LAB DATA : 57mm Diameter Bottle Sample
FIELD OATA : 57mm Botile Samplee 44mm Subcore
8AMPLE DATES Jan-Dec 1083

CURE TIME: 14 DAYB

AVERAGE OF 3 SAMPLES
FIGURE 7 20

2.3

FICURE 7 21

2.4

ROUTINE LABORATORY GROUT TESTING

GROUTA

GROUT QUALITY CONTROL

EFFECT OF UNDERWEIGHT BAGS
GROUTA 14 DAYS CURE

14 DAYS CURE
120
CO

LU

100 -

CO
LU
>
CO

co
LU
oc

io

Q_

o
_j

<

2.1

2.2

DENSITY g/cc
1002/1003 LAB DATA
1004 LAB DATA
5 7 m m Diameter Bottle Samples 5 7 m m Diameter Bottle Samples

*
MANUFACTURERS DATA
100mm CUBES

1004 LAB DATA

100mm CUBES

D
1.0

2.1

2.2

DENSITY (g/cc)

2.3

GROSS BAG WEIGHT 25.46Kg GROSS BAG WEIGHT 24.60Kg

Bag Weight 0.15Kg
Bag Weight 0.15Kg
CURE TIME 14 DAYS
57mm DIAMETER BOTTLE SAMPLES

FIGURE 7 22
FIGURE 7 23

2.4

CHAPTER 8
ROOFBOLT DEVELOPMENT
8.1 LIFTING AND SUSPENSION OF EQUIPMENT
8.1.1 INTRODUCTION
AT rockbolts are of a single geometric design and material
specification. The bar is produced by a single steel mill by whom
it is distributed to three supplier companies who cut the bar to
length and form the thread on one end of the bolt.
The supplier companies use a cold rolling process to form the
thread onto the bolt. This process increases the tensile strength
of the threaded section, therefore matching the UTS of the bar
despite an area reduction. However ductility and toughness are
impaired. Alternatively if the thread were to be cut onto the bar
this process would effectively reduce the tensile strength by
15%.
More significantly the tolerance of the bar to bending is
restricted by thread rolling. If the bar is subjected to tensile
and bending loads in the threaded section failure can occur at
loads considerably lower than the nominal ultimate strength.
Tests have shown that when loads are applied at angles of around
10 to the bolt axis the UTS is considerably reduced.
Following investigations AT rockbolts were prohibited for lifting
purposes. British Coal introduced an acceptance test which
required that a tensile load equivalent to five times the lift
rating should be achieved when loading at 3 0 to the axis (Fig
1).
8.1.2 APPROVED LIFTING BOLTS
Bolts were introduced specifically designed for lifting and
suspending heavy equipment. Initially these were supplied by
manufacturer H but recently a second manufacturer I has produced
a similar bolt.
Lifting bolts are made from good quality low carbon steel with
certain alloying elements which give improved ductility. The UTS
of this material is approximately 15% less than that of AT bolts.
They have a thread form which has a deeper less intensely cold
worked layer than AT bolts. The lifting bolt, by its design
features, permits a larger degree of bending and is more suitable
for the use of lifting and suspending equipment.
8.1.3 CODE OF PRACTICE
AT roofbolts have been limited in their use for lifting purposes.
They may only be used for suspending light loads up to a maximum
of 1 tonne such as pipes, conveyor structure and cables etc.

131

A Technical Guidance on special purpose resin bonded anchor bolts

for the purpose of lifting and suspension of equipment was
produced in January 1992. This was revised in January 1994 and
is included in Appendix V.
8.2 ALTERNATIVE THREAD
8.2.1 OBJECTIVES
To install special bolts at a site where lifting or suspension
of heavy items of equipment is required is inconvenient and
expensive and involves installation procedures which differ from
those used for AT bolts.
Modifications required to optimise the AT bolt for support
purposes and to make it suitable as a lifting anchor have been
investigated. This work was carried out in conjunction with the
steel manufacturer to determine the tolerance of the threaded end
of AT bar to bending loads and how improvements could be made.
8.2.2 INVESTIGATIONS
Three routes were examined by which bar performance might be
improved:
1) Optimisation of the bar metallurgy i.e. control of alloy
additives, control of impurities.
2) Heat treatment of the bar following thread rolling to
reduce the effects of work hardening.
3) Thread - change of thread form or forming process.
8.2.3 CONCLUSIONS
The performance in bending of the AT bar used by British Coal is
seriously impaired by the use of the ISO metric thread profile.
Tensile strength can be reduced to 16% of its normal value when
loaded at an angle of 30.
Heat treatment can be effective through stress relieving the bar
but quality assurance is problematic and the bar is affected by
scaling and bowing.
Bar made from steel with a much lower yield strength improves
bending performance to an acceptable level but use of a low
strength bar for rockbolts would be unacceptable. Use of the bar
for lifting bolts would entail high costs from short production
runs and risk low strength bar being mistakenly used for rockbolt
production.
The standard thread form is a 'Vee' profile to a coarse pitch ISO
metric design as specified in BS3643. The profile produced by
thread rolling requires considerable displacement of material and
consequently work hardening. This could be alleviated by either
cutting the thread or by rolling a profile which causes less
132

material displacement.
Studies of common profiles showed that the 'knuckle' design
defined in the German DIN 405 standards is a less 'geometrically
severe' profile than the vee form. Samples of this thread form
on different strength bars were tested.
The DIN 405 knuckle profile provides acceptable bending
performance with standard AT rebar and tests carried out to
evaluate lifting performance produced satisfactory results.
Figure 2 shows the comparative results.
8.3 DIN THREAD TRIALS
Following this investigation a limited installation trial took
place using AT bolts with Din 405 threads. Six collieries were
chosen for the trial, the three bolt manufacturers each supplied
two sites. Each site used 2,000 bolts.
Colliery

Manufacturer

Prince of Wales
Bentley
Asfordby
Welbeck
Daw Mill
Longannet

J
J
K
K
L
L

Each site was to use a continuous run of 2 000 bolts. Monitoring

to ascertain the operational advantages or problems associated
with the bolts as well as the monitoring of roof dilation by
placement of a sonic extensometer in addition to the routine tell
tale monitors was to be carried out.
With the trial under way a random sample of bolts was obtained
from a production batch. These were obtained from one
manufacturer. 30 angle pull tests were carried out in an
identical manner to the original investigation. The results of
these tests were poor. The original tests of 15 bolts had given
failure loads of between 201 and 272 kN. Of the six samples taken
five failed at loads lower than 160kN, including three below
70kN, the lowest failing at 45kN. The tests were carried out on
the same machine by the same operator using the same wedge block
as the original tests. Similar results were obtained from the
other manufacturers.
Further detailed examination showed that a number of the thread
roots contained areas where the metal had been partially
separated during the thread rolling process and then rolled back
into the thread profile, producing a 'lapped' appearance and
effectively a small crack. Failure had occurred at one of these
laps.
The original bolts were produced using new thread rolls. This
demonstrates that threads produced on the same piece of rebar
show substantially different bending performance when produced
133

with rollers that have been in use for some time.

Even though straight tensile pulls on all these bolts were
satisfactory it was concluded that it was not possible to allow
DIN threaded bolts to be used for lifting and suspension purposes
until further work was carried out.
8.4 HIGH STRENGTH BOLT
8.4.1 INTRODUCTION
Conditions are being encountered at on a number of sites where
high reinforcement densities are required. Consequently there has
been a need to develop a high capacity bolt such that densities
can be reduced. The new design of bolt, known as the 'Big Bolt'
has double the capacity of the existing system.
At sites which use high powered hydraulic drill masts either
machine mounted or self propelled and used with place changing
techniques, installation of a larger bolt and the need for
drilling larger hole sizes should present no problem. It can be
seen that there would be significant advantages gained by their
introduction.
8.4.2 BOLT SPECIF ICATION
The bolt is designed to be installed in a 3 5mm hole. It has the
following specification:
Circular with low profile rib (0.5 - 0.75mm)
31mm core diameter
Yield strength 500 kN (50 tonnes nominal)
Ultimate strength 60 kN (60 tonnes nominal)
Elongation 16 to 18%
Weight 6 kg/m
Thread DIN 405 knuckle Spec M32, 150mm +/- 10mm in length
Nuts have a shear pin with a breakout range of 165 -185 Nm
8.4.3 RESIN SPECIF ICATION
High strength/stiffness low viscosity unmodified polyester 'AT'.
Capsules are fast set and slow set 32mm 600mm.
8.4.4 INSTALLATION TRIALS
An installation trial was carried out during June 1993 in the
Parkgate Seam at Asfordby C olliery using Fletcher mobile bolt
rigs. Fourteen 2.4m bolts were installed as spot bolts in an area
requiring additional reinforcement. Standard AT bolts were
installed at the same time allowing a cycle time comparison. This
proved to be satisfactory, they were installed as quick as the
standard bolts and the resin capsule combination gave full column
resin bonding. Operators could not see any particular problems
with installing this type of bolt.

134

A full trial was started in May 1994 which is continuing. The

site chosen is 103's Tail Gate G ladder roadway in the Deep Main
Seam at Asfordby.
This roadway is being driven by a Joy ED18 Entry Driver Bolter
Miner. The roadway is on sole support by rockbolts and is
installing an identical pattern to that driven on AT bolts i.e.
7 bolts per row with rows at 0.6m centres.
A full monitoring station indicates very low stable loads on the
bolts with very low roof movement and no softening. It is planned
to progress shortly to the next stage which will be a reduction
in bolt density by spacing bolts at 5 per row. Further reductions
in bolt density are planned when bolt rows may be spaced wider,
depending on monitoring information.
8.5 WAISTED/BENDABLE BOLTS
These bolts have been purposely designed for a private mine in
South Wales. This mine operates in a working section of 1.2
metres and requires a bolt of 2 metres in length to provide
adequate roof support. At present the colliery are having to
install coupled bolts to achieve this height of reinforcement.
8.5.1 BOLT DESCRIPTION
The bendable bolt is manufactured by manufacturer A from BS4449
steel. It is 20mm diameter with a minimum yield stress of 4 60MPa
and has a minimum yield strength of 145kN. Thread profile differs
from the AT bar in that the ribs are more pronounced and form an
ellipsoid around the bar circumference rather than the thread
type profile of the AT. The bar has a rolled M20 thread.
In order to allow installation of the bolt in limited heading
height, a 'waist' is hot forged into the bar at approximately mid
length. The waist permits bending of the bolt and straightening
after installation without incurring damage or permanent 's' type
deformation of the bar which could lead to installation
difficulties.
8.5.2 INSTALLATION TRIALS AND TESTING
Installation trials on site showed that the bendable bolt would
be installed by pre-bending to 70-90 degrees to the bolt axis,
inserted and then straightened. It was found that the action of
straightening could result in a bend in the opposite direction
of up to 10 degrees before straightening properly. Further
bending was found to be unnecessary.
Tests were carried out in the laboratory at T.S.R.E. to determine
the mechanical performance of the waist section of the bendable
bolt. These consisted of tensile tests with the bolts bent at 70
and 90 degrees then straightened, one at 90 degrees, straightened
and bent in the opposite direction up to 40 degrees and a further
bolt not subjected to bending. The results of these tests are
shown in table 1.
135

These results show that the minimum tensile strength in all cases
was 150.5kN. Maximum strength was 162kN. Tensile failure occurred
in the waist section in all cases. Although elongation was not
measured, all failures exhibited good 'necking' characteristics
indicating good elongation before failure. The forging process
can induce cracking in some circumstances, this effect was
measured and it showed that the tensile strength of the
bent/straightened waist section was unaffected.
8.5.3 CONCLUSION
The tests show that the bendable bolt can be bent, straightened
and re-bent without affecting its performance or properties.
Therefore the design of the bolt is capable of providing the
necessary high strength support in a limited height situation.
Compared with the existing coupled bolt system it offers an
improvement in tensile strength and a potential to reduce hole
diameter and consequentially improve the achieved bond strengths.
Short encapsulation pull tests are presently being undertaken to
determine if bond strengths can be improved. If these prove
satisfactory a trial site, which will be fully monitored, is
proposed solely on bendable bolts.
8.6 COUPLED BOLT
Coupled bolts are an extended form of the AT roofbolt to provide
reinforcement at a higher horizon to that provided by standard
length bolts. Extension is provided by using a purpose designed
coupler to allow standard roofbolts to be connected together.
Thus reinforcement and further confinement of strata can be
attained for example at 3.6 metres (coupling 2 1.8 metre bolts)
or at 4.2 metres (coupling 1 2.4 metre bolt to a 1.8 metre
bolt).
This system is suited to applications where softening occurs
immediately above the bolted height. Coupled bolts can be
installed more quickly and with less interference to heading
operations than cable bolts and they provide a stiffer system.
Its limitation is the length of coupled bolt that can practically
be installed and achieve full encapsulation of resin. 4.2 metres
is the maximum practical length but it is more normal to use a
3.6 metre bolt.
8.6.1 ORIGINAL METHOD
This system enabled two standard AT bolts to be coupled and
provide reinforcement above the bolted height. However it used
a coupler with an o.d. of 30mm which although it had a strength
equivalent to that of the rebar its size precluded installation
within a 27mm hole.
Reinforcement of the higher horizon with this system required
136

drilling
normally
coupler.
extended
allowing
bolt was
bar.

the lower section of the hole with an oversize bit,

35mm., this allowed for the accommodation of the
Resin was installed at the top of the hole to suit the
bolt (450mm Fast and 800mm Slow for a 2.4m bolt)
this length to be fully encapsulated. Thus the lower
not encapsulated and performed the task of an extension

This was not a satisfactory system. Although reinforcement was

provided above the bolted horizon no additional confinement was
given within the bolted height.
8.6.2 MODIFIED SYSTEM
From work carried during this programme the above system has been
modified in order that a coupled bolt can be installed within a
27mm hole and achieve full encapsulation. This has been achieved
working in conjunction with several manufacturers to obtain a
high strength coupler having an o.d. similar to that of the AT
bar. The aim was to optimise the coupler strength to be as good
as the bolt thread.
M2 0 couplers having an ultimate tensile strength of 22 tonnes and
an o.d. of 22.5mm. were found to best meet the criterion. Several
sites have successfully installed this modified form of coupled
bolting. 19's Loader Gate at Ollerton Colliery was one typical
installation. The experience is outlined in Chapter 9.
The sequence of operations for this system is shown in figure 1.
This shows a 3.6m coupled bolt system comprising of 2.4m bolts
extended by the addition of a 1.2m bolt. In this situation one
fast capsule (450mm) plus two slow capsules of 800mm would be
required to achieve full encapsulation.
8.6.3. OVERVIEW
Coupled bolts have been successfully used at several sites and
they have demonstrated their capability in certain situations to
control the extent of the softening above the bolts. Their
success is very much dependent on responding to a deteriorating
situation speedily before the height of softening extends further
and designing the system to ensure sufficient reinforcement
capacity is provided.
Achieving full encapsulation with this system is very much
dependent on how early the bolts are placed following excavation.
If compressed air systems are used it is imperative that a good
working pressure is maintained to allow
for
the
insertion
through additional resin capsules than normally used.
Coupled bolts will provide additional stiffness to shearing which
can be particularly beneficial in resisting the stresses within
the front abutment zones on face retreat.

137

30 SCREW ON
WEDGE
- ^

PLATEN

JAWS OF TESTING
MACHINE

LOAD

Figure 1. T e n s i l e Test in Bending

138

FIGURE 2
LOAD IN
BENDING

VARIATION IN BENDING PERFORMANCE

M24 660 YIELD

GOOD METALLURGY

kN
53

HEAT TREATED

MANUFACT.

45

47

60

300

DIN24 660 YIELD

280

232

350
MAX
300

AVERAGE

250

Ul
IO

O
2
O
2
LU

2
O
<
O

AVERAGE

200

150

100

50

AVERAGE

M24 660 YIELD

MIN

MAX

,,PrYHEAT
u METALLURGY

TREATED

BOLT TYPE

DIN24 660 YIELD

MANUFACT

INSTALLING C O U P L E D BOLT
INSERT FINAL RESIN SEPARATELY
1 GREEN CAPSULE

INSERT RESIN TO TOP OF H O L E

1 RED 4- 1 GREEN

3.6m

3.6m

STAGE 1
STAGE 2
2.4m B O L T INTO HOLE
COUPLER IN B O L T C H U C K

PUSH TO ROOF
DO NOT SPIN

COUPLE 1.2m BOLT TO 2.4m

PUSH AND SPIN H O M E

I
3.6m

3.6m

PUSH

STAGE 3

F i g u r e '3

140

i 3.6m

PUSH

SPIN

STAGE 4

STAGE 5

FORGED/BENDABLE ROC KBOLTS

MANUFACTURER A

Test No
1

Test Type
Tensile only

Failure
Load kN

Waist

152.0

Norma 1

162.0

II

150. 5

tt

152 . 0

152. 0

tl

90 bend/
straightened
6

156.0

Radiused

160. 4

Normal

7 0 bend/

160.2

tt

stra ightened

160.0

It

10

90 bend/
straightened
/4 0 bend/
straightened

161. 7

161.9

11

NOTE:
Normal waist

Radiused sides and flat surface

Radiused Waist -

Forms arc of a circle

TABLE 1

141

j
I

11

Remarks

|i
Surface
crack
before
test

CHAPTER 9
FIELD WORK
9.1 STILLINGFLEET MINE
9.1.1 BACKGROUND
203s Tail Gate was one of the first roadways in the UK to
progress to primary support on roofbolts. The majority of this
was done using Australian consumables, HS1045 roofbolts and
chemfix resin.
203s face was planned to be stopped at the 300m mark. Due to
additional production requirements it was necessary to prolong
the face life and extend its run a further 40 metres.
The length of the Tailgate outbye of the original planned finish
point was supported by 4. 8m 3. 0m arch supports supplemented by
roofbolts. The new planned face finish position was not however
bolted and was close to a vulnerable junction which also in
ground not reinforced with roofbolts (fig.l).
Due to the angle of the roadways to the line of maximum
horizontal stress the Tail Gate received a stress notch whilst
on retreat and thus suffered a considerable front abutment when
compared with the Main Gate. The relatively light density
Australian roofbolting system coped well with this front
abutment, particularly the rib bolts, although it was necessary
to set cribs up to 50 metres ahead of the face, to provide
additional support.
9.1.2 GEOLOGY
Table 1 shows the roof lithology and the strengths of the beds
above the Barnsley Seam in the vicinity of 203's Tail Gate. This
is taken from the underground borehole used for the geotechnical
assessment for roofbolting. It can be seen that the seam is
overlain by a mudstone seatearth of very low strength above which
is 600mm of a friable dark mudstone which includes plant debris.
This seat earth is mined with the coal so that the roof of the
roadway is directly above this horizon. Above this are stronger
beds of mudstone which increase in silt content higher up above
which are strong beds of siltstone and sandstone.
Within the roofbolted length of the roadway short encapsulation
pull tests were undertaken for the geotechnical assessment of
support design. The mean value was determined at 6.3 Mpa with
+5Mpa achieved at all the horizons in the roofbolted length.
9.1.3 CABLE BOLTING
In order to facilitate face salvage from the tailgate in the
stress notched, front abutment zone a systematic cable bolt
reinforcement programme was implemented.lt was planned to cable
bolt 30m of the Tail Gate, the junction and a section outbye the

143

junction. At this period limited experience was available within

the coalfield in cable bolting techniques.
8m double birdcaged cables imported from Australia having a
capacity
of 52 tonnes were placed at a density of one cable per
1.7m2 of roof area, 3 bolts per metre run. Chemcrete cable
bolting grout, also imported from Australia was pumped into the
holes.
Holes were drilled using a pro-ram cable bolting machine (figure
3) , initially using 53mm tri-carbide bits which due to the coarse
strata and broken ground conditions proved to be slow and
required frequent replacement, each bit lasting for one or two
holes. These were replaced by a poly-crystalline diamond bit
which was used for the remainder of the holes drilling each of
the holes in about 25 minutes.
The pro-ram proved to be a very effective drilling machine but
its drawbacks were that it used a considerable amount of water,
approximately 2 00 gallons per hole. This proved to be a
considerable problem as no water range facilities were available
to pump the water away. Following the bogging down of FSVs in
the junction area cable bolting operations were terminated before
the completion of the planned work. Another drawback to using the
pro-ram was that it proved to be not very manoeuvrable and took
three men to reposition the machine for each hole drilled.
9.1.4 MONITORING
A sonic roof extensometer was installed to monitor the effect of
the cable bolting as the face approached. It was installed when
the face was 85m away and readings were maintained until the face
retreated to within 5m.
Figure 2 shows the increase in roof displacement as the face
approached. It can be seen how roof softening developed, the
majority of movement occurring within the first three metres. It
was at this point that the hole sheared preventing any further
readings being taken. These results are typical of a roof where
no reinforcement is provided from roofbolts.
9.1.5 CONCLUSION
Cable bolts were installed in a situation where the roadway was
excavated many months before and not rockbolted and considered
at risk due to high stresses induced from the retreating face.
The monitoring showed that although softening of the strata was
developing due to the effects from the face retreat the cables
successfully restricted further softening to well within the
anchorage horizon and was effective in controlling the roof. The
reinforcement provided by the cable bolts gave sufficient support
to allow the successful salvaging of the powered supports and
associated face equipment.

