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Permanent excavation reinforcement using

cement grouted split set bolts

Article · December 1997

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 Excavation reinforcement using cement grouted split set bolts

E. Villaescusa
Western Australian School of Mines

J. Wright
Ingersoll Rand (Australia) Ltd.

ABSTRACT
A series of in-situ pull tests have been conducted to determine the holding capacity
of the standard SS46 Split Set ® Stabilizers. The experiments have been conducted in
a wide range of geological conditions ranging from bedded rock to blocky ground.
The results presented in this paper indicate that cement grouted split sets bolts are
likely to provide up to three times the initial bond strength per metre of embedment
length provided by the ungrouted bolts. The increased load transfer capacity of the
grouted bolts provide an alternative for permanent excavation support using split
sets stabilizers.

Introduction
The split set stabilizer consists of a hollow rolled tube (with a slot along the entire
length) which is driven into a drilled hole of smaller diameter and when left
ungrouted, relies on friction between the tube and the rock to provide support. The
system does not suffer from the problems encountered with other reinforcement
systems such as point anchored rockbolts where if the anchor slips or the rock
around the plate fails the capacity of the bolts drop to zero and failure of the rock
around an excavation can occur. This problem is less severe in the case of a fully
coupled frictional bolt because even if slip does occur, or if the face plate breaks off,
the remaining length of the bolt is still anchored/bonded and will continue to
provide a degree of support.
Experience to date indicates that split set bolts provide very effective support in
bedded rock, where the overall effect is to create a thick composite beam that is
stronger than any of the individual layers (See Figure 1). Split set bolts are
particularly useful in fissile, buckling or sheared ground, where it is sometimes
difficult to secure a point anchor. The bolt provides dynamic support because it has
the ability to move with the ground providing support along the entire length of the
bolt.

Interactive CB
rockbolts

Interactive
rockbolts

CB CB CB = Composite beam building

Figure 1. Composite beam effect in laminated strata (beam formation and

suspension).
® Split set is a trade mark of Ingersoll-Rand Company.
One critical limitation of ungrouted split set bolts is that although the bolts are
simple and quick to install and stand up to blast vibrations relatively well, they have
a very low initial bond strength per metre of embedment length. This may be
insufficient to guarantee effective support of wedges, blocks and slabs potentially
formed within the immediate back of the excavations. The initial bond strength is
developed during bolt insertion, where the drillhole tolerance with respect to bolt
diameter is small and is likely to control the available frictional forces along the bolt
length (Davis, 1979). In soft ground the driving time to completely install a bolt is
sometimes reduced indicating an even lower initial bond strength per metre of
embedment length as shown with hole number 2, Table 1. Figure 2 presents a relative
comparison on the measured strength using different hole diameters with respect to
the SS46 split set bolt dimensions. A significantly lower strength was determined for
the bolts installed in the larger hole as expected. Figure 3 shows the results of
laboratory testing conducted at Mount Isa Mines to determine the shear strength of
the 3mm thick tubular SS46 split set bolts. The maximum shear value (11 tonnes)
compares favourable with the value obtained for an untensioned 20mm thick solid
rebar (10.7 tonnes).

Table 1. Performance test data - ungrouted SS46 Split set stabilizers, Stawell Gold
Mines Pty Ltd.
Hole Tube Bit Hole Drill Hole Drive Pull Remarks
No length style diam time orienta time test
(SS46) (mm) (m : s) tion (sec) (tonnes)
1 3m button 46.75 1:58 wall 35 11.0 slip
2 “ “ 46.75 1:48 back 29 6.0 slip
3 “ “ 46.25 2:12 back 47 10.5 slip
4 “ “ 45.50 1:57 back 34 11.5 slip
5 “ “ 46.30 1:37 back 33 13.0 slip
6 “ “ 44.50 1:47 F/W 40 13.0 slip
Hilton SS46 ungrouted
2.1m embedment length
12

10

8
Load (tonnes)

2 42mm hole diameter

46mm hole diameter

0
0 5 10 15 20

Deformation (mm)
Figure 2. The influence of hole diameter on the experimental frictional
strength.

In the context of supporting bedded ground, the bolt effectiveness is not only a
function of the bond strength per metre of embedment length, but it is a function of
the mechanical properties of the composite beam formed, the size of the span and the
level of induced stress. Nevertheless, because of the low bond strength achieved with
ungrouted bolts, individual layer delamination within a composite beam can still
occur, and effective back support may not be achieved. This may be the case when
the excavation process (blasting) "overbreaks" into the exposed bedding plane layers
at the excavation boundary.

