* *

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

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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

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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 19 19 19 19 20 20 21 21 22 23 23 24 24 24 24 25 25 26 33 33 33 35 36 37 41 41 41 41 42 45 46 46 47 47 49 49 49 49 50

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 CHAPTER 3 3.1 3 2 3 3 3 4 3 5 CHAPTER 4 4.1 4.2 GROUTS EARLY EXPERIENCE GROUT CHARACTERISTICS GROUT MIXING QUALITY CONTROL FIELD EXPERIENCE 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 BRITISH COAL LABORATORY TESTING OF CABLE BOLT SYSTEMS AIM OF BRITISH COAL LABORATORY TESTING TEST MATERIALS 5.2.1 CABLES 5.2.2 GROUTS

4.3

CHAPTER 5 5 5,

5.3 5.4

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 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 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

53 53 54 55 55 57 57 59 59 59 71 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

5.5

CHAPTER 6 6.1 6.2

6.3

6.4

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

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 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

131 131 131 131 131 132 132 132 132 133 134 134 134 134 134 135 135 135 136 136 136 137 137 143 143 143 143 143 144 144 149 149 149 149 150 150 151 151 160 160 160 160 161 161 170 170 170 170 171 171 180 180 180 180 181

9.5.5 9.5.6 9.5.7 9.5.8

CABLE BOLTING ROUTINE MONITORING RIB REINFORCEMENT CONCLUSION

181 182 182 183 191 191 191 191 192 192 195 195 195 195 196 199

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

9.7

CHAPTER 10 CONCLUSIONS AND RECOMMENDATIONS ILLUSTRATIONS CHAPTER 1 FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 CHAPTER 2 PHOTO 1 PHOTO 2 FIGURE 1 FIGURE 2 TABLE 1 BIRDCAGE CABLE PERFORMANCE COMPARISON STANDARD AND BIRDCAGE CABLES CONFINEMENT MECHANISM OF CABLE BOLTS SUSPENSION MECHANISM OF CABLE BOLTS TYPES OF CABLE BOLT TYPES OF CABLE BOLT WOMBAT CABLEBOLTER MODULAR BOLTING SYSTEM DOUBLE NUTCAGE DESIGN

16 12 17 18 27 28 29 30 31 38 39 42 43 44 44 45 46 51 53 54 60 62 61 61 62

CHAPTER 3 FIGURE 1 GROUT MIXER/PUMP (MANUFACTURER A) FIGURE 2 GROUT MIXER/PUMP (MANUFACTURER G) 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) CHAPTER 5 TABLE 1 TABLE 2 TABLE 3 FIGURE 1 FIGURE 2 PHOTO 1 PHOTO 2 PHOTO 3 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 CHAPTER 6 TABLE 1 FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4

GENERAL ARRANGEMENT OF GUILLOTINE TEST RIG DETAILS OF GUILLOTINE TEST RIG FLOW CHANNEL GROUT MIXER/PUMP

63 65 68 69 71 85 85 86 86 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

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

CHAPTER 7 TABLE 1 FIGURE 1 FIGURE 2 TABLE 2 TABLE 3 TABLE 4 TABLE 5

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

103 116 116 117 117 106 118 118 109 119 119 120 120 121 121 122 122 123 123 124 124 125 125 126 126 127 127 128 128 129 129 138 139 140 140 145

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 CHAPTER 8 FIGURE 1 FIGURE 2 FIGURE 3 TABLE 1 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

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

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

203 203 206 217 217 221

CABLE BOLT TRAINING REQUIREMENTS APPENDIX IV UNIAXIAL COMPRESSIVE STRENGTH AND DENSITIES OF CABLE BOLTING GROUTS APPENDIX V TECHNICAL GUIDANCE ON SPECIAL PURPOSE RESIN BONDED ANCHOR BOLTS FOR THE PURPOSE OF LIFTING AND SUSPENSION OF EQUIPMENT

221 225 225 235 237

10

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.

1 1

Figure 2

30-

Tcnstt J.lu'e

L O A D lionnes)

8>'dc9e Cable

S O

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.

CABLE a
A C D 220 160 19 0 230

DISTANCE (mm) b 270 270 270 280 e 270 280 280 270 330 310 300 360 d e 300 270 270 270

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) b) c) d) e) High strength Rapid cure time Suitable pumping/setting characteristic Expansive properties (to enhance bond and anchorage) Non corrosive properties and high stiffness

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 AXIAL TESTING OF CABLE BOLTS the of for be

shear

Axial testing conducted in the laboratory is usually in a Single or Double Embedment format as shown in Figure 4.1.

Load Pom

r 1

$/*,

in
]

IJ
s
m

>x\v.

>m.

t\
> :
:

?
. j

Sr/Xt-

i' h w

a) Single Embedment Figure 4.1

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

IO turn Potentiometer

t2mm 7vire rond

LVOT

Grout IwmerAementO-'Sr

-BT

iJ 7
Suoporl lenqth

10 turn Poienticnttr .'' - ' - veiohu.jnrrn

Rubber stopper

Embedment lenqth

'Jt'i d hivot
~SCraent
frtih

Plue-

H*y>w;
S S J F ^

Test M/C JOW5-7

1*1

Test specimen, for pullout of wires

Test specimen for pullout of strand

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.

Figure 4.2

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.