144

145

British C oal Rock Mechanics Software at 18.11 on 17/JAN/1991

Sti lllngf loot. 203'3 T/G. Cabla bol tod sect lon. F i lo
Station A. 20m MM.
Roof C centr-o)

S203RAX2

o
-<

~*

Tv

2 2'0C~/? 0
<- 02'W\f/90
6 W^0\//90
7 15/S0V/9O
8 21'MO./'90

rr
UJ

>
o
<

.
~*
aJ

r.

10

l _ . 1 . _..!..._.

20

Figure 2

30

0
50
60
70
80
DISPLACEMEN" C nm)

90

100

110

120

TOTAL ROOF DISPLACEMENT, CABLE BOLTED SECTION

146

85m
19m
7
6n
5n

nvrtiv
ROUND
RTABLE
CABLEBOLTER
m

mm

Figure 3

147

i i i K

HQTD Rock Mechanics Branch Software a t 14: 37 on 15/0CT/i989

F i l e : ST203P:::.

STRATA SECTION

SITE:
COLLIERY:

H203 Geotechnical BH (RH Gate) 25a

Stllllngfleet

AREA:

N Yorks

DEPTH
fTHCKNS)

MPa

580

E
GPa

I'

" ""

.....

I
t

48.4

15.3

.13

4.14

Sands, f-f&g. laa certi prtngs

52.9

11.3

lH

<

Silta. fg. caatx sands Isa OOS

62.3

14.3

.21

3.5

S i l t a , asava. f . f nods

.19

3.5

Muda, allty. mssv in parta

*y4 *n

!...

1:1:1:1:1

*W4 Of

582 48
1

52.1

12.1

I
1

58397
W J
52.1
583.21
583.28.

'

Table

xxxx
1

*rt

*"~**(1 "

12.1

.19

3.5

Muda, allty. asav In parta

40

J2

,?5

3,$

Muda, sijty, qu assv. few Dlnt

31

3a

.25

Muda, sa, caen cosi pianta

20

.25

2.7

Muda eatearth

~==~
583.88
583.98

Canna

IP. J |

148

9.2 RICCALL MINE

9.2.1 BACKGROUND
Like, Stillingfleet and the other Selby Mines Riccall's workings
are in the Barnsley Seam. Depth of working varies from 600 - 900
metres, the western side of the colliery being the shallower.
Earlier faces at the colliery, see figure 1 (shown hatched)/ had
their gate roads driven in an unfavourable direction to the line
of maximum horizontal stress and in those situations roofbolting
was not used in the support of roadways.
More recent panels have had their gate roads driven close to the
line of maximum horizontal stress. These roads have responded to
reinforcement by roofbolts and have progressed to primary
support. This has transferred the stability problem to the face
line drivages which besides being in an unfavourable direction
are also wider excavations.
It has been seen that conditions differ from the shallower
workings in the west to the excavations in the east and southern
part of the mine. Slip planes within the bolted height are
present in the deeper workings which together with the higher
vertical stresses due to depth can cause severe problems. It is
essential to ensure that the immediate roof is well controlled
and the effects of vertical stress minimised. Typical roof
behaviour characteristics in the deeper workings are shown in
figure 2.
9.2.2 GEOTECHNICAL INFORMATION
Average seam thickness at the colliery is 2.4m. The immediate
roof is a weak friable mudstone normally 300mm thick. This has
been found to be thicker and varies from 600mm to 1.35m in the
most easterly workings. Above this are stronger grey mudstones
which increase with silt content at the higher horizons, see
table 1.
The majority of the roadways are driven to the top of this weak
mudstone parting, a slip plane which allows the ribs to slide in,
providing reasonable roof conditions with some rib movement.
From tests taken on the various roof cores taken at different
locations it can be seen that it is a medium strength roof with
a good strength/stiffness ratio. Good results from short
encapsulation pull tests give high bond strengths which further
indicate the suitability of the roof for rockbolting.
9.2.3 GATE ROADS
From experience in the north westerly block it can be seen from
table 2 that the height of softening is usually in the order of
1 to 1.5 metres. It can be seen clearly that the effects of a
wider excavation at face junctions without additional long tendon
reinforcement measures extends the height of softening up to
above 3 metres and with the addition of small roof displacements

149

extends up to 5 metres.
Roofbolting densities in the gate roads are in the order of 1.5
bolts/m2 at a nominal drivage width of 4.7 metres. Where
monitoring indicates additional reinforcement being required, 8m
twin birdcaged cables are placed in a 2:1 pattern (i.e 1.5
cables/metre run).
9.2.4 FACE LINE DRIVAGES
Primary support was achieved initially on 432's face line. In
order to achieve this it was necessary to supplement the
roofbolting pattern with systematic placement of cable bolts at
a prescribed distance from the face of the heading.
In order to accommodate the installation of powered supports it
is necessary to drive the face lines at a width of 5.4 metres.
Experience gained on 432's showed that acceptable conditions were
maintained using a support density of 1.67 bolts/m2(not including
an angled face side bolt). Additional 8m twin birdcaged cable
bolts were placed within 7 metres of the face heading in a 2:1
pattern with rows spaced at a metre at a density of 0.27
bolts/m2.
On more recent face line drivages (433's, 476's and 503's) which
have progressed to stage 5 support the nominal width has been
reduced by the absence of wood legs, thus marginally increasing
the support density. Cable bolt placement has been relaxed to 12m
from the face of the head, due to practical constraints, without
affecting the stability requirements. Even with these constraints
the drivage rate is maintained at around 30m per week.
504's face line at 880 metres depth has experienced more
difficult conditions. The immediate roof comprises of 2 metres
of weak mudstones which contain slip planes which have caused
some early movement to occur. It has been necessary to revert to
the earlier placement of cables (7m from the head end) in an
attempt to stabilise the excavation. In addition some areas of
the face line the cables have had to be trussed to provide
further containment to the weak roof conditions.
9.2.5 FACE JUNCTIONS
Face junctions have progressed to primary support by roofbolts
in conjunction with cable bolts. The excavation width required
at face junctions is 6.3m. Support density is increased by
spacing bolts at 0.5m centres through the widened area. This
gives a roofbolting density of 2.38 bolts/m2. A 2:1 pattern of
cable bolts is employed for the normal 4. 5m roadway width section
of the junction supplemented by an additional cable in the
widened face opening area, figures 3 and 4. This reinforcement
has controlled the roof enabling stable conditions to be
maintained.

150

9.2.6 MONITORING
A typical tell tale plot of a face heading is shown in figure 5,
which shows the roof displacement experienced on SOS's. Further
analysis of roof behaviour can be seen by observing height of
softening plots (figure 6) , taken from sonic extensometer
information, which show a progressive increase in the height of
softening at the monitoring stations along the face line. Height
of softening is maintained between 3 and 4 metres.
It is evident that the increase in the height of softening with
a moderate increase in roof displacement means that early
reinforcement by cable bolting is essential. It is also evident
that there is a requirement to provide the high level of
reinforcement provided by twin birdcaged cables to a minimum
height of 8 metres.
9.2.7 CONCLUSION
On face line drivages at this colliery there is an essential role
for the additional reinforcement provided by cable bolts. They
limit the amount of roof deformation and maintain suitable
conditions to allow installation of the face equipment.
The design of the cable pattern and timing of their placement has
been optimised following extensive design monitoring.
As conditions vary at either side of the colliery
continual
detailed monitoring is required to ensure the reinforcement
measures continue to maintain stability in all situations.
Use of cable bolts at the face junctions is essential to ensure
stability is maintained. A number of excavations have been
closely monitored which has enabled the support requirements to
be optimised.

151

152

BARNSLEY SEAM (DEEP)

x x x x

X XX

XX

Mudstones
&
Sillslones

Slip plane within

bolted height

X X

LH
W

high vertical stress

slip plane within bolted height

lower horizontal stress

high bolt loads - yield

moderate rib displacement

some rool movement

OK provided immediate roof can be controlled and vertical stress minimised

RM/AA/7.

Figure 2

I I I I I
I I I I I
I I I I I
I I I I I
4

I
I
I
I
+

I I I I I !
I I I I II
I I I I II
I I I I I I
4'444

Q
CD G

.-1- O im

1 I I I 1 I I I I l
I I I I I I I I I I I I I I I

miuMumumu.uiiUiii n a a a g g m r a a r a

CD

t Imi) imi) ido.mb.ldo Jo e J I I I I I I I

0 ' m oDpi.

Biffi

MfliEaMBjnitnnaaaMainaMatnaiiBitttfiaaiiip

I I I I I I II I I I I I I
k | . . ( , , - , . ) , <, t 4 ) ,|

'-""'

I
+

I
+

I
+

ROOrBOLIINC k MONITORING
10 SC cwnito oui m cryirjwcc M IMC u w / t f n SCM(UC
ron IMSIUIHOW ucxnonmc or tunc pcnrotuwcc'
1 n A CCOA DA HCl TM lH( PRtStHI nnisn COA l C00( 01 PIUCKI

WOICS ro CUOWCt. Suiro! 0 ' ui( PW)JV$

"CA 0I.C OOltINC TOR ROf SUPPOT!'

(rr eoc0<XIS'

BOLTING SPCCiriCATION
Oftrr to\t '0 et i ^ t u t / i * r n H A Mufft .inri
tiXfocvn " t u m ( I M U v t i o m fHowcH
S T V P * NiC*)(0 * * t . I J > V (1 M l PtO)

SCt rCI """ niiir^

ro . l i d i lil I M I S

yyrcus 'Q t . * r*mi(i ** ** M I F M .

r T w c . , v o u i I J * itvfM t , t:\ ' t n w (DI

uai
' V"* f / ) ' l ' *1> *&*< * ( ( \ il O C H

SECTION B - B

0* WNC/.l''tK/ M J M wuli ni * i r " * , i / o o

wlA M r*M.t<nx'> M I I M 10 0 * 6 M H \ (

SECTION A - A

tt

0.9m
NORUA). HOOINC SUPPONI
(SlACt 1 BOvtINO)

IASI R O * or BOUS

I Jm 10 0>

^ ' 2t rF^cFE;

3|

3UCM

v~<aiw)u
See tHlRliNO PROCCOURC COOt
or PRACUCI TOR BRLAXIHROUCM

oex

^"o7^{

tecun

CXIRA. B O l l S "A Y OC iNSCRICO if LOCA I

iNOiCAc

I HA I

:,<cv

COMOHiONS

A RC R I O U I R C D

) ^ S

-
Cl o

IG. 3 B a i

ta.

0.6m I.Om cil.

SCI errxCCN CKIIIMC SIRA PS

i
J O ' I rA Cf
CAOINO

& Q G G S

:..

* G

CD G G B j j g ^ g gj
B CD *fe CD CD c f j ^ CD
b /=i
U i RO" Of BOUS

OU
A l MtlCHl I t U t A U ( W im)

SONIC CXItNSOuntR

OOuBlC BiROCA CC OS IC BOU ( t m )

cTrPOl Q

ORHiSH

COA I.

NORIHCUN

CROUP

RlCCALL MINE

JUNCTION PLAN

illmr

H54S MAIN CATE /

UAIN CA TC

().Jm)

NORMAL HCA OINC SUPPORI

(SUCt S B O U I N C )

~im
THIS

Figure 3

^ "?:

PLAN

CD ~
th"
0?
t . ;.m Rooreous

LOOIION

fS

coie

. HEADING

1 /

S'CNtO
uANiccr:
O'iC

PLAN TO BE READ IN CONJUNCTION WITH HEADING SUPPORI RULES

PLAN RCrCRCNCC ilo

SJ 1 0 7

I
I
-+-

I
I
-4~

l o i " l o 4^1 o r.- i..lo ir- fc^U I n i

I I IIh-1f1
I I I I I I I I I I
I IJ I I I I I
4- 4- 4- 4-4- -4|... | ) > ~ t

J_
0 bn\ jpproi

1
1
1

'.LAM

1 1
1 1
1 1

+ +

1
1
1

1 1 1
1 1 1
1 1 1

+ 4- +

1
I I
1
1 1
1 i 1 1
I I
+ + 4-J-

ROOFBOLIING k MONITORINO

I
!
i
I
+

'O O CAflPico oui IL icroiOANCT WIIM 'IMI UVIAGCIM s/*.ncuc

'oe IM( I.ISI>IL>I'0'. k uOHiioflmo o' <:>30'(, cpronuwcr
4 CCOROANCC MTH IM( PRCSCNI OSmM i o n COOC O PRCICt
i HOICS roR CUiOA C(. 'SUPPORI Of umi e0rs o< locuaous'
U 'CA BI.C BOLlINC rOR RCOr SUPPORT'

BOLTING SPECIFICATION
C*Hn P 0 \ ' 10 'nlKUO ". * t\j>(

coAi

sec rACC MOO SIJPPO! u n i

roR s e t ooi oc u n :

tu

Q
ra

CD

;: Q
iii
rj
G

10 fl( 1 ir*
SIOJB ( ( *1

.O OOWO *<\&H(k

< 0 * U / ( . v t * n < x i r

l.roiK/<

". . no~~ rvi* . t-'< (moi

. . * / > * . ' ^ 1 . (
jtUlfftH IO IV- '.ev. / .S - * t * ( 0 >*

r . ower^, ue~ (*>>< tc*i>>) ' . :iv. <oi \|i (ini

gflUKM> '0 *M*KO IO H V**f *ICinc*IONS

SECTION A - A

oiRCCiiON o r ORIVACC

l Jm f./-)") ' ! 1 0 SK>viMC O" / . r\ >_

lOO-m ( C ( M l C * ' 0 l ( KS
. 1"0* K l O
* * u-wCU*lfta i < \ ( S m.rtI *( n ( - O n M t O
- Ki fUMVCMxr PO-OL IO 0*K'^t OU

SECTION B - B
?

CNCJ or JUNCTION

UH*CCI*ei(

cnzrc U o" G M G" G G

1
UI
UI

G G G G G %
:
G G G G G G G

CXTRA BOUS
MAY OC INS CRICO ' LOCAI. CONDITIONS
I N O I C A I C THAI THCr ARE nCOlMREO

Y7?i

QQfi^
a cfa a

ci

a tb a G a a
a aa a

B 1.6m SIRAP CXTCNSIONS

WITH THRCC Roorsoiis s n
O 0.6m c l i . PLUS
H ROOCBOUS * PIAICS
O D i m cli OCIWCCH
CXlSIINC SIRAPS

G g G G*G G G,G cff.G G

SCC TACC HOC. SUPPORT RUICS

G G G G G G.l3
,

Figure 4

G G G G

Otfl-

G G B B ^ B
B

BRI1ISH COAL

B
IO ROOrOOLlS li PIAICS O 0 6m ci>

B B

F2F

ya-

B'DfG B

9 ROOreOUS * PLA1C5 O 0 6m cil

ROOroOUS 4 PuMCS O 0 6m cl
STARI 0 JUNCTION

m nil.

KY

H504S TAIL GATE /

DUAL MCICHI TCll-l*lC (Sm/ Jm|

FACE HEADING

Sede

SONiC CTCN!,OunCl ( ) Sm) >

PLAN

GROUP

JUNCTION PLA

m SIRAP CxtCNSiOV WIIM 2 OOroOi.15

0 lw

NOR'HERN

RICCALL MINE

Btb B

B B B G G

-A-

G fa G

G G G G G G G
|

-A- -A-

NORuAl HCAOIN'", SuPPORI

(SIACC J BOUiNCI

- 1/

OOUOU OIRDCACC CAdiC (lOlt (6m)

09m<)
NORMAL HCAOINC SUPPORI
(StACC i BOUlNG)

THIS PL AN TO BE READ IN CONJUNCTION WITH HEADING SUPPORT RUL ES

SiCNCO
IJANACC

PLAN RCFERENCC No

S JI06

ritish Coal Rock Mechanics No: 448382964l at 10 53 15/FEB/94

File; R503TGF
RICCALL MINE H503's F ACE HEADING (T/G)
TELL TALE MOVEMENT
Date: 24/N0V/93

Figure 5

175

175

150

150

125

125

e
e

100
Ln

2
LU

LU
U
<
-J

a.
co

100

75

75

50

50

25

25

-40 -20

20

40

60

80

100 120 140 160 180 200 220 240 260 280 300 320 34G50
TELL TALE POSITION

BOLTED HEIGHT 'A'

g|

(metres)

ABOVE BOLTED HEIGHT 'B'

ABOVE ACTION LEVELS

RICCALL COLLIERY
503'S FACELINE
HEIGHT OF SOFTENING (m)

||

ILI3o

t
l/l

vi

WP

C)

u 2
O

X
LU '
X

gh

\f

10

20

30

40

50

60

DISPLACEMENT (mm)
Station 1
4 MM

Station 2
20 MM

Station 3
70 MM

Figure

Station 4
120 MM
A

Station 5
170 MM
O

70

ROCK MECHANICS. TSRE : ROOF STRATA ASSESSMENT

Colliery:
Seam:
Oistrict:

Metre Mark:
Date:
Logged by:
Cored by:

Riccall
Barns ley
H430's Tail Gate

Log

Sample
s
No
MPa

Sept 1992
D J leigh
Group

E
GPa

/E

18.3

4.03

Bond
Strgth

SILTSTONE

Grey, fine-grained. Micaceous. Scattered

lant debris. Rare, sandy laminae

top. Generally hard.
? ovaras

73.8

7.09
to
9.18
82.8

18.8

HUOSTONE
Grey, silty. scattered, finely
coercnuted plant debris throughout.
Micaceous in part. Locally
coarsergrained. Darker grey at base.