Mount Isa Mines

SS46 ungrouted
tested in single shear
12

10
Shear Load (tonnes)

0
0 2 4 6 8 10 12 14 16 18

Deformation (mm)

Figure 3. Shear strength of tubular SS46 split set bolts.

Load transfer and embedment length

The load transfer concept is the most fundamental aspect regarding the
understanding of reinforcement behaviour, including the action of the different
support devices and their effect on excavation stability. The concept is shown in
Figure 4, where three basic components can be defined (Windsor and Thompson,
1993).

A) Ground movement at the excavation boundary, which causes load transfer from
the unstable rock,wedge or slab to the reinforcing element.

B) Transfer of load via the reinforcing element from the unstable area to a stable
interior region within the rockmass.

C) Transfer of the reinforcing element load to the rock in the stable interior zone.
 For a fully coupled frictional bolt such as an ungrouted split set bolt, failure by
slippage of the reinforcement element can either occur within the unstable or the
stable regions in the rockmass depending of the amount of embedment length
available in both regions. The critical embedment length is the minimum length of
reinforcement needed to mobilize the full bolt capacity or strength. This minimum
length may need to be increased if the reinforcement element is oriented at
unfavourable angles with respect to the free surface (Windsor and Thompson, 1992).
In the case of a fully coupled frictional system, the load transfer results from friction
between the reiforcement element and the borehole wall. The strength per metre of
embedment length of an ungrouted split set bolt is limited by the radial prestress set
up during installation. This is a function of the split set bolt diameter, the borehole
diameter and any geometrical irregularities occuring at the borehole wall. The radial
pressure distribution between the split set bolt and the hole wall can be related to a
force along the length of the tube (Davis, 1979).
Bolt slippage within the stable region can only be prevented if the longitudinal
friction forces provide the total anchoring force needed to support the weight of the
unstable region in Figure 4. This anchoring force is directly related to the support
capacity per unit length and ultimately to the total amount of embedment length
available within the stable region. On the other hand, slippage within the unstable
area is also a function of the longitudinal friction forces acting within that portion.
Slippage and failure within the unstable area due to short embedment lengths, can be
minimized with the installation of a proper face plate to provide surface restraint.

total frictional
resistance
available to
support wedge
join embedment
t se
t2 1 length within
t se t
join stable region
cal
e ologi nuity
g onti
disc

unstable
bolt & wedge region
analyzed
wedge
movement
enlargement

Figure 4. Load tranfer and embedment length concepts.

Ungrouted frictional strength

Although the initial pull out strength of the split set bolt is equal to the force required
to drive it into the hole, experience has shown that the ungrouted frictional resistance
increases slightly when there is some degree of ground movement. Figure 5 shows a
slight increase of strength with time of ungrouted split set bolts that were installed
within buckling, highly fissile shales at the Hilton Mine in Queensland. Slight
corrosion of the split set bolt has also been known to increase the frictional strength.
However, in most cases when standard (black steel) bolts are used, susceptability to
internal and external corrosion may become an issue in wet areas, where the split set
bolt support can become inefficient within three months. Galvanizing of the split set
bolts is one solution to the corrosion problem. However, experience has shown that a
mine water environment having a pH lower than 6 and greater than 12 is likely to
increase the corrosion rate even in galvanized split set bolts. In any case, when split
set bolts are used, laboratory testing of the mine water is required in order to
determine if aggressive elements likely to accelerate the corrosion process are
present, even against galvanizing.
A series of in-situ pull tests have been conducted during the last six years in order
to determine the average strength per metre of embedment length for ungrouted split
set bolts installed in different ground conditions throughout Australia. All field tests
have been carried out following the ISRM suggested methods for rockbolt testing
(Brown, E.T., 1978). The field tests carried out with ungrouted bolts at different
embedment lengths have shown a low initial bond strength per metre of embedment
length developed during insertion, which is insufficient to guarantee effective
support of large wedges and blocks. Figure 6 shows data collected by Ingersoll Rand
in Australia, in which an average strength of approximately 4 tonnes per metre of
embedment length can be seen to be mobilized along the entire length of the split set
bolt. This can be considered a low frictional value, if the ungrouted split set bolts are
to be used for permanent back support in blocky ground.
Hilton Mine SS46 (44.5mm bit)
Footwall support (Thinly bedded shale)
Ungrouted bolts
6

4
Load (tonnes)

1 tested after installation

tested 7 days after installation

tested 28 days after installation

0
0.0 0.2 0.4 0.6 0.8 1.0

Embedment Length (m)

Figure 5. A slight increase in strength due to ground movement.