19.2

2.1

4.40

5.5
to
9.18

67.7

2.4

3.52

8.76
to
9.18

1.8
1.5
1.2
".90

IRONSTONE
MUOSTONE
Grey/dark grey. Abundant plants.
Quite eat.

50.4

MUOSTONE
Dark grey, caroonaceous. Abundant
plants, very weak and broken.

-1

Table

158

5.42
to
6.26

.60
.30

ROCK

MECHANICS,

TSHE

: ROOF

STRATA

ASSESSMENT

Metre

RICCALL COLLIERY

Colliery.

Ricca))

Seam:

Barnsley

Oistrlct:

473's

Mark:

58

Date:
Logged y:

BARNSLEY SEA M 473'S MA INGA TE (L\H)

HEIGHT OF SOFTENING (M)

C.P.Eaton

Cored 0y:

T/G

Log

ample

No

MPa

GPa

10

59. 1

52.4

Dond
Strqth

X
r

->

JD

5
SILISIONE-MUOSIOHE
CooMm. u n r t banni
and ferruginous are

t?;
1 . 12
4
4

Z
9

37.5

32.6

?3 3

1) ""

34.9

4.6

93.0'

Z?~I 5

43.6

31.5

40.5

1 . 15

3
3
YnON^tONE 0NO

Ln

5ILI5II!WCUVIO5I0W[
Cooilinl In D i r t i
SMIISINEHUOSIONE'

'

VKONSTONE NO

LO

HuOSTOUE
S'ootn

'"

'

SILiSTONE-huOSTOHr
~
S K I - c o a p i u n i , plant
m t i r n in parti

-*'

S i l IS'ONE-HUOSTONE
Plant d t o r l i .
tak
p a r l i n o , ! ana bandi

40

60

80

DISPLACEMENT (mm)
Station 1
5.5m Wide
D

St. 2 205 MM
5.5m Wide

Station 3
5.5m Wide
O

Station 3A
5.5m Wide
*

Oct'90Ocf91

Table 2

41.6

37.9

17.6

Seam Depth (m) 6 5 0

1.2
3

.90

3
torn

2.1

1 .5

St. 4 455 MM St. 5 698 MM St. 6 35 MM St. 7 1115 MM

5.5m Wide
5.5m Wide
5.5m Wide M\G FACE JUNC

1 .38

i.e

5KI510f*L-HlK)5INE
Slat - c o f * p t i t n i

SH.1SI0NE-HUOSI0NE
Sealrartny. . u t . plant

2.4

20

.710

29. 1

2 . 15

.60

.30

9.3

CASTLEBRIDGE

COLLIERY

9.3.1 BACKGROUND
Workings at the Castlebridge Access area of the Longannet Complex
in the Upper Hirst seam are at a depth of 500m. Seam thickness
varies from 2.1 to 2.3 metres. In block '' the system of working
is by a series of 'Z' faces, each of the panels are connected by
several cross cuts from the adjacent panel (Fig.l). Because of
this layout some roadways are required to remain open behind the
face lines.
9.3.2 GEOTECHNICAL FEATURES
The roof strata is composed of weak but stiff dark grey
carbonaceous mudstone to a height of 15 metres. There are
occasional ironstone bands and nodules at various horizons and
there is an increase in silt content higher up. Polished surfaces
and listrics are prevalent in the immediate 1-1.2 metres. A
detailed log of the immediate 5 metres of roof is shown in table
1. However the roof lithology is known to be changeable and where
the poorer roof conditions exist there is an abundance of
slickensided joints. Where this situation exists conditions
deteriorate rapidly. The strength to stiffness ratio indicates
that the immediate roof will be capable of absorbing relatively
high strains before softening of the rock occurs.
The immediate floor of the seam consists of seat earth mudstones
of variable thickness and sand/silt content. Thickness can vary
from 0-0.6 metres. This is underlain by 2 metres of medium
grained competent sandstones
The roof is susceptible to softening above the bolted height.
Softening to heights in excess of 5 metres have occurred whenever
the roadway width has exceeded 3.9 metres. Effects of roadway
width are shown in figure 2.
Roadways are driven at about 45 degrees to the known line of
maximum horizontal stress. When the faces are operational
roadways are subjected to changing stress patterns from the
adjacent panel. This has a marked effect on the stability of the
roof where significant softening may have already occurred above
the bolted height.
9.3.3 SUPPORT CRITERIA
Roofbolt patterns in the Castlebridge Block roadways, confirmed
by monitoring, are established as 6 2.1 metre AT bolts set
through a 'w' strap at 600mm centres. In the lengths of roadway
that achieved primary support at stage 4, with wooden legs, at
widths of 3.9 metres this gave a roofbolt density of 2.56/m2.
Where total primary support was achieved in B06's the excavation
width was reduced to 3.8 metres giving a density of 2.63
bolts/m2.Ribs are meshed and reinforced with 3 1.5m AT bolts
set through patch plates, steel on the solid side and fibreglass
on the face side set at 1.2 metre centres.
160

Initially the criteria established for action levels of

reinforcement from the early experience gained at the colliery
were:
TELL TALE 'A'

TELL TALE 'B'

>

15mm

<

15mm

>

15mm

<

10mm

10mm < < 2 0mm

>

20mm

Coupled bolts
Coupled bolts
Cable bolts

9.3.4 CABLE BOLTING - EARLY EXPERIENCE

Early experience of cable bolt installation was gained in B05's
Tail Gate. This roadway was driven at 4.2 metres width. Routine
monitoring indicated high amounts of roof dilation. From the tell
tale plots in figure 3 it can be seen that movement in several
places was above the bolted height. Significantly two of the
areas with the greatest movement displayed were mobilised
following
the mining of wider excavations (a sub-station and
junction, followed by a further junction). Further investigation
also revealed that deterioration was additionally caused by a
change of roof conditions and was in an area which had an
abundance of slickensided joints. When compared with B05's Main
Gate (excavation width 3.9 metres) it can be clearly seen how
sensitive the Hirst Seam is, in this area of the colliery to
width of excavation.
Initially 8 metre single birdcaged cables were installed in a 3/2
pattern which gave a density of just over 1 bolt per
square
metre. This pattern was dense to reflect the conditions that
prevailed and consideration was given to the role of this roadway
and the likely stress effects from operating the adjacent panel
B04's.
The established pattern of cable reinforcement for a 3.9m
excavation width is 2/1 and by using the above criteria for
action levels by quick identification this density is sufficient
to prevent further deterioration.
An example of this is shown in figure 4 where a section of B15's
Main Gate required reinforcement by cables. Early placement of
8 metre single birdcaged cables contained the amount of
displacement to an acceptable level. Following the installation
of the cables the continuing strain within the roof increased the
height of softening up to 4.2 metres. Above this height only
minimal movement occurred proving the need for the chosen length
of reinforcement. The face was allowed to progress without any
hindrance.
9.3.5 CABLE BOLTING - LATER EXPERIENCE
Following the considerable amount of monitoring information now
available the previous action levels have been superceeded. Cable
161

bolts are installed when the amount of movement above the

roofbolted height exceeds 25mm.
Double birdcaged cables have superseded the single birdcaged
type. They are employed using the same lengths and densities as
previously used. The improved reinforcement capacity provided by
the higher capacity cable has graat significance with this type
of roof.
The results obtained from sonic extensometers in B06's Maingate
have been analysed and summarised into two plots. Figure 5 is a
multiple plot showing total roof displacement both above and
within the rockbolted horizon and the height of softening at each
sonic extensometer station along the gate. Figure 6 is a similar
plot which relates tell tale measurements above the bolted
horizon to the height of softening recorded with sonic
extensometers.
These plots indicate that the roof of the Upper Hirst seam in
this area of the mine is susceptible to softening occurring above
the bolted horizon for modest total roof displacements. They also
indicate that the degree of resolution required to accurately
identify roof softening at discrete horizons is best obtained
from sonic extensometers. Based on this information the
installation of additional reinforcement in these areas has
maintained roadway stability and prevented the softening
progressing to higher roof horizons.

162

LAYOUT PLAK

Figure l

LU

EFFECT OF ROADWAY WIDTH ON ROOF STABILITY

CASTLEBRIDGE.

LU
O
>
O

<

100
90

7m

<
I

LU

HEIGHT OF SOFTENING

LL

> 7m

70

60

(au.

50

40

cr

<

Z
LU

3.5m
30

20

LU

Q.

C)

2.5m,
<7

Ii

u.
O
O
oc
_J

10

(B

0
ROADWAY WIOTH (m)

Figure 2

B05"$ M J G
30
>

3.9m Wide

4 .210

6 B o l t s / s t r a p @ 0.6m c e n t r e s

SF

25

20

iJ

12

IS

IO

sa
72

133 2

148 fi 182 4

201.6
2*2.4
266 4
Measure Mark 'm)

T E L L T A L F . A (2

lm)

rrra pr?

LTS

Ss

324

366

411

4M)

S06

(2 I Sm)

BOSs T/G
100

4.2m Wide

7 Bolts/strap + spot

bolts

80

60

40

Junction

T16

TO
261.6 529.2 559.2
822
829.2 922.8 1009.2 1054.8 1131.6 1197.6 1270.8 1346.4 1432.8 1531.2
498
558
606
804
870
975.6 1012.8 1090.8 1154.4 1236 131S2 1404 1480.8
Measure Mark (m)
T E L L T A L E A (2.1m)

165

(2.1 Sm)

Figure 3

British Coal flock Mechanics No: 44838189611 at 09: 54 30/JUN/92

CASTLEBRIOGE Bl'S
File: C SB15X2
M/G STATION
ROOF EXTO.
OISTANCE INTO STRATA (m)
8

Rdg HOS (mm)

2 1474
7 2662
12 2662
15 356
IB 35B6
19 35B6
21 3586
24 356
26 4295
27 4295
28 4295
29

2 09/AUG/91
16/AUG/91
28/AUG/91

0 9 / S E P / 9 1
0 - 0 18 3 1 / 0 C T / 9 1

-+ 19 12/N0V/91
- - 21 22/N0V/91
M - 24 23/DEC/91
0 - 26 13/JAN/92
* -f 27
03/FEB/92

- * 28 2 4 / F E B / 9 2

- 29 09/MAR/92

....
7
1
/
.. / 4 1

4295

i^srfa

en
en

HH-5.mgg5S^

1 M

bi U ^ x
t

100 90

BO

70 60 50 40 30
STRAIN (mm/m)

""*

20

10

10

20

30

40

50

60

70

DISPLACEMENT [mm)

Figure 4

_L

_L

90 100

2im
65m
92m
i02m
317m
295m
276m
230m
211m
164m
175m
16Bm

BO's Maingate Mid Roof Extenso meter Analysis

>

500

1,000

1,500

2,000

Distance Along Maingate from C3 I's (m)

Displacement
Above Bolted Horizon

Displacement
Within Bolted Horizon
A
Figure 5

TotalI Displacement
DlSDUk

Ht of Softening
4<

B06's Maingate Tell-Tale/Ht.Of Softening Analysis

en
oo

500

1000

1500

Distance Along Maingate from C31's (m)

Tell-Tale Disp.

Hi. of Softening

Figure 6

2000

C r l l i e r j : Lc.f06ftuio&r

Seam uPP&jg. H I R S T

D i r t r i e t : B lS"k

<^

Dare: ( / s / ^ /

Logged by: NToMSS

Cored bv:

JRCKSON

~3

Desrrip.ion

o;

G?a

1
bl

.""~

//

02

/O

75

?3*
fi/l

osjr>ftAj"r

SJry

~=r

ft

I rco

U^-5

19

^^~

S
1

U-U

WM,
r////

HIKST

i
6

'

' 1 i.

/ / / / / /

58 '

90

7///

^W

1
otes 0 r e l a t e s t o bottom of core i . e . roof l e v e l . Log r e q u i r e d t o top of seam or
" l o t l e v e l whichever i s l o w e s t . Bond s t r e n g t h o b t a i n e d from s h o r t e n c a p s u l a t i o n p u l l
!3t a t same l o c a t i o n .

Table

'

333

I
1

113

'

91

IM

'

25

f I S "

level

UPPER.

55 I

_"z.r_

3~~"

I
82

C/*&&*AJ/*C^O(JS

36-8

.8
~

SU?***

_I

/M

!
Su+m-v

11'

AJSTC
J S

b'

I S t i f f n e s s S t r e n g t h
rife

S t i f f n e s s I S r r s n g t h / sono.

SsJDole S t r e n g t h
MPa
1 Vo"

Log

[tetrc Mark: 174"

169

9.4

KIVETON PARK COLLIERY

9.4.1 BACKGROUND
36's Loader Gate in the Clowne Seam, see figure 1, progressed to
primary support by roofbolts (stage 4) during 1991. At this
location the Clowne Seam is 1.1m thick and at a depth of 250
metres. The roadway was driven at a high angle to the maximum
horizontal stress and so required a dense roofbolting pattern.
Figure 2 shows the relationship of roadway orientation to the
maximum horizontal stress direction determined by stress mapping
carried out during the site investigation for the geotechnical
appraisal for roofbolting. Vertical stress values were low by
virtue of its depth, except for a short length of drivage over
a pillar edge in the Barnsley seam.
9.4.2 GEOTECHNICAL FEATURES
The lithology and strength of the five metres immediately above
the Clowne Seam can be seen from the log of an underground
borehole taken in 36's Main Gate and shown in table 1. The
immediate 1 metre of roof consists of a weak mudstone varying
from a slightly silty to a sandy laminate. Above this horizon is
a medium strength siltstone, finely graded with occasional
ironstone layers and nodules. The siltstone is overlain by a
partly carbonaceous mudstone. Mechanical testing of this strata
log confirmed the immediate 2.8 metres of roof to be of medium
strength and stiffness with increasing strength towards the top
of the section. The strength to stiffness ratio of the weaker
strata was found to be low.
On average the roadway was at an angle of seventy degrees to the
line of maximum horizontal stress but there were localised
variations in stress direction due to changes in seam dip and
consequently there were corresponding changes in roof conditions.
The inbye section of the roadway was affected by the presence of
a fault, inbye of the face line position. This length of road was
at an angle approaching ninety degrees to the maximum horizontal
stress.
9.4.3 MONITORING
Initial support of the roadway, which supplemented the delta
section arches, was by 7 2.4m bolts set through 'W' straps with
2 1.5m rib bolts either side in a 4.5 metre roadway. This
initial support allowed the roadway to progress to primary
support even though the immediate 0.3m of roof was weak and
prone to early failure.
Once an increase in roof movement was recognised on the outbye
monitoring stations support density was increased
initially by
post bolting with an additional 3 bolts/metre. Support design was
modified as the heading progressed to take account of the
additional roof dilation. The inbye half of the drivage
progressed by intensive monitoring to 12 bolts/metre, the width
being reduced to 4.2 metres.
170

A comparison of roof behaviour at the first three stations shows

how the height of softening develops above the bolted height
(figure 3 ) . Development of roof movement had a delayed effect.
At station 3 the roof softened to a greater height but took
longer to develop.
An appreciation of the changing situation caused by the seam
topography and stress can be judged from the results obtained
from routine monitoring shown in the tell tale plots in figure
4. The rate of movement can be judged by examining the two plots
which cover a time span of three months.
9.4.4 CABLE BOLTING
The changing situation became very apparent within the last 250
metres of drivage with stress breaks and stress fractures
becoming evident soon after drivage. Additional bolting was
immediately employed but was not sufficient to control the
continuing displacement and development of softening and further
reinforcement by cable bolts became necessary. Twin birdcaged
cable bolts were employed to reinforce the ground and prevent
further deterioration. From the nearby sonic extensometer plots
the development of the height of softening was seen to be
stabilising at 2.9 metres so 6 metre long cables were considered
to be sufficiently long enough to reinforce the failed ground.
They were placed in a 2:1 pattern (1.5m either side of centre
line and then 1 on centre) at 1 metre intervals.
A Modular Bolting System (MBS) machine was available and was
found to be suitable both for its drilling capability and its
mobility. The response to employing additional reinforcement
measures prevented further deterioration taking place. Figure 5
shows the stabilising effect on station 15 following the
installation of the cables. The effect from working the face on
the station can be seen in figure 6. It can be seen that although
further softening has developed the effect of the cable
reinforcement is to contain the movement within acceptable limits
without inhibiting the passage of the face.
9.4.5 CONCLUSIONS
The lessons that were learnt form this site:
a)

A high bolt density is essential to limit softening to

within the bolted height where roads are driven at a
high angle to maximum horizontal stress.

b)

A uniform pattern of bolts is the best design where

stress is at a high angle to the drivage.

c)

Important to keep gate width to a minimum.

d)

Roof movements at this site increase some time after

drivage over a period of a few days as the roof
failure occurs at higher horizons due to the action of
horizontal stress.
171

e)

Local seam topography can have a significant effect on

the stress field and support conditions.

f)

Precise reinforcement requirements can be designed

after identification of the failure mechanism and the
level of roof deterioration determined by the height
of softening.

172

LO

LAYOUT

PLAN

 34
N 36

m/g

34

t/g

Max. Horizontal Stress Direction

KTVETON PARK

STRESS MAP

Figure
174

m/g

KIVETON PARK

N36

LOADERGATE

ROOF FAILURE CHARACTERISTIC

5 -

4 -

2
LU

3 -

u.