 Split set bolts (SS46)
Ungrouted strength
14

12

10

Load (tonnes)
8

4
Thalanga Mine
Stawell Mine
2 Hilton Mine 1991
Hilton Mine 1996
0
0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00

Embedment Length (m)

Figure 6. Typical ungrouted strength for fully coupled friction bolts.

Figure 7 shows the results of a recent test conducted at the Hilton Mine in
Queensland, where an average strength value of approximately 4-5 tonnes/metre of
embedment length was found for galvanized and standard ungrouted split set bolts.
A constant level of loading was observed while the bolts were slipping along the bolt
axis. Although the results obtained indicate a slightly higher strength than other
similar bolts tested elsewhere, the concern regarding the low initial bond strength
still remains, if ungrouted bolts are used as the primary form of back support.
Hilton SS46
ungrouted
1m of embedment length
8

6
Load (tonnes)

0
0 2 4 6 8
Deformation (mm)

Figure 7. Ungrouted split set bolts pull test strength.

Cement grouted strength

Despite their low bond strength limitation and their susceptibility to corrosion, the
split set bolt or friction bolts are extensively used throughout the mining industry
even for permanent back support in blocky ground. This is because of the advantages
that the system has to offer. These can be listed as:

1). Immediate support to the face, when the bolt behaves extremely well under
dynamic loading and the damage from blasting is minimal. Development advance
can be effectively increased due to minimal delays in ground support.

2). Quick, mechanized bolt and mesh installation with a minimum of components.

3). Split set bolts can also be meshed at a later date by installing a short split set bolt
within the existing ungrouted bolts.

4). The bolts can be installed into partially collapsed holes, providing support in poor
ground conditions and reducing the number of holes that require re-drilling.

5). In some cases, corrosion resistance can be minimized with the use of galvanized
or stainless steel support.

Nevertheless, the critical problem of low frictional strength per metre of embedment
length still remains and the ungrouted bolts can only be used for temporary back
support in blocky ground.
In order to overcome the low bond strength limitation of the ungrouted bolts,
cement grouting of split set bolts has been undertaken over the last six years at
several Australian mines. The experimental results have shown a potential for an
increase on the frictional strength per metre of embedment length as demostrated
following a recent grouting program in the Hilton Mine in North Queensland. Split
set bolts having an embedment length of 1m were cement grouted following
installation and pulled systematically at 2, 3, 4, 5.5 and 7 hours after grouting
respectively. The results in Figure 8 show that a consistent value of 10 tonnes per
metre of embedment length can be achieved after 5.5 hours following grouting. This
matches the design strength value (per metre of embedment length) achieved by
most typical M20 cement grouted rebars used elsewhere (Villaescusa et al, 1992).
 Hilton SS46
cement grouted
1m of embedment length
16
15
2 hrs
14
2 hrs
13
3 hrs
12
3 hrs
11
4 hrs
10
Load (tonnes)

4 hrs
9
4 hrs
8
5.5 hrs
7
5.5 hrs
6
5.5 hrs
5
7 hrs
4
7 hrs
3 7 hrs
2
1
0
0 2 4 6 8 10 12 14 16

Deformation (mm)

Figure 8. Increased strength with time for grouted split-set bolts

The actual strength achieved with the grouted split set bolts tested 8 hours after
installation was in excess of 15 tonnes/metre of embedment, however in order to
avoid damage to the pull testing gear, only a few bolts have been pulled to such
values. Figure 9 shows that a consistent value of 13 tonnes per metre of embedment
length was obtained in all the pulled bolts at the McArthur River Mine tested 3 days
after grouting. Interpretation of the results indicate that the increased strength of the
grouted bolts is mainly due to the " partial dowelling and interlocking effect"
achieved by the high strength grout being in contact (bonded) with the rock all the
way along the split axis of the bolt. The bolts were grouted toe to collar using a thick
grout having a water cement ratio of 0.3 and a Uniaxial Compressive Strength of 28
MPa at 7 days. The frictional resistance along the entire bolt axis is also increased by
the high compressive strength grout minimizing any inward deformation in the bolt
needed to achieve bolt slippage.
 MRM SS46 galvanized
cement grouted (72 hrs)
0.85m of embedment length
18
16
14

Load (tonnes)
12
10
8
6
4
2
0
0 2 4 6 8 10 12 14 16 18 20

Deformation (mm)
Figure 9. Grouted friction anchor pull test strength after 3 days.