2 -

I
1 -

ROOF DEFORMATION (MM)

Figure 3

KIVETON
N36's M/G TELL TALES

mm
100
80
60

^1

en

START OF PRIMARY SUPPORT

ON BOLTS

80

10/FEB/92

CABLE BOLTING ONGOING

60
40
20

JLgggiJflUvti*
184 261 330 377 431 476 543 635 735 838 925 1025 1112 1193 1290 1380 14711555 1586 1636

METRES ALONG GATE

Figure 4

A TYPE

TYPE

Bpltleh Coei Rock Hochonice Softwaro et i l: 20 on 02./FEB/1992

KIVETON PARK COLLIERY
N36'9 LOADER GATE S T A T I O N (IB)
HIO ROOF EXTO 0 1650m

File:

Br-Uisn C ool Rock Mocnonics Software 11:20 on 02/FF.B/199;

KIVI6RXS

KIVETON PAflK C OLLIERY

N3B'9 LOAOER GATE : S I OM 5)
HIO ROOK

EXTO

F\\0-

KIVI5RXS

1669P.

30
I
3

9
.... ij

4 16
-0 16
- 17

02/N0V/9I
I 1/N0V/9I
IB/N0V/9I
07/OEC/9I
14/0EC/91
07/JAN/92
20/JAN/92
Ol/FF.8/92

lm
24m
53m
93m
l I lm
1 14m
1 14m
1 14m

33

o - o o
.in
* .334948
1
' 2,277034

30

27
2

h-

21

-J
^i
IO

2
IU
X

<

7.
IH

/
15

I?

.... .. ..I.' ..I. ... J ... . .. . ) ) b \

6
9
12 15 IB 21 24 27 30 33 36
DISPLACEMENT (mm)
-.%

Figure 5

' - ' l '- ' ' ... I -..!.. J ...I I . . |. . | |

IO 20 30 40 50 60 70 0 90 100 I IO 120 130 H O 160

Ur.F.

lue va)

British Coal Rock Mechanics No: 44838289630 at OB: 34 02/DEC/92

KIVETON PARK COLLIERY
File: KIV15RXS
N36'S LOADER GATE STATION (15)
MIO ROOF EXT @ 1559m (FACE LINE @ RM 1580
Rate of Movement - 487mm/i00days HOS/DISP B 60mm/mm
DISTANCE INTO STRATA (m)

Rdg HOS (mm)

1 0
3 724
20 2BB4
30 2BB4
39 2BB4
40 2BB4
45 2BB4
49 5261
50 5261

1 02/N0V/91

114m
-1 J 11/N0V/91 114m
V i n 03/MAR/92 114m

24/AUG/92 114m
" u JU
0- - -0 39 20/0CT/92
96m
4- - -+ 40 22/0CT/92
91m

- 45 05/N0V/92 50m

- 49 15/N0V/92
27m
0--- -0 50 17/N0V/92
21m
-

oo

100 90

70 60 50 40 30
STRAIN (mm/m)

30 40 50 60 70
DISPLACEMENT (mm)
Figure 6

BO

90 100

Sean: ( > 0 ^

Colliery: k t / g - r W
3_g

l K :

District:

Logged b y : ^ - U / W r O g C o r e d by: C^ofZjCS

~ escripnon

Log

Sample S t r e n g t h
Ho

<]

* i : T o /f, , CK -- -J c - o O i ,
C-^r^^t- 'J T o p <-i^ii_T=

kiCfHL^Y

Pc/CCC,.^o<Ji.

IJ T O P

">>5->/. , Sit_T-7 (f.^iz.

rw>vJA

BiTlrWe

SA^nSi

(1IC .HT1V TV ,

if l e v e l hft> Co P f
r^>p o f "DLrA

. . J D S T W

lV3,* M Q Metre Hark:

/fc n

L\P Zo ***<* T f e , ^
StiffnessIStrength/
Bond
GPa
S t i f f n e s s Strength

S5-7-

/S-5

/?f

3>^3

/go

/-?

33

5^42

Q-il

42-Q

/7

2-

37/

/f

Z-Z

245

27-2

/7-3

27

/7?

/5<

2?-f
2-7

ZI

2-3/

o 13 ~

'/KZCJM

""

.CjVjS^^A tJS.ootS

-2-.ifS

iAi_ oDtj tv/e seA**

- 3-"o
<_ixv\tA<_T.

s 0 relates to bottom of core i.e. roof level. Log required to top of seam or
"level whichever is lowest. Bond strength obtained from short encapsulation pull
at same location.

Table 1

179

9.5 OLLERTON COLLIERY

9.5.1 INTRODUCTION
The Parkgate seam is predominately overlain by strong silty
mudstone in most situations and locations in the Nottinghamshire
Coalfield. However in the South East section at Ollerton Colliery
it was found to be overlain by a weak mudstone of a thickness
varying from 1.75 to 2.75 metres.
19's district Loader Gate was driven in this type of strata with
the intention of progressing to primary support by roofbolts. The
drivage started in early 1992.
In this locality the Parkgate is at a depth of 770 metres and had
been overworked by the Top Hard Seam which is some 19 0 metres
above. The Loader Gate was crossed by a small area of Top Hard
goaf between 330 and 358 metres. The remainder of the gate was
driven in the solid (figure 1).
9.5.2 GEOTECHNICAL INFORMATION
The stress regime was identified by underground stress mapping.
Major horizontal stress was found to follow the national trend
NNW/SSE. This meant that 19's Loader Gate was to be driven at
approximately 30 degrees to the major horizontal stress component
which would give a stress notch on the right hand side of the
roadway on drivage. As the majority of the roadway was in the
solid the vertical stress would be eguivalent to the weight of
overburden.
An underground core confirmed the weak nature of the immediate
roof and that weak mudstone was found up to 2.3 metres above the
seam. A core taken at the 1012 MM found it up to a height of
2.8m. This was overlain by stronger beds of mudstone progressing
into unlaminated siltstones and sandstones.
It was not possible to achieve acceptable bond strengths from
27mm negative rake bits from short encapsulation pull tests.
26.5mm positive rake bits were tried as an alternative and these
gave acceptable results, and were used for the majority of the
drivage length.
9.5.3 ROADWAY SUPPORT
Initially the roadway was supported with 4.8m 2.6m flat topped
arches set at 1.2m centres this was supplemented by a roofbolt
pattern of 2.4m length in a 6/5 pattern placed through 4.5m 'W'
straps spaced at 0.6m centres.
The ribs were reinforced with 1.8m AT bolts on the solid side and
fibreglass bolts on the face side, three bolts set at 1.2m
intervals.
Results from the initial monitoring station showed the bolts to
be highly loaded and considerable shear occurred at the 1.8'
180

horizon. Roof movement stabilised after 3 0mm of total movement

occurred but the ribs continued to mobilise.
Consequently the roof pattern was modified to a 7/6 pattern.
Results from the confirmatory station of this support density
showed the bolt loads to be less but still subject to high
bending at the 1.8m horizon. The roof behaviour was consistent
with station 1 showing less displacement (15mm) and the softening
extending to a height of 1.8m.
Progression was made to primary support with the addition of a
spot bolt on the right hand side of the six bolt strap, and with
the roadway width reduced to 4.2m. At 850m progress was made to
stage 5 support (removal of wood legs) which allowed the roadway
to be cut to a tighter profile thus by decreasing the roadway
width improving roof stability.
At around the 1000MM the roof horizon was lowered to the top of
the seam to provide a more uniform top to a good parting.
As the heading progressed changes were made to the rib bolting
pattern. Initially modified to a 2:1 pattern at 1.2m centres then
increased to 0.6m centres.
9.5.4 COUPLED BOLTS
High bolt loads were continued to be monitored and although the
height of softening was contained within 2 metres, a 2 bolt
pattern of 3.6 metre coupled bolts was introduced to increase the
support capacity above the bolted height and improve the
stability of the road for when the face retreated.
Coupled bolts were preferred to cable bolts as they could be
applied more rapidly and offered a stiffer reinforcement system.
Pull tests were carried out on the coupled bolts to determine the
achievable bond strengths at the upper horizons. 5-6 Mpa was
measured and as it satisfied the minimum standard as laid down
in the code of practice was considered to be satisfactory.
However the density of coupled bolts had to be increased to a 3:2
pattern as shown in figure 2. This additional reinforcement
capacity above the 2.4 metre horizon of 125 tonnes/metre was
revised to take account of the additional stress surcharge
anticipated on retreat due to the high angle of the roadway to
the direction of maximum horizontal stress.
It can be seen from the results from stations 3, 4, and 5 (figure
3) that the initial coupled bolting pattern reduced the rate of
roof dilation and slowed the increase in bolt loads. The revised
pattern was considered necessary to make further improvements.
9.5.5 CABLE BOLTING
As the heading progressed the height of softening, determined
from the monitoring stations developed up to 3 metres. However
no extension of the height of softening occurred with time and
there was no indication of any significant strain in the higher
181

strata after time.

Roof movement was controlled but not totally stabilised. This
movement was generated by strain within the bolted height caused
by the extra benefit provided by the addition of coupled bolts.
Cable bolting was introduced and recommended to be carried out
for an extensive length of the Loader Gate to provide additional
reinforcement against further development of strains at the
higher horizons during face retreat. Priority was given to areas
exhibiting the higher heights of softening.
The initial design consisted of 5 metre long twin birdcaged cable
bolt anchors at 1.2 metre centres placed in a 2:1 pattern, shown
in figure 4.
During the process of cable bolt installation additional movement
occurred. This was triggered by the use of water during the
drilling process. The reinforcement provided by cable bolting in
the main stabilised the movement except at stations 7 and 8
(1070m and 1136m). The roof strain in these areas reached
softening levels at a height of approximately 5.5 metres.
8m long twin birdcaged cable bolts were installed in these areas,
initially and then their use was extended throughout the length
of the roadway to ensure adequate reinforcement was provided for
the longer term stability of the road during production.
9.5.6 ROUTINE MONITORING
The amount of displacements and the extent of the cable bolting
works along the length of the loader gate can be seen from the
tell tale plot shown in figure 5.
Additional tell tales, purposely designed for cable bolted areas
were installed to monitor further roof movement as an extra
control mechanism. They are identical in design to the existing
type of tell tale. To distinguish them from the conventional type
these are coloured white, blue and yellow. They were installed
between the existing roof bolt tell tales. The 'A' type was
anchored at 4.5 metres, the ' ' at 9 metres such that any
movement occurring within the cable bolted length and in which
portion of it could be instantly recognised.
A threshold level of 10mm of movement on the 'B' type was used
as the initiation level for higher levels of reinforcement being
necessary.
These monitors were formally incorporated into the collieries
monitoring scheme.
9.5.7 RIB REINFORCEMENT
As part of the extensive repairs undertaken to rehabilitate the
roadway prior to mining the face entry it was necessary to take
182

a substantial floor dint. This was responsible for reactivating

fresh rib movement.
A programme of additional rib reinforcement was undertaken to
control this movement and stabilise the ribs. It was recognised
that further rib movement would be generated by the abutment
ahead of the retreat face. This was required to be controlled to
ensure that the passage of the stage loader and the associated
face equipment was not inhibited.
5m twin birdcaged cables, steel, were installed on the solid side
and fibreglass cables on the face side, at a density of 0.9m in
a 'W' pattern as shown in figure 6. This was one of the first
sites in the UK to use cuttable cables. These were the type
manufactured by manufacturer A and were installed initially in
43mm. holes.
Some installation difficulties were experienced in inserting them
in this size of hole. The problem being that they were a tight
fit and were furnished with a small bore 5mm breather tube, which
was not successful, being too small a diameter for the duty
required. The problem was resolved by increasing the hole size
to 50mm and replacing the breather tube with a conventional 10mm
bore which was incorporated in the design, by positioning through
the centre of the cable.
This work was started 100 metres from the face start line,
systematically working out along the roadway. Positioning of the
cables within the ribs was particularly important to ensure that
the ribs were not allowed to be further coupled to the roof, thus
preventing any further movement in the ribs transmitting into the
roof.
9.5.8 CONCLUSION
An extensive amount of reinforcement work was necessary in order
to allow mining operations to continue. The consequential costs
involved and restricted performance levels seriously affected the
colliery results. In February 1994 development of the district
ceased following the announcement of the closure of the colliery.
Progress of the face line drivage had been slow and difficult
requiring cable reinforcement to be maintained throughout the
excavated length and to be undertaken within 10 metres of the
face of the drivage. These problems were due to an even thicker
mudstone combined with the effect of a wider excavation at an
increased angle of drivage to the maximum horizontal stress.
The level of reinforcement in the Loader Gate was sufficient to
maintain conditions and allow the further progress of the
development. Extensive design and routine monitoring had enabled
optimisation of the reinforcement requirements to be determined
in very extreme conditions.
However the curtailment of activities at the colliery prevented
the verification of the extensive roof and rib reinforcement
183

programme carried out to provide the longer term stability of the

roadway, during production, being assessed.

184

F GURE 1
Siopped foces

(V)

Working foces
Development

]y

foces(?-

i
^^'h~''~^-l .d
"*. ; -

Spi
?':]
J "Z>

^/(sf
/ 7

185

Ollerton Colliery
Parkqate Seam

Ollerton 19's Loadergate

3x2 Coupled Bolt Pattern - Stage V
2.6m
1.3m-

3.6m long
coupled bolls

2.4m Roofbolts

1.8m sleel
Rib Bofts

1.8m GRP
Rib Bofts

Faceside

Ribside
4.5m wide

Section

36m

^ u

1
coupled
bolts

-2m 13 hole strap

T)

'-*" *E1

M.

M.

'

if

>

|- -)

Plan View

Side View

Rock Mechanics
JSOV 17-11-82

186

British Coal Rock Mechanics No: 44838189630 at 16: 57 26/JAN/93

Ollerton Colliery - Parkgate Seam
1 9 S Loader Gate - Station 3 595.5 MM

o Stn . 3. 595m
+ Stn . 4. 795m
Stn .5. 925m

70

60

50

LU

oo

^1

tu

40

<

30

>
o

cr
-

U)

_)
<

20

10

20
TIME (days)

Figure 3

Ollerton 19's Loadergate

2x1 Cable Anchor Pattern - Stage V
5 m long twin
b i r d c a g e d cable a n c h o r s
1.5m

3.6m long
coupled bolts

2.4m Roofbolts

1.8m steel boil

1.8m steel
Rib Bofts

8mGRP
b Bolts

Faceside

Ribside
4.5m wide

Section
3 6rT

- Vwn2 .,

coupled bolts

-2m 13 hole strap

-v

P3< .8m Rib Bolts

ET

)a im -e|

Sm Tuvin Birdcaged
Cabla Anchors

Plan View

Side View

Rock Mechanics
JSOV17-11-92

Figure 4
188

1.00m

British Coal R O C K Mechanics NO 44838289641 at 07 34 02/MAR/9<I

File: 019LGTT
OLLERTON 19'5 L/6
Oate: 22/FEB/94
500
450
400

350
300

LU

_>
c
ID

250

<

200

LU

_|

150
100
50
200

1000
TELL TALE POSITION

1200

(metres)

Monitorino
I

Station

I BOLTED

-s

HEIGHT

Stage

f C a o ] e B o l t e a
'

>3

ABOVE

BOLTED

1300.345

HEIGHT

'B

Fig-ure 5
AOVE

ACT[ON

LEVELS

OLLERTON COLLIERY, 19's LOADER GATE

Suggested rib cable pattern
Face side

Solid side
Plan view

5m double birdcaged

5m double birdcaged
GRP cable bolts

steel cable bolts

Existing 2 + 1 5m double birdcaged roof cable bolting pattern

Figure 6

Side view

190

9.6 LITTLETON COLLIERY

9.6.1 INTRODUCTION
415's was a retreat panel in the Park Seam at Littleton Colliery.
It was one of five faces planned to be worked in an area where
the Eight Feet Seam had recently been extracted with a succession
of panels (Fig 1) . This area of coal had been previouslyoverworked by the Benches Seam. The Park Seam workings are at a
depth of 800m, being 42m below the Eight Feet Seam which is 64m
below the Benches Seam.
The panels were laid out such that 415's Tail Gate (L.H) was to
be reused as a tail gate for the adjacent retreat panel 425's.
In order to ensure that the roadway was maintained in good
condition for a second use it was decided to cable bolt its whole
length after the completion of the drivage.
9.6.2 GEOTECHNICAL FEATURES
The immediate strata
above the Park
Seam consists of
predominantly competent mudstones with varying levels of silt and
interspersed with ironstone bands and plant debris. Beyond 5m the
strata becomes progressively more sandy with a series of
interbedded sand and siltstones. Rock strengths obtained from the
roof core taken for the purpose of the geotechnical assessment
for roofbolting indicated that the roof was moderate to strong.
Short encapsulation pull tests carried out for the roofbolting
assessment were found to be of a high value with an average bond
strength of 8.6Mpa achieved from results ranging from 6.5 11.3Mpa.
As shown in figure 1 415's has been overworked by 315's in the
Eight Feet seam. 415's Tail Gate runs under 315's waste
approximately 9m from its rib edge for the whole of its length.
This should have the effect of reducing vertical stress levels
from the effect of crossing pillar edges that remain from the
Benches workings.
Underground observations of roadway conditions in 415's roadways
indicated that the gates did not suffer from any induced stress
failure of the roof or floor, with no fracturing or excessive
spalling of the ribs. This would indicate that the major
horizontal stress was acting approximately in line with 415's
development. The national trend is 335 whilst the direction of
415's roadways is 31 east of south (149), approximately in line
with major horizontal stress.
9.6.3 ROADWAY SUPPORT
Drivage commenced with the Tail Gate roadway. This was supported
by delta arches supplemented by a bolting pattern consisting of
7 2.4m AT roofbolts placed in 4.2m "W" straps at 1.0m centres
with 3 1.8m fibreglass rib bolts placed through 2.4m rib straps
at either side of the roadway also at 1.0m centres.
191

The results obtained from the initial monitoring stations showed

that softening occurred in the immediate l.lm which resulted in
a total displacement of 21mm. Above this horizon there was
minimal dilation. Strain gauge bolts showed high loads at the
l.lm horizon. As a result of this high shear zone three
additional spot bolts were installed midway between the straps
to increase the bolting density to 2.38 bolts/m2.
This modified bolting pattern resulted in a very stable roof with
low mean strains and strain difference being recorded. The
remainder of 415's Tail Gate was driven using this modified
bolting pattern which enabled the roadway to progress to primary
support (stage 4 ) . The good results obtained from the monitoring
stations in the Tail Gate enabled the entire length of the Main
Gate to be solely supported on roofbolts.
Approximately halfway along the drivage of the Main Gate
localised faulting was encountered which caused some stress
changes to occur. This resulted in roof displacements above the
threshold levels necessitating some areas of the roadway being
additionally reinforced by cable bolts. Because of the nature of
the faulting and the uncertainty of its extent it was decided to
swop the gates around such that the Main Gate became the Tail
Gate of the district. This then meant that the gate to be reused
was the Main Gate of the district.
9.6.4 CABLE BOLTING
A 2/1 pattern of 8 metre twin birdcaged cable bolts was employed
in the new Tail Gate which was sufficient to control and contain
the affected areas where movement had occurred.
Throughout the length of the new Main Gate on the modified
roofbolting pattern roof dilation was minimal, less than 5mm. It
was decided that because of the extensive length of reinforcement
that was required (860m) and the excellent conditions that
prevailed that 8 metre single birdcaged cable bolts would be
sufficient reinforcement to contain the roadway for a second use.
A 2/2 pattern of cables were installed following the development
of the roadway. In addition to the cable bolting a cementituous
monolithic pack was to be pumped at the goafside edge of the
roadway as the face retreated. Support would be further stiffened
by the addition of hardwood cribs positioned in the middle of the
roadway behind the face as it retreated.
9.6.5 CONCLUSION
The measures taken to reinforce the Main Gate were sufficient to
contain movement generated from working the face within and above
the bolted height to an acceptable limit. Only small additions
of movement were observed on tell tales.
Unfortunately before the face retreated to the square line
position the closure of the colliery was announced and production
was consequently halted.
192

193

9.7 THORESBY COLLIERY

9.7.1 MEDIUM SET RESIN CAPSULES
In addition to determining the optimum dimensions and properties
of bird-caged, multi-strand long tendons and the associated
grouts used, research has been conducted within the Project on
the development of associated materials used in rockbolt
reinforcement.
A single speed medium set resin capsule was developed in
conjunction with the manufacturers (L) for the purposes of rib
bolting only. Its object was to increase installation speed and
reduce bolt installation failures.
Prior to the introduction of this single capsule system all
rockbolts were installed using a two capsule system, one fast and
one slow speed the objective being to allow bolt installation to
be fast, giving full encapsulation. Whereas this has been
achieved with roofbolting, certain sites, for a variety of
reasons, have had difficulties achieving successful bolt
installation in the ribsides. The most common failure is that the
fast set resin can harden before the rib bolt is fully inserted
causing the torque/shear pin nut to be spun home prematurely.
The medium set resin capsules were developed using similar
mechanical characteristics to standard 'AT'resins, namely high
strength and stiffness and medium viscosity. Gel time at 27 is
between 40 and 55 seconds. This was extended slightly following
the initial experience with trials conducted at collieries in the
Selby Complex.
9.7.2 MONITORED TRIAL
A continuous trial was conducted starting in March 1994 at
Thoresby Colliery to fully evaluate the use of medium set resin
capsules for rib reinforcement. The site for the trial was 125's
Loader Gate development heading in the Parkgate Seam. Three steel
1.8m bolts and three fibreglass 1.8m bolts were installed per
metre using hand held borers and a Modular Bolting System (MBS)
which was permanently attached to the heading machine, a Joy
Continuous Miner (Figure 1) . A 1250m long capsule, yellow in
colour, was used to replace the standard twin capsule system.
9.7.3 OBSERVATIONS
Following the completion of 4 00m of drivage a report was compiled
by the Colliery Roofbolting Co-ordinator who made these
observations.
a)

Transport and handling of one capsule was generally more

efficient than two although 16 capsules in a standard type
box requires improved packaging as the box was inadequate
for the weight and length of capsule. This matter was
addressed by the manufacturer who have since delivered
further supplies in heavier duty packages.
195

b)

The single capsule could be inserted into the drilled hole

at least as efficiently as twin capsules either by hand or
by resin loading tube.

c)

The yellow colour was very distinctive

different from either the red or green.

d)

After storage in the heading for four weeks at 30c the

capsules had lost their original stiffness and were
becoming difficult to handle efficiently.

e)

Noticeably less physical effort was required to spin the

bolt through the capsule especially towards the back of the
hole when the red fast set resin would otherwise been
encountered.

f)

There were no failed bolts within the test length.

g)

The trial length of roadway was monitored for rib movement

using multi-wire extensometers. Total movement in either
rib was in the order of 40mm and deep seated up to 5.0m
into the rib. This is similar to the results from
comparable lengths of roadway using the twin capsule
system. The stability of the immediate rib in badly broken
ground appeared to be improved with the medium set resin
(no doubt due to improved encapsulation) but this will only
be proven when the face retreats.

h)

The installed bolts were continuously monitored for length

of encapsulation by removing patch plates and examining the
installed bolts. In unbroken ground and in particular the
dirt band above the coal, encapsulation was 100%. In quite
heavily broken coal the worst encapsulation measured was
74% with the majority being 85% - 90%, this represents an
improvement on measurements taken with the twin capsule
system.

i)

In very good ground conditions the 1250mm capsule was found

to contain too much resin for a 1.8m bolt, with excessive
resin being forced out of the mouth of the hole. In these
circumstances a 1050mm capsule would be appropriate.

j)

The cost per hole of the resin was not insignificant, 27

pence more compared to the twin capsule system.

and

obviously

9.7.4 CONCLUSIONS AND RECOMMENDATIONS

The single capsule medium set resin capsule provides both
operational and geotechnical advantages when used for rib
reinforcement using either hand held or mechanised bolting
systems. The single capsule concept would also offer operational
advantages when used in the roof especially with bolter miner
operations.
Following the field trial at Thoresby Colliery an extension of
the use of the medium set capsules was given to three other

196

collieries in the Midlands Group of British Coal in order to gain

additional experience. Bilsthorpe, Daw Mill and Harworth
Collieries have been designated to extend the trial of the resin,
which is now under way. For this purpose capsules have been made
available in two sizes, 1050mm and 1250mm.
A trial of medium set resin in a roadway roof at a site to be
decided has been proposed, to gauge its operational suitability.
Monitoring of bolt loads and an undertaking to carry out short
encapsulation pull tests would have to be incorporated within the
trial to ensure its geotechnical performance as an alternative
to the existing twin capsule system.
If both of these trials are successful then full operational
acceptance of the medium set resin capsules could be granted.

197

. * &

Figure 1

MBS Mounted on Joy Continuous Miner

1 2 5 ' s Loader Gate Thoresby C o l l i e r y

198

CHAPTER 10
CONCLUSIONS AND RECOMMENDATIONS
i)

The design of cable bolting systems should be regarded as

being site specific if the most effective design and
results are to be achieved.

ii)

All the relevant factors of cable characteristics, grout

characteristics, rock mass characteristics and the stress
environment need to be considered in order to optimise
support design.

iii) Work in the field has enabled parameters of support

density, length and the positioning of tendons to be more
clearly identified.
iv)

Use of the double embedment technique has enabled a

comparative study of long hole tendon systems to be
undertaken together with an evaluation of various cable
bolting grouts.

v)

Results from axial and shear testing of single and double

birdcaged cables show that there is no significant
difference in performance of the cables supplied to British
Coal by the two different manufacturer.

vi)

Alternative types of cable bolts, the nutcaged cable, the

bulbed cable and wire rope have been tested in the
laboratory. Both the nutcaged cable and wire rope have
system performances similar to that of a double birdcage
while having a design that allows for installation into
smaller holes. Field trials will verify this.

vii) Cable bolting grouts have been evaluated by assessing their

strength and stiffness development with time, viscosity and
performance. A fast strength and stiffness development
being desirable.
viii)Key design features, installation practices, training,
monitoring and quality assurance requirements have been
identified and incorporated within a Code of Practice for
cable bolting.
ix)

A quality control procedure has been implemented to check

grout strengths and densities from colliery sites where
cable bolting is being conducted. More work is needed to
develop this system to obtain more accurate results. The
procedure for taking samples allows them to dry out before
they are tested. Also due to the non-compatibility of
testing procedures an accurate figure for Youngs Modulus
cannot at present be obtained.

x)

The double embedment test technique has been used to

evaluate the design of non-metallic tendons. Tests have
shown that they exhibit similar tensile and stiffness

199

characteristics
to
single
birdcage
cables.
Their
development in the field has provided a suitable method of
reinforcing ribsides requiring to be cut out by the face
shearer.
xi)

An inadequacy of available mixing and pumping equipment was

recognised requiring the development of high shear, high
pressure mixer/pump units for grouting of cable bolts. Two
types have been developed enabling the correct mixing and
pumping procedures to be conducted underground.

xii) A series of operational and safety training seminars for

all the personnel involved with the installation of cable
bolts has enabled a high standard of work to be achieved in
the field. This has enabled a list of approved contractors
to be produced to ensure only bona fide personnel are
employed in cable bolting work.
xiii)Work has been directed to develop an AT rockbolt having the
capability to act as a lifting point and suspend heavy
equipment from in addition to its support function.
Identification of an alternative thread has not yet been
successful and further work is required to develop a
suitable bolt.
xiv) Development of a high strength bolt utilising the existing
steel specification has been successful. If the field
trials give satisfactory results, this type of bolt could
provide large benefits particularly at sites using a high
support density.
xv)

Observations from the field trials of the medium set resin

capsule development have
indicated
it to provide
operational and geotechnical advantages for rib side
reinforcement.
Further
trials
will
determine
its
suitability in varied conditions.

xvi) Application of the Strata

and the implementation
materials and equipment
maintained of consumables

Reinforcement Acceptance Scheme

of a register of acceptable
has enabled a control to be
used in the field.

200

REFERENCES
Brady B.H.G. & Brown .T. 1985
Rock Mechanics for Underground Mining.
George Allen and Unwin.
Fuller P.G. & Cox R.H.T 1975
Mechanics of Load Transfer from Steel Tendons to Cement
Based Grout.
Proc. 5th Conference on the Mechanics of Structures &
Materials, Melborne, ppl89-203.
Gale W.J. & Fabjanczyk M.W. 1987a
The Mechanical Properties of Cement and Resin Based Grouts
with Application to the Grouting of Long Tendons.
AMIRA, Project 84/P207, Report No. 7.
Gale W.J. & Fabjanczyk M.W. 1987b
Quantative Measurement of the Behaviour of Grouted Tendons
Subject to Axial and Shear Displacement.
AMIRA, Project 84/207, Report No. 4.
Gale W.J. & Fabjanczyk M.W. 1987c
Coal Mine Roof Reinforcement
: Summary
Application of Long Tendon Reinforcement.
AMIRA Project P84/207, Report No. 14.

Report

on

Gendron ., Jacob D. & Potvin Y. 1992

Grout Evaluation for Cable Bolt Support.
In: Rock Support in Mining and Underground Construction,
Kaiser & McCreath Eds., Balkema, Rotterdam, pp335-339.
Goris J.M. 1990
Laboratory Evaluation of Cable Bolt Supports.
In two parts:
Pt. 1,
Evaluation of Supports using Conventional Cables,
USBM RI93 08, 23p.
Pt. 2,
Evaluation of Supports using Conventional Cables with Steel
Buttons, Birdcaged Cables & Epoxy Coated Cables.
USBM RI9342 (1991), 14p.
Hyett A.J., Bawden W.F. & Reichert R.D. 1992
The Effect of Rock Mass Confinement on the Bond Strength of
Fully Grouted Cable Bolts.
Int. J. Rock. Mech. Min. Sci. & Geomech. Abstr.,
Vol. 29. No. 5, PP503-524.
Hyett A.J., Bawden W.F., Powers R. & Rocque P. 1993
The Nutcase Cable Bolt.
Paper Presented at Queens University, Ontario, lip.
Courtesy of Dywidag Systems International Ltd.
ISRM 1981
Rock

Characterisation,

Testing

201

and

Monitoring,

ISRM

Suggested Methods.
Ed. E.T. Brown, Pergamon Press.
Neville A.M. 1964
Properties of Concrete.
Pitman.
Nguyen V.N, Aziz N.I., Hill J. & Fabjanzcyk M.W. 1986
An Experimental Investigation of Cable Bolt Reinforcement
Ground Movement and Control Related to Coal Mining Symp.,
1986, Aus. IMM Illawarra Branch.
Stillborg . 1990
Rockbolt and Cablebolt Tensile Loading Across a Joint
James Askew Associates, Lulea, Sweden, 24p.
Vutukuri V.S., Lema R.D. & Saluja S.S. 1974
Handbook on Mechanical Properties of Rock, Vol. 1.
Trans Tech Publications.
Windsor C R . 1992
Invited Lecture: Cable Bolting for Underground and Surface
Excavations.
In: Rock Support in Mining and Underground Construction,
Kaiser and McCreath Eds., Balkema, Rotterdam, pp349-366.

202

COAL

CODE of PRACTICE

:->:-XS--y.-Sio:wW-w:*;:

Cable Bolting for Roof Support

1. Introduction and Scope
The use of fully grouted long tendon anchors constructed from wire rope has
become widespread within British Coal mines over the last five years. These
anchors are known as cable-bolts. A single bird caged cable is one in which a
seven strand high tensile steel rope is rewound to form a structure of alternately
tightly clustered, then open mesh strands. Double bird caged cables are formed
from two such ropes.
This Code applies to situations where cable bolts are installed either:
a.as additional support when excessive strata movement is experienced or expected
in roadways, junctions or salvage faces supported principally by rockbolts.
or
b.as principal support in conjunction with rockbolts and set at a specified
maximum distance from the face of the drivage.
Additionally there are areas of good practice described in this Code and Notes of
Guidance which will apply when cable bolts are used in conjunction with standing
supports.
When reading and applying this Code, reference should also be made to British
Coal Operations Instruction OI/30 "Rockbolting in Mines" and its associated Codes
of Practice and Notes of Guidance.

2. Site Investigation
The Code of Practice "The Support of Mine Roadways by Rockbolts" specifies that
a full assessment of all factors which are likely to affect the performance of
rockbolted support in a roadway shall be carried out prior to the design of any
principal rockbolt support system.
Normally, cable bolts will only be applied as part of a rockbolted support system if
monitoring and previous experience with principal support using rockbolts have
shown it to be inadequate, normally because roof softening is occurring above the
bolted height.
In these circumstances, the major additional requirements are for geological
information above the bolted height to the height reached by the cable bolt and for
the mechanism of failure to be understood.

203

3. Cable Bolt System Design and Specification

3.1

Only cable bolt types which have satisfied the requirements of British Coal's Strata
Reinforcement Materials and Equipment Acceptance Scheme (SRME) shall be
used. The use of double bird caged cable bolts is strongly recommended when
used in roadways principally supported by rockbolts, because they have a high
degree of stiffness when compared to single bird caged bolts. A list of accepted
products is given in the Notes for Guidance.

3.2

Cable bolts should normally have a minimum length of 8m when used in roadways
less than 5m wide, and 10m when used in other applications, unless monitoring
information indicates otherwise.

3.3

Cable bolts should be full column grouted using a grout which has gained
acceptance through the SRME scheme.

3.4

It is important that the liquid to solids ratio of the mixed grout is accurately
measured to ensure the correct consistency for both pumping and strength.
Recommendations on the correct liquid/solids ratio shall be made by the grout
supplier. Where possible sufficient grout shall be mixed to fill the hole in one
operation.

3.5

In roadways principally supported by rockbolts, cable bolts shall be installed to a

pattern designed by a competent person, based on the results of monitoring.

3.6

All cable bolts should be installed as near to vertical as is practicable, unless the
design specifies otherwise.

3.7

In roadways principally supported by rockbolts cable bolts shall be installed at a

minimum density of not less than 0.16 cable bolts per m .

4. Monitoring
4.1

Routine Monitoring Systems for roadways principally supported by rockbolts are

specified in the Code of Practice "The Support of Mine Roadways by Rockbolts".
Where cable bolts form part of this principal support, the length of any
multi-horizon extensometer and tell-tale shall be sufficient to indicate movement
within the cable bolted length.

4.2 Tell-tales which have become inoperative or can no longer be read shall be
replaced. Replacement tell-tales shall be suitably identified.

5. Training
5.1 All personnel involved with the installation of cable bolts shall have received
appropriate operational and safety training, and be duly authorised.

204

5.2

Management and officials/supervisors shall have general training to include

information on the action of cable bolts, correct installation techniques, monitoring
arrangements and testing procedures.

5.3

Operators shall receive training to ensure that they are familiar with the machinery
and consumables to be used and the procedures to be followed when installing
cable bolts. Emphasis shall be given to maintaining satisfactory standards at all
times. Training shall be recorded.

5.4

All contracting companies which are engaged in the installation of cable bolts shall
be approved for such activities by the Corporation and be chosen from an approved
list. The major consideration for inclusion on the approved list is that both
supervisory personnel and operators shall have received training to the standard
indicated in section 5.2 and 5.3 above.

6.

Definitions
The following definitions apply throughout this Code of Practice and Notes of
Guidance.
Principal Support

Rockbolts provide the principal means of support if

free-standing supports;
i. are not used; or
ii. exceed the statutory spacing
In all other circumstances, free standing supports
provide the principal means of support, even when
associated with supplementary rock bolting systems.

Competent Person

A rockbolting specialist with significant experience

of rockbolting support design in UK Coalmines,
authorised by the Mine Manager

205

COAL

NOTES of GUIDANCE
Cable Bolting for Roof Support

1. Installation of Cable Bolts

1.1

Preparation of Bird Caged Cable Bolts

Prior to installation, all cable bolts should be laid out and inspected. The cables
should be in good condition and be free from oil and excessive mud contamination.
The structure of bird caged cables should be intact and not distorted, for example,
by crushing.
A breather tube (normally 13 mm O/D) should be attached to within 100mm of the
top end of the cable bolt and at several positions along its length. Where possible,
the breather tube should be pressed into the cable matrix.
The length of the breather tube should be approximately 2 metres greater than the
cable so that the free end of the tube can be located in a test water container.
The breather tube should be notched approximately 50mm from the top of the tube,
to provide a second path for air should the top become blocked during the
installation.
A grout injection tube, normally 20mm O/D, should be attached to the cable so thai
when installed, the top of the tube will be approximately 1 metre above the mouth
of the hole. However, this may be varied depending on the condition of the
immediate roof. Severely broken ground may warrant the placing of the top of the
grout injection tube higher up the cable. The grout injection tub^should be of
sufficient length to allow it to be connected to the grout pumping system.