The experimental results have shown that increased back support can be effectively
achieved by fully grouting split set bolts close to the advancing face. If grouting of
the bolts using a thick cement grout is included in the mining cycle, a total strength
of up to 18 tonnes per metre of embedment can be achieved as shown in Figure 10.
The results on this figure indicate an increase in strength with an increasing
embedment length following grouting. Care must be taken to minimize immediate
exposure in cases where the embedment length is less than a metre as shown in
Figure 11. The results suggest that at least 8 hours are needed following grouting
when short embedment lengths are designed. This is particularly true for flat lying
beeded rock where the support concept of beam formation and suspension is created
by the spli-set bolts. In cases where suspension of a potentially unstable thicker beam
is achieved by interactive rockbolting as shown in Figure 1, the embedment capacity
per metre of embedment length within the stable region is critical.
Split set bolts (SS46)
ungrouted vs. grouted strength
20
18
MRM grouted (72hrs)
16 range from 15-18 tonnes Thalanga ungrouted

14 Hilton ungrouted
Load (tonnes)

12 Thalanga grouted (72hrs)

10 MRM ungrouted range (5.2-6.7 tonnes)
Thalanga grouted (7days)
8
Thalanga grouted (28days)
6
Hilton grouted (7days)
4
Hilton grouted (28days)
2
0
0.00 0.50 1.00 1.50 2.00 2.50 3.00

Embedment Length (m)

Figure 10. Increase of strength achieved by grouting the split set bolts.
 Hilton SS46
cement grouted (0.3 w/c)
0.5m of embedment length
13
12
11 ungrouted
10 ungrouted
9
ungrouted
Load (tonnes)
8
7 grouted 4 hrs
6
grouted 4 hrs
5
4 grouted 7.5 hrs

3 grouted 7.5 hrs

2
1
0
0 2 4 6 8 10

Displacement (mm)

Figure 11. Increase of strength with time for short embedment lengths

Alternative methods, other than cement grouting following bolt installation, have
been tried to increase the strength of the split set bolts and to provide permanent
back support. The option of installing a grouted rebar inside a split set bolt in order
to achieve a more permanent support was pursued at Mount Isa Mines dating back
to 1987. The idea is to over drill the initial hole length in order to allow a longer rebar
to be installed and grouted inside the split set bolt. Figure 12 shows the results of
recent testing conducted at the Thalanga Mine, where no significant improvement
over the strength achieved by only grouting the split set bolts was found. Experience
suggests that if this method is going to be effective, then overdrilling of the hole at
the anchor point (toe of the hole) should exceed the critical embedment length of the
grouted rebar used, (0.3 to 0.5m) in order to guarantee the full capacity of the
combined system. This method can be very expensive, and the results shown below
suggests that it may not be required.
Thalanga SS46 (44mm bit)
18
dowel protruding
16 0.25m beyond SS
14 dowel protruding
0.34m beyond SS
12
Load (tonnes)

10

4 grouted 7 days

2 grouted with 20mm

rebar inside 7 days
0
0.0 0.2 0.4 0.6 0.8 1.0

Embedment Lenght(m)

Figure 12. A comparison of two methods available to achieve long term support
using split set bolts.
 Conclusions

The experimental results have shown that ungrouted split set bolts are capable of
providing immediate four tonnes of support per metre of embedment length. Blast
damage to the bolts is minimal and they can be installed very close to the face.
However, because of their initial low bond strength, ungrouted bolts are not
recommended for permanent support. The experiments have also shown that cement
grouted galvanized split set bolts are the most practical and economical way of
achieving permanent back support in a wide range of geological conditions including
blocky ground. The grouted bolts are likely to provide up to four times the initial
bond strength per metre of embedment length provided by the ungrouted bolts.

Acknowledgments

The authors wish to thank the management of the Thalanga, Hilton, Stawell and
McArthur River Mines for their permission to publish the data presented in this
paper.

References

Davis, R.L., (1979) Split set bolt rock bolt analysis. Int. Journal of Rock Mechanics and
Mining Sciences & Geomechanics Abstracts. Vol 16, No 1, 1-10.
Brown, E.T. (Ed.), (1978) Rock characterization testing and monitoring. Commission
on Testing Methods, International Society for Rock Mechanics, Pergamon
Press, Oxford.
Villaescusa E., M.P. Sandy and S. Bywater, (1992). Ground support investigations
and practices at Mount Isa. Rock Support in Mining and Underground
Construction, Sudbury, 185-193.
Windsor, C. R and A. Thompson, (1992). Reinforcement design for jointed rock
masses. Proc. 33 rd US Symposium on Rock Mechanics, Santa Fe, 521-530.
Balkema: Rotterdam.
Windsor, C. R and A. Thompson, (1993). Rock reinforcement - technology, testing,
design and evaluation. Comprehensive Rock Engineering (J. Hudson, Ed.),
Volume 4, Chapter 16, 451-484, Pergamon Press, Oxford.

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