1.2

Installation of Bird Caged Cable Bolts

A typical reinforcement design for roadways comprises rows of alternately two,
then one double bird caged cables spaced not greater than 0.6m apart measured
along the roadway axis (equivalent to a density of 0.25 cables/sq metre in a 5m
wide roadway).
Other designs/densities may be appropriate and will depend on geotechnical factors
including monitoring. The minimum effective cable bolt reinforcement density is
0.16 cables/sq metre.
Cable bolts will normally have a minimum overall length of 8m. However other
lengths may be appropriate dependant on information obtained from monitoring.
The cable must be installed in the hole with the breather and injection tubes
206

attached. Once installed, the cable should be checked, to ensure that it is securely
located and will not fall out. Anchoring wires where fitted should be bent
outwards prior to cable insertion.
The installed cable should be located at the top of the hole leaving approximately
250mm of unbird-caged tail protruding from the roof. A cable bolt not properly
installed shall be replaced.
The mouth of the hole should be sealed using a suitable method, which will depend
on the accessibility and condition of the immediate roof. A number of sealing
methods are described in Section 2.
If required, pre-injection or preliminary grouting can be carried out to seal
extensively broken ground.
Full column grouting should be attempted as it is necessary to ensure optimum
cable bolt performance. Full column grouting can be ascertained by the presence
of grout in the breather pipe.
A high shear mixing technique should be adopted to ensure an adequate mix of
grout and water. High efficiency mixing pumps accepted under the SRME scheme
should be used.
On completion of grouting, the grout and breather tubes should be sealed by
folding and taping the tubes in order to prevent leakage.
Following completion of the grouting and checking procedures, an end plate with
barrel and wedge anchor may be fitted to the cable tail to improve support to the
immediate roof strata. Normally this would take place 24 hours after grouting was
completed.
Double bird caged cables are most effective when installed in holes drilled to
55mm in diameter. Holes for single bird caged cables are normally 43mm in
diameter. Holes will normally be drilled using water flushing. However situations
may arise when dry drilling is preferred. In such situations the frictional ignition
risk shall be assessed.

2. Method of Sealing Cable Bolt Holes

The mouth of the cable bolt hole should be sealed following installation of the
cable and preparatory to grouting, in order to prevent leakage of the grout.
Several methods may be employed depending on the severity of roof conditions
and accessibility.
Example methods of sealing are described below:
2.1

If the immediate roof exhibits only minor dilation and surface spall it should be
trimmed back to competent ground, then the hole may be satisfactorily sealed

207

using sacking, cotton waste and/or clay stem. The hole should be plugged to a
depth of at least 150mm. Cotton waste or sacking should be placed firmly into the
hole using a wooden dowel or similar (Fig. 1).
2.2

If there is dilation of the immediate roof beds which results in migration of grout
into the surrounding strata, then the sealing method described in 2.1 above may
still be utilised, but the injection tube should be located higher up the cable approximately 3m above the hole mouth. Injection should then be carried out in
two stages as follows:
a.

pre-inject by using a relatively small quantity of grout which will flow into
the base of the sealed hole and into fissures in the surrounding strata The
amount of grout will be determined on site. Disconnect the pump and allow
excess grout to drain from the injection tube. Establish that the tube is free
of grout. (Fig 2).

b.

Return to the installation after a minimum of one hour and complete grouting
in the normal way.

Alternatively, two separate injection tubes fitted at different horizons could be

employed.
2.3 An alternative method of sealing the hole against fissures is to utilise a tubular
fibre sock or bandage which is fitted over the cable tail at a position corresponding
to the first 300-450mm of immediate roof. A secondary (13mm bore) injection
tube is then fitted into the sock prior to installation.
Grout injection consists of filling the sock through the secondary tube, and
allowing this to harden for at least one hour prior to full injection of the column.
(Fig. 3).
The sock length may need to be extended depending on conditions of the
immediate roof.

3. Training
The training packages for cable bolting personnel will be performance based in
keeping within current British Coal practice. Performance based training is
organised around ar itemised programme that concentrates upon the trainee
working towards demonstrating his ability to perform a particular task or action to
a minimum standard or criteria. The training is not dependant upon time, but is
dependant upon whether the trainee has attained the necessary skill and knowledge
elements, which, together with the necessary experience and personal attitude,
makes them competant.
On successful completion of training the following skill levels will have been
attained.

208

1.

Demonstrate the ability to read and comprehend the appropriate Codes of

Practices concerned with Rockbolting and Cablebolting.

2.

Read and interpret the Manager's Support Rules and demonstrate a specific
knowledge of the cable bolting requirements.

3.

Demonstrate awareness and understanding of the safeguards associated with

Cablebolting Systems.

4.

Demonstrate ability in the application of pre-start checks, close down

procedures and daily maintenance requirements.

5.

Demonstrate ability in the process of safe drilling.

6.

Demonstrate ability in the preparation and installation of Bird Caged

Cablebolts.
Demonstrate knowledge and use of approved equipment for the purpose of
mixing and placement of cable bolting grouts.

7.
8.

Demonstrate a clear understanding of, and the adoption of, effective Quality
Control procedures.

4. Quality Assurance
For cable bolts to provide optimum performance, the installation of the cables,
grouting etc, must be carried out to the highest standards. In order to ensure that
standards are achieved and maintained, a quality assurance procedure should be
agreed and operated by the colliery and cable bolt installation team.
4.1 Quality Assurance During Installation
Quality assurance during installation should include the following basic procedures:
i.

Determine that the completed cable has been full column grouted by
checking that grout has flowed into the breather tube by a visual inspection
or air pressure testing.

ii.

Establish a reporting system for the cable installation by identifying all cables
and reporting actions taken to ensure a good installation, for example:
a.

number of grout bags pumped for each cable, or group of cables.

b. whether full column grouting was achieved.

c. what actions were taken if full column grouting could not be established.
-iii. Set up a routine grout sampling procedure where a minimum of three grout
samples from any batch mix are obtained. Sampling will be repeated at
random during cable bolting operations. These samples should then be
subjected to tests to determine grout quality.

209

The grout should be collected in a suitable container and stored underground

for 24 hours, then removed from the mine for testing.
The testing should include:
a.

weighing of the sample, determination of density and hence

water/solids ratio.

b.

measurement of uni-axial compressive strength.

Results should be compared with standard data for the relevant grout and
should fall within an acceptable range as defined by the supplier.
4.2 Quality Checking After Installation
After the cable grouting has been completed but prior to the fitting of end plates, a
competent person should check the installation. The following points should be
noted:
a. The seal at the mouth of the hole should be intact and appear adequate.
b. The grout tube should be blocked, and preferably filled with hardened grout.
c. The breather tube should be filled with grout. Grout should have entered the
breather tube so that no air passage up the tube exists.
Installed cables not meeting the quality assurance requirements should be replaced
by additional cables.

210

5. List of Consumables Currently Accepted Under the SRME

Scheme
1. Single and double bird-caged cable bolts, factory formed. Single or double
tailed.
Supplier:
2.

150 150 10 single tail bearing plate c/w barrel and wedge assembly.
Supplier:

3.

ANI Amali or Dywidag Systems

200 150 10 double tail bearing plate c/w barrel and wedge assembly.
Supplier:

4.

ANI Amali or Dywidag Systems

ANI Amali or Dywidag Systems

13mm o/d breather tubing

Supplier:

Dywidag Systems

5. 20mm o/d injection tubing

Supplier:

ANI Amali or Dywidag Systems

6. Cementitious cable bolting grout

Pozament CBG
Excem VS
Technik Lokset CB
7. Grout mixer/pump unit.
ANI Amali GB7 mixer/pump
Monopumps Ltd Grout Mixer Pump

211

DOUBLE
BIRDCAGED
CABLE
SECTION

TAIL

BREATHER TUBE
INJECTION TUBE
FIGURE 1
213

c->
>>
(il>

'/

V
'

DOUBLE
BIRDCAGED
CABLE
SECTION

'/

\l
v>

// \ \

if

\\

II

//

\\
\\

V\ '

II

w
//

II

//

> t

II

\\

II

//

\\

II

vv

//
//

\\

' r

/(

II

> * .'/
*\\

/r

\\

vi

II

//

5
' r

\\

II

H
II

vv

><

VI

^^_

3 metres

II
if f/

1
l
1
1
1
1
1

1
1
1
1 1
I 1
I I 1
Ull

1
1

1
1
1
1
1

TAIL

f ^
1

1
1
1
1

CLAYSTEM

:
1
1

1
1

I 1
1
I 1

BREATHER TL

f 11

INJECTION TUBE
FIGURE 2
214

DOUBLE
BIRDCAGED
CABLE
SECTION

SEALING
TUBE

BREATHER TUBE

INJECTION TUBE
FIGURE 3
215

BRITISH COAL

OPERATIONS DEPARTMENT

STRATA REINFORCEMENT ACCEPTANCE SCHEME

REGISTER OF ACCEPTED STRATA REINFORCEMENT

MATERIALS AND EQUIPMENT

SEPTEMBER 1992

British Coal
Operations Department
Eastwood Hall
Mansfield Road
Eastwood
Notts
NG16 3EB

September 1992

EXPLANATORY NOTES
1.0

This Register lists British Coal Accepted equipment embraced by the Procedure for the CoCoordination and Control of the Selection and Introduction of Strata Reinforcement
Materials and Equipment (See Appendix A). The Acceptance Scheme does not apply
to products and equipment within the scope of British Coal Specifications.

2.0

British Coal Acceptance Numbers have been granted to products which have been satisfactorily
tested and are considered suitable for use in British Coal mines. For certain categories of
materials and equipment it may be necessary for the product to satisfy the requirement of more
than one Acceptance Scheme, i.e. the Acceptance for Mechanical Equipment and/or the
Acceptance Scheme for the use of Non-Metallic Materials and Substances. In such cases a
Strata Reinforcement Materials and Equipment Acceptance Scheme number will not normally
be granted until all other requirements have been satisfied.

3.0

The appropriate British Coal Acceptance Numbers are prefixed by either the letters POA
or FOA. Provisional Operational Acceptance (POA) is initially granted and generally
limits the number of any one particular item which can be introduced underground. After
satisfactory operational experience, the acceptance status is normally up-graded to Full
Operational Acceptance (FOA), which allows unlimited use of the produce throughout
British Coal.

4.0

An example of the numbering system is given below:Acceptance Status

Product Category

Serial Number

POA

10

057

Usually written as POA 10057. The product in this case being NEI-Victor Mk2 Tornado
Compressed Air Operated hand Held Drill.
5.0

Variations to existing accepted types or designs of product may be accepted into the
scheme under the British Coal Acceptance Number for the existing design. However,
manufacturers must submit details of the variations to Operations Department, Eastwood
Hall and these must be agreed by British Coal before being implemented.

6.0

It is intended that the register will be up-dated at 12 monthly intervals.

218

BRITISH COAL

APPENDIX A

OPERATIONS DEPARTMENT
Notes of Guidance on the Acceptance Scheme for
Strata Reinforcement Materials and Equipment
1.

Introduction

1.1

These Notes of Guidance for the appraisal and acceptance of new types of Strata Reinforcement
Materials and Equipment have been prepared by British Coal, Operations Department, Eastwood
Hall.

1.2

All materials and equipment supplied by manufacturers to British Coal in the categories listed
shall be of a type accepted by British Coal as signified by an official British Coal Acceptance
Number.

1.3

The Acceptance Scheme does not apply to materials and equipment within the scope
of British Coal Specifications.

1.5

Special care shall be taken to ensure that operation of the Acceptance Scheme does not
impede development of materials or equipment by the manufacturer.

2.

Procedure for Acceptance

2.1

The procedure for acceptance of strata reinforcement materials and equipment shall
operate as follows:
a.

All newly developed strata reinforcement materials and equipment supplied

by manufacturers for use in British Coal mines after 1st September 1981 shall
be submitted for appraisal and if deemed necessary subjected to the
appropriate testing by British Coal (for which commercial rates will be
charged) or by a NAMAS accredited test establishment and trials, before
being accepted into this scheme.

b.

Manufacturers shall contact the Head of Mining, Operations Department and

provide full details of each new product which they wish to offer for use
by British Coal. If the product has potential merit then the above assessment
procedure will be adopted.

c.

As part of the product assessment, dependent on the type of product, it may

be necessary to conduct underground trials for which the manufacturer will
be responsible for providing sufficient samples. Subject to satisfactory
testing a Provisional Operational Acceptance number will normally be
granted, allowing controlled use of the product underground.

d.

Following satisfactory underground trials and after an appropriate period of

use underground the acceptance status of a product will normally be
upgraded to Full Operational Acceptance.

e.

A British Coal Acceptance Number is issued subject to a series conditions

as specified on the acceptance letter, one of which is that commercial
agreement is agreed with British Coal, H.Q. Supply and Contracts
Department at Fence National Plant Centre.

August 1989
Amended September 1992

219

TRAINING
CODE OF PRACTICE
It is specified within the Code of Practice "Cable bolting for
Roof Support" (Appendix 1) that all personnel involved with the
installation of cable bolts shall have received appropriate
operational and safety training.
Management and offacials/supervisors
training incorporating the relevant
technology, installation techniques,
procedures.

should receive general

aspects of cable bolt
monitoring and testing

Operators should receive training encompassing the theory and

practice of cablebolting to ensure that they are familiar with
the machinery and consumables in the installation of cable bolts.
Emphasis is given to maintaining satisfactory standards at all
times.
TRAINING SCHEME
A training package was formulated by Rock Mechanics following the
publication of the Code of Practice and all personnel involved
with Cablebolting have attended these courses. No person is
allowed to instai or supervise cablebolting work unless he has
satisfied the requirements of this course.
The training package is a two part performance based scheme. It
is organised around an itemised programme which requires the
trainee to demonstrate an ability to perform a particular skill
to a minimum standard. The training is not time dependent but
depends on the trainee attaining the necessary level of
competency.
The first part of the package is classroom orientated
involves instruction on the following elements:
i)

Cablebolting
practice,
control aspects.

ii)

The behaviour
of coal
influence of stress.

standards
measures

and
strata

and

quality
and

the

iii) T h e monitoring of, and responses to, strata load

movement.

and

The second stage of the package involves underground assessment

at a cablebolting site, the focus of attention being:
i)

Operators demonstrating good practical skills.

ii)

Approved equipment being available and in use.

iii) Knowledge of quality control standards.

iv)

U s e of quality control reporting systems.

221

Following both stages and having acquired the minimum standard

operators are individually authorised. Where minimum standards
have not been met further training is offered.
A detailed programme
overleaf.

showing

the

course

content

is shown

All personnel participating in these courses receive signed

documentation such that it can be included in their training
records.
CONTRACTORS
It is specified within the Code of Practice that all contracting
companies which are engaged in the installation of cable bolts
shall be approved by the Corporation and be chosen form an
approved list. To qualify for consideration to carry out
cablebolting work the company has to satisfy British Coal that
all its operators and supervisors have received training to the
standard outlined above.
All cablebolting works is negotiated by competitive tendering and
the control of cablebolting companies is maintained by Supply and
Contracts personnel.

222

Rock Mechanics Branch

Training Course
Cable Bolting
A two day course for supervisors and operators.
DAY 1.
Morning.

Teach In
Basic Principles of Rock Behaviour
Stress & Roadway Behaviour
Reinforcement
Monitoring
Cable Bolting

Afternoon

How cables work

Application/Installation
Design

Teach In
Equipment

Drilling machines and bits

Pumps and mixers
Consumables
Quality control and assurance

Demons trat ion

Cable assembly
Stemming
Grout mixing and sampling
Injection
Plate fixing
Grout testing

DAY 2.

SITE VISIT
Visit to cable bolting site
Demonstration of cable techniques including
hands on opportunity.
Discussions with operators and supervisors.

223

GROUT A
UNIAXIAL COMPRESSIVE STRENGTH AND DENSITY
57mm DIAMETER BOTTLE SAMPLES

Density
(gm\cc)

Average
Density

41.1

2.04
2.05
2.04

2.04

58.2
55.4
* 60.6

58.1

2.05
2.07
2.06

2.06

60.1
65.3
* 66.2

63.9

2.05
2.07
2.06

2.06

14

70.6
64.5
* 75.8

70.3

2.08
2.06
2.07

2.07

28

84.1
84.7
* 78.7

82.5

2.08
2.09
2.09

2.09

Cure Time
(Days)

U.C.S.
(MPa)

42.4
48.4
32.4

Average
U.C.S.

Sample subcored to 44mm diameter for Youngs Modulus

YOUNGS MODULUS
3 DAYS
7 DAYS
14 DAYS
28 DAYS

15.1
16.4
18.7
19.3

GPa
GPa
GPa
GPa

100mm CUBES
100mm CUBE SAMPLES
CURE TIME
(Days)

UCS
(MPa)

AVERAGE
UCS

DENSITY
(g/cc)

AVERAGE
DENSITY

51.4
40.1

45.8

2.07
2.06

2.07

67.7
66.7

67.2

2.06
2.08

2.07

14

72.8
63.6

68.2

2.07
2.08

2.08

225

GROUT
UNIAXIAL COMPRESSIVE STRENGTH AND DENSITY
57mm DIAMETER BOTTLE SAMPLES

Cure Time
(Days)

U.C.S.
(MPa)

20.3
23.2
21.6

1_

Density
(gm\cc)

Average
Density

21.7

2.22
2.23
2.22

2.22

71.3
70.6
* 54.4

64.4

2.25
2.27
2.26

2.26

82.6
80.0
* 75.3

79.3

2.28
2.26
2.27

2.27

14

90.7
86.2
* 84.0

87.0

2.28
2.26
2.28

2.27

28

85.1
99.3
* 101.9

95.4

2.25
2.26
2.28

2.26

Average
U.C.S.

Sample subcored to 30mm diameter for Youngs Modulus

YOUNGS MODULUS
YOUNGS MODULUS
CURE TIME
(Days)

YOUNGS MODULUS
(GPa)

23.0

27.1

14

27.2

28

28.1

226

GROUT C
UNIAXIAL COMPRESSIVE STRENGTH AND DENSITY
57mm DIAMETER BOTTLE SAMPLES

Cure Time
(Days)

U.C.S.
(MPa)

Average
U.C.S.

Density
(gm\cc)

Average
Density

46.9
47.7
47.2

47.3

2.21
2.22
2.18

2.20

54.5
50.8
50.8

52.0

2.21
2.21
2.18

2.20

56.4
63.1
58.3

59.3

2.19
2.22
2.19

2.20

14

61.4
62.4
58.4

60.7

2.20
2.24
2.21

2.22

28

65.7
64.6
* 71.0

67.1

2.22
2.22
2.21

2.22

Sample subcored to 3 0mm diameter for Youngs Modulus

YOUNGS MODULUS
YOUNGS MODULUS
CURE TIME
(Days)

YOUNGS MODULUS
(GPa)

7
14

28

31.9

227

GROUT D
UNIAXIAL COMPRESSIVE STRENGTH AND DENSITY
57mm DIAMETER BOTTLE SAMPLES

Cure Time
(Days)

U.C.S.
(MPa)

Average
U.C.S.

Density
(gm\cc)

Average
Density

56.7
54.7
59.1

56.8

2.21
2.18
2.21

2.20

67.3
62.4
68.4

66.0

2.23
2.19
2.22

2.21

66.3
64.1

65.2

2.20
2.20

2.21

14

65.5
61.5

63.5

2.18
2.19

2.19

28

69.9
72.4

71.1

2.22
2.20

2.21

YOUNGS MODULUS
YOUNGS MODULUS
YOUNGS MODULUS
(GPa)

CURE TIME
(Days)
3

14

28

228

GROUT E
UNIAXIAL COMPRESSIVE STRENGTH AND DENSITY
57mm DIAMETER BOTTLE SAMPLES

Cure Time
(Days)

U.C.S.
(MPa)

Average
U.C.S.

Density
(gm\cc)

Average
Density

46.8
38.3
38.2

41.1

2.15
2.12
2.12

2.13

55.0
49.6
51.1

51.9

2.13
2.12
2.13

2.13

55.3
58.8
57.1

57.1

2.13
2.13
2.15

2.14

14

53.9
60.9
* 56.6

57.1

2.13
2.14
2.11

2.13

28

64.7
61.7
66.7

64.4

2.14
2.12
2.15

2.14
1

Sample subcored to 3 0mm diameter for Youngs Modulus

YOUNGS MODULUS
YOUNGS MODULUS
CURE TIME
(Days)

YOUNGS MODULUS
(GPa)

14

24.9

28

229

GROUT F
TESTED AT NOTTINGHAM UNIVERSITY
UNIAXIAL COMPRESSIVE STRENGTH AND DENSITY
57mm DIAMETER BOTTLE SAMPLES

Density
(gm\cc)

Average
Density

39.7

50.3
56.6
48.4

51.8

2.00
2.01
2.04

2.02

57.8
57.4
49.6

55.0

2.01
1.99
2.00

2.00

14

63.5
64.7
60.6

62.9

1.98
2.03
2.03

2.01

28

71.7
* 79.8
* 73.2

74.9

Cure Time
(Days)

U.C.S.
(MPa)

Average
U.C.S.

44.1
33.5
41.4

2.05

2.05

Sample subcored to 30mm diameter for Youngs Modulus ?

Youngs Modulus Av. of 2 samples : 17.1GPa

50mm CUBES
50mm CUBE SAMPLES
CURE TIME
(Days)

UCS
(MPa)

AVERAGE
UCS

DENSITY
(g/cc)

AVERAGE
DENSITY

61.5
62.7

62.1

2.02
2.03

2.02

59.0
63.2

61.1

2.04
2.03

2.04

14

73.2
73.8

73.5

2.01
2.00

2.01

230

GROUT G
UNIAXIAL COMPRESSIVE STRENGTH AND DENSITY
57mm DIAMETER BOTTLE SAMPLES

Density
(gm\cc)

Average
Density

62.6

2.02
2.03
2.03

2.03

67.3
68.1
* 73.1

69.5

2.04
2.04
2.02

2.03

80.3
77.6
* 78.9

78.9

2.04
2.04
2.03

2.04

14

62.1
85.3
* 86.0

77.8

2.04
2.04
2.04

2.04

Cure Time
(Days)

U.C.S.
(MPa)

66.6
59.4
61.8

Average
U.C.S.

84.0
* 95.1

28

89.6

2.04
2.05

2.05

Samples subcored to 44.5mm diameter for Youngs Modulus

Sample lost on preparation

YOUNGS MODULUS
3 Days
7 Days
14 Days
28 Days

15.5
15.5
16.8
17.9

GPa
GPa
GPa
GPa
100mm CUBES

CURE TIME

U.C.S.
(MPa)

Average

Density
(g/cc)

Average
Density

68.9
62.2

65.6

2.03
2.03

2.03

69.9
62.2

66.1

2.04
2.04

2.04

14

82.5
77.9

80.2

2.05
2.01

2.03

(Days)

U.C.S.

231

ORDINARY PORTLAND CEMENT

WSR 0.31

UNIAXIAL COMPRESSIVE STRENGTH AND DENSITY

57mm DIAMETER BOTTLE SAMPLES

Density
(gm\cc)

Cure Time
(Days)

U.C.S.
(MPa)

Average
U.C.S.

35.9
33.7
42.4

37.3

58.7
54.8
* 62.6

58.7

2.13
2.13
2.12

2.13

63.3
67.1
* 73.6

68.0

2.12
2.14
2.13

2.13

14

82.3
73.4
* 81.3

79.0

2.15
2.14
2.14

2.14

28

82.9
87.8
* 87.6

86.1

2.15
2.14
2.15

2.15

Average
Density

Sample subcored to 44mm diameter for Youngs Modulus

Samples incorrectly weighed
YOUNGS MODULUS

3 DAYS
7 DAYS
14 DAYS
28 DAYS

17.4
20.5
17.9
19.2

GPa
GPa
GPa
GPa

100mm CUBES
100mm CUBE SAMPLES
Cure Time
(Days)

UCS
(MPa)

Average
UCS

Density
(g/cc)

Average
Density

58.4
49.5

54.0

2.16
2.14

2.15

47.4
49.0

48.2

2.14
2.14

2.14

14

80.0
79.7

79.9

2.15
2.15

2.15

232

ORDINARY PORTLAND CEMENT

WSR 0.37

UNIAXIAL COMPRESSIVE STRENGTH AND DENSITY

57mm DIAMETER BOTTLE SAMPLES

Cure Time
(Days)

U.C.S.
(MPa)

Average
U.C.S.

Density
(gm\cc)

Average
Density

32.3
27.4
29.1

29.6

2.02
2.01
2.O0

2.01

39.6
42.2
* 44.6

42.1

2.03
2.04
2.05

2.04

51.8
48.7
* 58.9

53.1

2.06
2.06
2 .06

2.06

14

64.6
45.3
* 58.9

53.1

2.09
2.08
2.09

2.09

28

71.3
44.3
* 75.1

63.6

2.06
2.06
2.06

2.06

Sample subcored to 44mm diameter for Youngs Modulus

YOUNGS MODULUS

3 DAYS
7 DAYS
14 DAYS
28 DAYS

Unrealistic result
16.8 GPa
19.7 GPa
21.3 GPa
100mm CUBES
100mm CUBE SAMPLES

Cure Time
(Days)

UCS
(MPa)

Average
UCS

Density
(g/cc)

Average
Density

48.0
46.7

47.4

2.07
2.07

2.07

58.3
59.5

58.9

2.06
2.07

2.07

14

64.3
68.6

66.5

2.10
2.09

2.10

233

GROUT H
UNIAXIAL COMPRESSIVE STRENGTH AND DENSITY
57mm DIAMETER BOTTLE SAMPLES

Density
(gm\cc)

Average
Density

51.6

2.08
2.07
2.07

2.07

66.8
63.0
* 60.2

63.3

2.08
2.09
2.11

2.09

67.3
70.3
* 59.9

65.8

2.09
2.10
2.10

2.10

14

79.3
79.2
* 82.4

80.3

2.11
2.08
2.12

2.10

28

81.4
79.1
* 88.5

83.0

2.09
2.11
2.11

2.10

Cure Time
(Days)

U.C.S.
(MPa)

54.2
54.3
46.3

Average
U.C.S.

Samples subcored to 44.5mm diameter for Youngs Modulus

Sample lost on preparation

YOUNGS MODULUS
3 Days
7 Days
14 Days
28 Days

17.2
18.1
19.4
21.4

GPa
GPa
GPa
GPa
50mm CUBES

CURE TIME
(Days)

U.C..S.
(MPa)

Average
U.C.S.

Density
(g/cc)

Average
Density

61.3
60.6

61.0

2.10
2.09

2.10

68.2
72.5

70.4

2.12
2.11

2.12

14

80.8
83.1

82.0

2.13
2.13

2.13

234

Appendix V

TECHNICAL GUIDANCE
ON SPECIAL PURPOSE RESIN BONDED ANCHOR BOLTS
FOR THE PURPOSE OF LIFTING AND SUSPENSION OF EQUIPMENT
(REVISED JANUARY 1994)

237

C O N T E N T S
PAGES

SECTION 1

Introduction

239

SECTION 2

Technical Considerations

240

SECTION 3

Special Purpose Bolts Installed as

Anchors for the Sole Purpose of
Lifting or Suspension of Equipment

241

SECTION 4

Lifting Equipment/Suspension Brackets

243

SECTION 5

- Typical Installation Procedures

(Becorit, BRC etc)

238

244

SECTION 1
DfTRCOJCTION
1.1

This Technical Guidance on Lifting and Suspension of Equipment using

Special Purpose Anchor Bolts has been produced primarily to assist
llieries where reck bolting has become the primary roadway support.

1.2

Maximum lifting and suspension loaeis are hereby specified for Special
Purpose Anchor Bolts installed for the sole purpose of lifting or
suspension of equipment. This particular document makes reference to
approved manufacturers of anchor bolts. However, any other Special
Purpose Anchor Bolts may be used provided they have been tested and
granted Mechanical Acceptance by Operations Department and issued with
an appropriate Mechanical Acceptance Scheme number.

1.3

AT Roof Bolts designed for strata control purposes shall not be used
for lifting purposes. They may, however, be used for suspending light
loads up to a maximum of 1 tonne (eg cables, pipes and conveyor
structure etc) provided they are adopted as anchors in accordance with
the Notes of Guidance for the lifting and suspension of equipment
recently issued as an actoendum to Operations Instrucionm 01/30
(Rockbolting in Mines).

239

SECTION 2
TECHNICAL CONSIDERATIONS
2.1

Special Purpose Anchor Bolts desicjned solely for lifting and

suspension of equipment are available. These may be of the point
anchor type (eg Berit type Anchor Bolts), or be full column bonded
(eg BRC) . Anchor Bolts have an Ultimate Tensile Strength of at least
five times their safe working load.

2.2

Special Purpose Anchor Bolts are suitable for lifting or suspension of

equipment provided that they have been manufactured to the required
standard, installed properly, the roof area is satisfactory for this
particular purpose and that any shackle, bow nut or suspension
brackets are properly desicjned and satisfy British Coal strenjth
requirements.

2.3

It is important that Special Purpose Anchor Bolts should be installed

in accordance with the bolt and resin manufacturers instructions (see
Section 5 ) .

2.4

Steel shackles manufactured to British Coal Specification 422 (alloy

steel shackles) or 524 (higher tensile steel shackles) should be used
wherever possible. These tend to aid the assembly and installation of
the lifting/suspension equipment. Lifting shackles may also follow
the line of lift/pull and as a consequence will be kinder to the
Anchor Bolts or any suspension brackets.

2.5

Improvisation using unsuitable lifting, suspension or pulling

equipment/devices is not permitted, and must not be practised.

240

SECTION 3
SPECIAL PUTRPOSE ANCHOR BOLTS INSTAI I .FD FOR THE SOLE PURPOSE OF LIFTING
OR SUSPENSION OF EQUIPMENT
3.1

POINT ANCHOR TYPE

3.1.1

These bolts are manufactured from a ductile steel and adopt

the point anchor system of securing the bolt into the roof.
These bolts should not be fully bonded in the roof holes (see
Section 5 ) .

3.1.2

This type of bolt is presently offered by Becorit Ltd and has

been Mechanically Accepted by Operations Department (MAS 202).
Any other similar type of bolt shall not be used unless
Mechanical Acceptance has been granted from British Coal
Operations Department.

3.1.3

The lifting or suspension end of the anchor bolt shall be

provided with a screwed shackle or bow nut which engages the
full length of the threaded portion of the bolt. Any other or
alternative attachment to the bolt will not be permitted
without Mechanical Acceptance obtained from British Coal
Operations Department.

3.1.4

This type of Anchor Bolt complete with shackle or bow nut

shall be colour coded green.

3.1.5

Maximum permissible lifting or suspension loads from each

Becorit bolt shall be:24mm dia. bolts (M24) - 4 tonnes with shackle, 5 tonne with
bow nut.
27mm dia. bolts (M27) - 4 tonnes with shackle, 6 tonnes with
bow nut.

3.1.6

Point anchor bonding resins approved by the bolt nianufacturer

shall be used. The bolt shall be installed in accordance with
the manufacturers instructions. (See Section 5).

3.1.7

The diameter of the roof hole provided for the Anchor Bolt
shall be in accordance with the bolt manufacturers
recommendations and the quantity of bonding resin used shall
be as prescribed by the bolt and resin manufacturers
reccmmendations. (See Section 5).

3.1.8

Prior to installation and before lifting or suspension of

equipment using Special Purpose Anchor Bolts an examination
shall be made in accordance with the Notes of Guidance for
lifting and suspension equipment recently issued as an
addendum to Operations Instruction 01/30.

241

3.2

FULL COLUMN BONDED TYPE

3.2.1

Themse bolts are manufactured from rebar steel and adopt the
full column resin bond anchor system of securing the bolt into
the roof. (See Section 5). They incorporate a lifting
attachment point, which is either integrally forged (eg BRC
anchor bolts) or mechanically retained.

3.2.2

This type of bolt requires Mechanical Acsceptance by British

Ccal Operations Department. Any similar type of bolt shall
not be used unless Mechanical Acceptance has been cjranted.

3.2.3

Only approved steel shackles or other approved lifting

equipment will be permitted for use with the bolts. Such
equipment must have a safe working load capacity at least
equivalent to the S.W.L. of the bolt used and must have an
ultimate strength of at least five times its safe working
load.

3.2.4

The maximum permissible lifting or suspension load from each

bolt shall be as follows:BRC Special Purpose Anchor Bolt - 3.5 tonne.
The safe working load must be clearly stamped on the integral
attachment point.

3.2.5

Fast and slow setting, full column, bonding resins approved by

the bolt manufacturer shall be used. The bolt shall be
installed in accordance with the manufacturers instructions.
(See Section 5). Bolts shall be supplied labelled with
installation instructions.

3.2.6

The diameter of the roof hole provided for the anchor bolt
shall be in acxrdance with the bolt manufacturers
recommendations and the cjuality of bonding resin used shall be
as prescribed by the bolt and resin manufacturers
recommendations. (See Section 5 ) .

3.2.7

Prior to installation and before lifting or suspension of

equipment.using Special Purpose Anchor Bolts an examination
shall be made in accordance with the aforementioned Notes of
Guidance addended to British Coal Operations Instruction
01/30.

242

SECTION 4
LIFTING EQUIPMENT/SUSPENSION BRACKETS
4.1

All lifting equipment/suspension brackets used for the purpose of

lifting or suspension of equipment from Anchor Bolts shall be suitably
desicjned and of adequate strength for the intended lifting/suspension
purpose.

4.2

Each lifting/suspension bracket shall be marked (preferably by

stamping) with its maximum Safe Working Load in suitably sized
letters/numbers.

4.3

The ultimate strength of the lifting/suspension bracket shall not be

less than five times its Safe Working Load.

4.4

Each design of lifting/suspension bracket shall be submitted to

British Coal Operations Department for Mechanical Acceptance. No
lifting or suspension brackets should be used unless the bracket has
been given Mechanical Acceptance and issued with an appropriate
Mechanical Acceptance Certificate.

4.5

All other lifting/suspension devices including pull lifts, chain

blocks, steel shackles, chain slings, wire slings and hooks etc, shall
comply with either the relevant requirements specified in British Coal
"Codes and Rules" for Lifting Appliances or Notes for Guidance
Document on the Suspension of Equipment issued in January 1988 and
circulated under cover of Mech/Circ(88)3 whichever is appropriate.
Equipment used for suspension purposes should not be used for lifting
unless the equipment complies fully within British Coal "Codes and
Rules for Lifting Appliances".

243

SECTION 5
5.1

TYPICAL INSTALLATION PROCEDURE f BECORIT POINT ANCHOR BOLTS1

Scope
Where no steel beams are set in the method of support, this
installation procedure relates to the suspension of monorail utilising
Becorit Special Purpose Anchor Bolts and approved attachments, none of
which form part of the strata control. The addendum covers the use of
the same bolts for lifting purposes.
Note
In the first instance it is recommended that collieries seek
independent technical expertise from a company acceptable to British
Coal Operations Department to confirm the agreed prccedure for their
particular application(s).
Installation
Each monorail section must have at least two supports.
The monorail may only carry loads which result in anchorage
and suspension chain loadings as specified by the
manufacturer.
Becorit Special Purpose Anchor Bolts should be green colour
coded, and installed as per the instructions below.
Instructions : See Figures 2, 3 and 4
(1)

For M24 bolt drill hole 27mm diameter by 2.27m deep (for M27
bolt drill 32mm diameter). The hole should be drilled using
water flushing wherever possible.

(2)

Place and retain one resin cartridge 24mm diameter by 450mm

long in hole using tube and plunger if required.
(For M27
bolt use 2 off resin cartridges same size). Ensure that the
capsule is installed at the back of the hole.
Resin type = Celtite AT "fast set".

(Red capsules).

(3)

Using drill and spinner tool adaptor, spin the fully assembled
bolt into hole. (Approximately 4 sees) .

(4)

Hold bolt spinning at final depth for 5 sees.

(5)

Hold drill and bolt stationary at final depth for further 15

sees before removing drill completely.

Note
The hole depth is chceen to allow the 75 - 100mm clearance
between the roof and shackle/bow nut. This should be
maintained, see Figure 2.
Becorit Special Purpose Anchor Bolts installed in this manner
with the respective approved attachments will hold the
following loads with a 5:1 safety factor after 30 mins as
below.
244

M24
M24
M27
M27

bolt
bolt
bolt
bolt

with
with
with
with

shackle:
bow nut:
shackle:
bow nut:

4
5
4
6

tonnes
tonnes
tonnes
tonnes

In the first instance for any new application of the Becorit Special
Purpose Anchor Bolts, a prcof load/pull down test should be witnessed
by a competent person duly appointed by the Colliery Manager.
Addendum
Becorit Special Purpose Anchor Bolts and Approved attachments installed in
accordance with these instructions and within the parameters shown by Fig 5
may also be utilised as lifting points with tr.3 carrying capacity as quoted
above.
Note
All lifting applications should be witnessed by a competent person duly
authorised by the Colliery Manager.
Anchor Bolts must not be subjected to repeated/reverse bending.

245

 t L U K il

.:*:'' /''

:'

brcLAL

:-T;" .:-:&;" v";' .:=;' vK.;" .:**;'

HUKFUbt tULI S

i.

<

i.

a.

SUSPENSION

FG

CHAiN^

i a BECORIT

FIG Ib SECORJ MUL T f-SUSPENSIN AND PijRf

MOA/O.A/L.

ROLLED THREAD
ANCHOR END

',

s
r\j

ALTERNATIVE
BOW NUT

TAPED PLAIN

FIG
/HONORA/L SUSPENSION FIG

DIA

0. I

BECORIT SPECIAL PURPOSE BOLT

2.0

ALTERNATIVE

SHACKLE
SPINNER

BOW NUT
SPNNER

A4-12037-U8

19 A/F

A4-2037-U7
SPINNER TOOLS

FIG

o
o

m
r^

1 . . .

:*:. .
.

'U

a 4 *
.

* t "

fr* V '

4.0
SHACKLE
LIFTING

BOLT ASSEMBLIES

SOW NUT
PARAMETERS

FIG

5.0

A4-7 2 0 3 7 - U 2 SHACKLE

M24

kA-}2037-US

SHACKLE H27

A4-12037-U3

V\2A

AA-12037-U6

BOU NUT M27

BOW NUT

246

5.2

TYPICAL INSTALLATION PROCEDURE (BRC FULL COLUMN BONDED BOLTS)

5.2.1

Where no steel beams are set in the method of support, this

installation procedure relates to the lifting and suspension
of equipment utilising BRC Special Purpose Anchor Bolts and
approved attachments, none of which form part of the strata
control.

5.2.2

In the first instance it is recommended that collieries seek

independent technical expertise from a company acceptable to
British Coal Operations Department to confirm the agreed
procedure for their particular applications.

5.2.3

Anchor bolt length is to be the same (nominally) as the strata

bolts being used, i.e. 1.8m, 2.1m, 2.4m, etc.

5.2.4

Resin cartridge length is to be the same as that being used

for the full column bond strata bolts. However, one fast set
cartridge and two slow set cartridges are to be used, not one,
and one as with the strata bolt.

5.2.5

The bore hole is to be drilled using a 32mm diameter drill

bit, to a depth of approximately 50mm less than the length of
the anchor bolt (excluding the forged eye). The hole should
be drilled using water flushing whenever possible. (See Figure
6).

5.2.6

Place and retain the three cartridges at the top of the hole
using a resin injection tube if required. Ensure that the
fast set (red) capsule is inserted in the hole first.
Resin Type = Celtite AT Fast Set
= Celtite AT Slow Set

(One Capsule)
(Two Capsules)

5.2.7

Using the bolt and spinning tool adaptor spin the bolt up the
hole. Continue spinning the bolt for approximately 5 seconds
after it has reached the top of the hole. This correctly
mixes all the resin.

5.2.8

Hold the drill and bolt stationary at the back of the hole for
a further 15 seconds before removing the drill completely.

5.2.9

Full column bonded Special Purpose Anchor Bolts installed in

this manner with the respective approved attachments will hold
the following loads with a 5:1 factor of safety after 30
minutes:BRC Anchor Bolts - 3.5 Tonne

5.2.10 In the first instance, for any new application of the full
column bonded Anchor Bolts, a proof load/pull test should be
witnessed by a competent person duly appointed by the Mine
Manager.
5.2.11 Anchor Bolts must not be subjected to repeated or reverse
bending.

247

r
BRC SPECIAL PURPOSE ANCHOR BOLT SYSTEM

Fast Set
(Red)
AT Resin

o
Q.

.
E
E

Slow Set
(Green)
AT Resin

Full Column
Bonded
Anchor Bolt

o
o

CT

\J

II
-C
Q.

32 mm dia
drilled hole

V
50 mm

FORGED ANCHOR RING END TO

ACCEPT BRITISH COAL SPEC.
SHACKLES
deg | deg
FICb.fo
248

CORDIS
The Community Research and Development Information Service

Your European R&D Information Source

CORDIS represents a central source of information crucial for any organisation - be it industry, small and
medium-sized enterprises, research organisations or universities - wishing to participate in the
exploitation of research results, participate in EU funded science and technology programmes and/or seek
partnerships.
CORDIS makes information available to the public through a collection of databases. The databases cover
research programmes and projects from their preparatory stages through to their execution and final
publication of results. A daily news service provides up-to-date information on EU research activities
including calls for proposals, events, publications and tenders as well as progress and results of research
and development programmes. A partner search facility allows users to register their own details on the
database as well as search for potential partners. Other databases cover Commission documents, contact
information and relevant publications as well as acronyms and abbreviations.
By becoming a user of CORDIS you have the possibility to:
Identify opportunities to manufacture and market new products
Identify partnerships for research and development

Identify major players in research projects

Review research completed and in progress in areas of your interest

The databases - nine in total - are accessible on-line free of charge. As a user-friendly aid for on-line
searching, Watch-CORDIS, a Windows-based interface, is available on request. The databases are also
available on a CD-ROM. The current databases are:
News (English, German and French version) - Results Partners - Projects - Programmes - Publications Acronyms - Comdocuments - Contacts

CORDIS on World Wide Web

The CORDIS service was extended in September 1994 to include the CORDIS World Wide Web (WWW)
server on Internet. This service provides information on CORDIS and the CORDIS databases, various
software products, which can be downloaded (including the above mentioned Watch-CORDIS) and the
possibility of downloading full text documents including the work programmes and information packages
for all the research programmes in the Fourth Framework and calls for proposals.
The CORDIS WWW service can be accessed on the Internet using browser software (e.g. Netscape) and
the address is: http://www.cordis.lu/
The CORDIS News database can be accessed through the WWW.

Contact details f or further Information

If you would like further information on the CORDIS services, publications and products, please contact
the CORDIS Help Desk :
CORDIS Customer Service
B.P 2373
L-1023 Luxembourg

Telephone:
Fax:
E-mail:
WWW:

+352-401162-240
+352-401162-248
helpdesk@cordis.lu
http://www.cordis.lu/

European Commission
EUR 17188 Mining operations
Optimization of cable bolting
and rock bolting material properties
British Coal Corporation
Luxembourg: Office for Official Publications of the European Communities
1997 248 pp. 21.0 X 29.7 cm
Technical coal research series
ISBN 92-827-9395-8
Price (excluding VAT) in Luxembourg: ECU 41.50

A test programme using the double embedment method has been

established as the best way of investigating the comparative performance
of long tendons to determine axial and shear properties. A variety of long
hole tendon reinforcement systems have been evaluated, together with
several cable bolting grouts.
Optimization of grout performance has been achieved through a continuous
laboratory testing programme, and a field quality control procedure has
been developed.
Field work at varied sites in terms of conditions and geotechnical situations
has been fundamental in optimizing system design and performance. A
number of case studies are presented to illustrate the variation in the
application and extent of different cable bolting options.
Experience with cable bolt installations at many sites within British Coal has
enabled key design factors to be identified and the establishment of quality
assurance techniques. This has resulted in the production of a code of
practice for cable bolt installations. It encompasses design, installation
practices, training, monitoring and quality assurance.
Development of rock bolt reinforcement is incorporated within the objectives
of this project. Work was concentrated on developing and modifying the 'AT'
bolt for various applications, as well as widening the scope of resin
encapsulation.
One notable occurrence has affected the compilation of this report. In
December 1993 a fire destroyed part of the buildings, including the rock
testing laboratory, occupied by Rock Mechanics Branch. In addition,
significant data discs and files which included information relative to this
report, notably laboratory test reports and field work results, were
destroyed.
Some, but not all, of the information has been resourced or, in the case of
the laboratory work, re-tested. Mention is made in the relevant sections of
the report of the effect this fire has had in obtaining information.

Venta Salg Verkauf Sales Vente Vendita Verkoop Venda Myynti Frsljning
BELGIOUE/BELGIE

GRAND-DUCHE DE LUXEMBOURG

SCHWEIZ/SUISSE/SVIZZERA

ISRAEL

Moniteur beige/Belgisch Staatsblad

Rue de Louvain 40-427
Leuvenseweg 40-42
B-1000 Bruxelles/Brussel
Tl. (32-2)552 22 11
Fax (32-2) 511 01 84

Messageries du livre Sari

5, rue Raiffeisen
L-2411 Luxembourg
Tl. (352)40 10 20
Fax(352)490 661
E-mail: mdl@pt.lu

OSEC
Stampfenbachstrae 85
CH-8035 Zrich
Tel. (411)365 53 15
Fax (41-1)365 54 11
E-mail: urs.Ieimbacher@ ecs.osec.inet.cn
URL: www.osec.ch

R.O.Y. International
17, Shimon Hatarssi Street
POBox 13056
61130 Tel Aviv
Tel. (972-3)546 14 23
Fax (972-3) 546 14 42
E-mail: royil@ netvision.net.il

Jean De Lannoy
Avenue du Roi 202/
Koningslaan 202
8-1060 Bruxelles/Brusse!
Tel (32-2) 538 51 69
Fax (32-2) 538 08 41
E-mail: jean.de.lannoy@infoboard.be

Abonnements:

Librairie europenne Europese Boekhandel

Rue de la Loi 244/
Wetstraat 244
B-1040 Bruxelles/Brussel
Tl. (32-2) 295 26 39
Fax (32-2) 735 08 60

J. H. Schultz Information A/S

Herstedvang 10-12
DK-2620 Albertslund
Tlf. (45) 43 63 23 00
Fax (45) 43 63 19 69
E-mail: schultz@schultz.dk
URL: www.schultz.dk
DEUTSCHLAND
Bundesanzeiger Verlag
Breite Strae 78-80
Postfach 10 05 34
D-50667 Kln
Tel. (49-221)20 29-0
Fax (49-221) 20 29 278

CESKREPUBLIKA
Messageries Paul Kraus
11, rue Christophe Plantin
L-2339 Luxembourg
Tl. (352) 499 88 88
Fax (352) 499 888 444
E-mail: mpk@pt.lu
URL: www.mpk.lu
NEDERLAND

CYPRUS

SDU Servicecentrum Uitgevers

Christoffel Plantijnstraat 2
Postbus 20014
2500 EA 's-Gravenhage
Tel. (31-70)378 98 80
Fax (31-70) 378 97 83
E-mail: sdu@sdu.nl
URL: www.sdu.nl.

Cyprus Chamber Of Commerce & Industry

38. Grivas Digenis Ave
Mail orders:
POBox 1455
CY-1509 Nicosia
Tel. (357-2)44 95 00/46 23 12
Fax (357-2) 361 044
E-mail: cy1691_eic_cyprus@ vans.infonet.com

OSTERREICH

MAGYARORSZAG

Manz'sche Verlags und Universitts

buchhandlung Gmbh
Siebenbrunnengasse 21
Postfach 1
A-1050 Wien
Tel. (43-1)53 161 334/340
Fax (43-1) 53 161 339
E-mail: auslieferunq@ manz.co.at
URL: www.austria.EU.net:81/manz

G.C. Eleftheroudakis SA
International Bookstore
Panepistimiou 17.
GR-105 64 Athens
Tel. (30-1)331 41 80/1/2/3
Fax (30-1) 323 98 21
E-mail: elebooks@netor.gr

Mundi Prensa Libros, SA

Castell. 37
E-28001 Madrid
Tel. (34-1)431 33 99/431 32 22
Fax (34-1) 575 39 98
E-mail: mundiprensa@ tsai.es
URL: www.tsai.es/mprensa
Boletn Oficial del Estado
Trafalgar, 27-29
E-28071 Madrid
Tel. (34-1) 538 22 95 (Libros)/
384 17 15 (Suscripciones)
Fax (34-1) 538 23 49 (Libros)/
384 17 14 (Suscripciones)
URL: www.boe.es
Mundi Prensa Barcelona
Conseil de Cent. 391
E-08009 Barcelona
Tel. (34-3) 488 34 92
Fax (34-3) 487 76 59

Journal officiel
Service des publications des CE
26. rue Desaix
F-75727 Paris Cedex 15
Tl. (33-1)40 58 77 01/31
Fax (33-1)40 58 77 00
IRELAND
Government Supplies Agency
Publications Section
4-5 Harcourt Road
Dublin 2
Tel. (353-1)661 31 11
Fax (353-1) 475 27 60
ITALIA
Licosa SpA
Via Duca di Calabria. 1/1
Casella postale 552
1-50125 Firenze
Tel. (3955)64 54 15
Fax (3955) 64 12 57
E-mail: licosa@ttbcc it
URL: id382.cilea.it/Virtual_Library/bibliot/vetrina/
licosa/tll .htm

Euro Info Service

Europa Haz
Margitsziget
PO Box 475
H-1396 Budapest 62
Tel. (36-1) 11 16 061/11 16 216
Fax (36-1) 302 50 35
E-mail: euroinfo@mail.matav.hu
URL: www.euroinfo.hu/index.htm
MALTA

PORTUGAL
GREECE/

NIS CR - prodejna
Konviktsk 5
CZ-113 57Praha 1
Tel. (42-2) 24 22 94 33
Fax (42-2) 24 22 94 33
E-mail: nkposp@dec.nis.cz
URL: www.nis.cz

Imprensa NacionalCasa da Moeda, EP

Rua Marqus de S da Bandeira. 16 A
-1050 Lisboa Codex
Tel. (3511)353 03 99
Fax (351-1 ) 353 02 94/384 01 32
Distribuidora de Livros Bertrand Ld.1
Rua das Terras dos Vales, 4 A
Apartado 60037
P-2701 Amadora Codex
Tel. (351 1 ) 495 90 50/495 87 87
Fax (351-1)496 02 55

Miller Distributors Ltd

Malta International Airport
PO Box 25
LOA 05 Malta
Tel. (356) 66 44 88
Fax (356) 67 67 99
POLSKA
Ars Polona
Krakowskie Przedmiescie 7
Skr. pocztowa 1001
PL-00-950 Warszawa
Tel. (48-2)26 12 01
Fax (48-2) 26 62 40

SUOMI/FINLAND
TRKIYE
Akateeminen Kirjakauppa /
Akademiska Bokhandeln
Pohjoisesplanadi 39/
Norra esplanaden 39
PL/PB 128
FIN-00101 Helsinki/Helsingfors
Tel. (358-9) 121 41
Fax (358-9) 121 44 35
E-mail: akatilaus@ stockmann.mailneLfi
URL: booknet.cultnet.fi/aka/index.htm
SVERIGE
BTJ A B
Traktorvgen 11
PO Box 200
S-22100Lund
Tel. (4646) 18 00 00
Fax (46-46) 18 01 25
E-mail: btj_tc@ mail.btj.se
URL: www.btj.se/media/eu

Dnya Infotel A.S.

IstikllCad. No: 469
TR-80050 Tunel-lstanbul
Tel. (90-212)251 91 96
(90-312)427 02 10
Fax (90-212) 251 91 97
BALGARIJA
EuropressEuromedla Ltd
59, Bid Vitosha
BG-1000 Sofia
Tel. (359-2)80 46 41
Fax (359-2) 80 45 41
HRVATSKA

Sub-agent for the Palestinian Authority:

Index Information Services
POBox 19502
Jerusalem
Tel. (972-2)27 16 34
Fax (972-2) 27 12 19
RUSSIA
CCEC
60-letiya Oktyabrya Av. 9
117312 Moscow
Tel. (095) 135 52 27
Fax (095) 135 52 27
AUSTRALIA
Hunter Publications
PO Box 404
3167 Abbotsford, Victoria
Tel. (61-3)9417 53 61
Fax (61-3) 9419 71 54
CANADA
Uniquement abonnements/
Subscriptions only:
Renouf Publishing Co. Ltd
1294 Algoma Road
K1B 3W8 Ottawa, Ontario
Tel. (1-613)741 73 33
Fax (1-613) 741 54 39
E-mail: renouf@ fox.nstn.ca
URL: fox.NSTN.Ca/~renouf

EGYPT
The Middle East Observer
41, Sherif Street
Cairo
Tel. (202) 39 39 732
Fax (20-2) 39 39 732
JAPAN
PSIJapan
Asahi Sanbancho Plaza #206
7-1 Sanbancho. Chiyoda-ku
Tokyo 102
Tel. (81-3)3234 69 21
Fax (81-3) 3234 69 15
E-mail: psijapan@gol.com
URL: www.psi-japan.com
SOUTH AFRICA
Safio
5th Floor Export House.
CNR Maude & West Streets
PO Box 782 706
2146Sandton
Tel. (27-11)883 37 37
Fax (27-11)883 65 69
UNITED STATES OF AMERICA

Mediatrade Ltd
Pavia Hatza 1
HR-10000 Zagreb
Tel. (385-1)43 03 92
Fax (385-1) 44 40 59

Bernan Associates
4611F Assembly Drive
MD20706 Lanham
Tel. (301 ) 459 2255 (toll Iree telephone)
Fax (800) 865 3450 (toll free fax)
E-mail: query@bernan.com
URL: www.bernan.com

ROMANIA

MEXICO

Euromedia
Str. G-ral Berhelot Nr 41
RO-70749 Bucuresti
Tel. (40-1)210 44 01/614 06 64
Fax (40-1) 210 44 01/312 96 46

MundlPrensa Mexico, SA de CV
Ro Panuco, 141
Delegacin Cuauhtemoc
ME-06500 Mxico DF
Tel. (525) 553 56 58/60
Fax (52-5) 514 67 99
E-mail: 104164.23compuserve.com

UNITED KINGDOM
The Stationery Office Ltd
(Agency Section)
51. Nine Elms Lane
London SW8 5DR
Tel. (44-171)873 9090
Fax (44-171) 873 8463
URL: www.the-stationery-office.co.uk

SLOVAKIA
ICELAND
Bokabud Larusar Blonda!
Sklavrdustig, 2
IS-101 Reykjavik
Tel. (354)55 15 650
Fax (354)55 25 560

Slovenska Technicka Kniznlca

Nmestie slobody 19
SLO-81223 Bratislava 1
Tel. (427)53 18 364
Fax (42-7) 53 18 364
E-mail: europ@tbb1 .sltk.stuba.sk
SLOVENIA

NORGE
NIC Info A/S
stenjoveien 18
Boks 6512 Etterstad
N-0606 Oslo
Tel. (47-22) 97 45 00
Fax (47-22) 97 45 45

Gospodarski Vestnlk
Zalozniska skupina d.d.
Dunajska cesta 5
SI-1000 Ljubljana .
Tel. (386)61 133 03 54
Fax (386) 61 133 91 28
E-mail: belicd@gvestnik.si
URL: www.gvestnik.si

REPUBLIQUE DE COREE
Kyowa Book Company
1 F1. Phyung Hwa Bldg
411-2 Hap Jeong Dong, Mapo Ku
121-220 Seoul
Tl. (822) 322 6780/1
Fax (82-2) 322 6782
E-mail: kyowa2@ ktnet.co.kr.
ANDERE LANDER/OTHER COUNTRIES/
AUTRES PAYS
Bitte wenden Sie sich an ein Bro Ihrer
Wahl / Please contact the sales office of
your choice / Veuillez vous adresser au
bureau de vente de votre choix

12/96 #

NOTICE TO THE READER

All scientific and technical reports published by the European Commission are announced in the
periodical 'euro abstracts', published every two months, and in the R&TD publications database of
CORDIS, the Community Research and Development Information Service.
For subscription (1 year: ECU 65) please write to the address below.

>

Price (excluding VAT) in Luxembourg: ECU 41.50

*
OFFICE FOR OFFICIAL PUBLICATIONS
O F T H E
"SB"
EUROPEAN COMMUNITIES
+ *

L-2985 Luxembourg

ISBN

^5-057-^3^5-0

7 8 9 2 8 2"793954 >