, CH U CK

tiptco

we coot xtiea
/IVSE DWTtti o (MB )

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

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 IttltCr* A

i 3

CiiO viCw

COOSS

StCIiO"

Figure 4.6 Direct Shear Frame as used by Gale & Fabjanzyck 1987b.

4.3 LABORATORY TESTING OF C EMENTITIOUS 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. 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. 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.

2.

3.

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
STRENGTH MPa *1 1 30 20 24 6 40 20 20 3 40
, ,

GROUT 1 2 3 4 5 6 7

W.S.R.

TIME Days 7 55 44 44 25 60 64 60 28 65 64 59 46 80 75 70

STATUS *2 FULL *3 FULL FULL *4 FULL PROVISIONAL NOT NOT

0.18 0.18 0.18 0.20 0.31 0.16 0.33

15 50
^m

NOTES *1 *2 Compressive strengths quoted by manufactures 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.) 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, 5 1

*3

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. 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 became Double

5.3 5.3.1

TEST PROGRAMME 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 5.2

The main test program for the cables is shown in Table below: TABLE 5.2 MAIN CABLE COMPARISON TEST PROGRAM HOLE SIZE (mm) 52 43 52 43 52 35 NO. Samples per day 2 2 2 2 2 2 1, 1, If TESTING TIME (Days) 3, 7, 14, 28, 3, 7, 14, 28,

CABLE TYPE Man. A Double Bird. Man. A Single Bird. Man. Double Bird Man.. Single Bird. Man. C Bulbed Cab. Man. D Wire Rope

GROUT TYPE A A A A A A

3, 7, 14, 28, 1, 3, 7, 14, 28, If 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 Man. A Double Bird. Man. A Double Bird. Man. A Double Bird. Man. A Single Bird Man. A Single Bird. Man. A Single Bird. GROUT TYPE C D C D HOLE SIZE (mm) 52 52 52 43 43 43 NO. Samples per day 2 2 2 2 2 2 TEST TIME (Days) I, 3, 7, 14, 28, 1, 3, 7, 14, 28, 1, 3, 7, 14, 28, 1, 3, 7, 14, 28, 1, 3, 7, 14, 28, 1, 3, 7, 14, 28,

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. 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.

2.

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 ( 1 " \

-*"* where: D = sample diameter L = sample length

0.304(^)+0.848

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 SINGLE BIRDCAGE

MILD STEEL CHUCKADAPTOR

450mm DOUBLE EMBEDMENT

STEEL TUBE

^ J \ ANTINODE CABLE WAVELENGTH 260mm JOINT (3.5 cages Per 900mm)

INTERNALLY THREADED SURFACE 2.0mm PITCH 0.5mm DEEP

CABLE WAVELENGTH 240mm

NODE INTERNAL HOLE DIAMETER 52mm

(3.9 Cages per Per 900mm)

BRmSHCOAL APPROVED GROUT

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 6 1

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

NOT TO SCALE

FIGURE S2

62

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Photograph 5.3 Guillotine Shear Frame in Test Machine

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Photograph 5.4 Flow Channel

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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 1 Day GROUT TYPE *1 GROUT 1 (1) GROUT 1 (2) GROUT 2 185 All Wires Pulled Out 156 2 Wires Frac. 5 Wire P\Out 165 All Wires Pulled Out 297 4 Wires Frac. 3 Wires P\Out 166 All Wires Pulled Out 7 Days 288 2 Wires Frac. 5 Wires P\Out 267 2 Wires Frac. 5 Wires P\Out 169 All Wires Pulled Out 288 All Wires Fractured 226 All Wires Pulled Out 14 Days 291 All Wires Fractured 263 2 Wires Frac. 5 Wires P\Out 224 All Wires Pulled Out 291 3 Wires Frac. 4 Wires P\Out 290 All Wires Pulled Out MAXIMUM FORCE (kN) / FAILURE MECHANISM

GROUT 6

GROUT 7

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. 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.

2.

3.

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. defined for single

6.2.2

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 1. the

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. 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.

2.

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

Initial Stiffness 0 - lOOkN (kN/mm) 1. 2. 50.0 50.0

Initial Yield (kN) 115 115

Working Stiffness 200kN-30kN (kN/mm) 10.5 13.3

Maximum Load (kN) 516 458

2x7-Strand Dyform Cable Node Antinode Antinode 24 Hours Node Antinode

Man. A DOUBLE BIRDCAGE 28.6 40.0 66.7 76.9 35.7 38.5 40.0 43.5 62.5 62.5 35.7 51.7 105 105 140 150 100 125 125 115 150 150 100 100 16.9 17.2 17.5 16.1 18.2 16.6 14.3 17.2 19.6 17.5 9.6 13.9 448 456 448 438 368 364 504 498 424 464 238 206

DCAGE Man. DOUBLE BIR]

Man. A SINGLE BIRI5CAGE Node Antinode

84

450mm DOUBLE EMBEDMENT TEST CABLEBOLT DEFORMATION CHARACTERISTICS

700

450mm DOUBLE EMBEDMENT TEST CABLEBOLT DEFORMATION CHARACTERISTICS

400

300
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DISPLACEMENT (mm)
DOUBLE BIRDCAGE DOUBLE NUTCAGE BULBED CABLE
CURETIME:14DAYS
FIGURE t\

10

DISPLACEMENT (mm)
WIRE ROPE SINGLE BIRDCAGE SINGLE NUT CAGE
CURE TIME: 14 DAYS
fiOUflE 62

450mm DOUBLE EMBEDMENT TEST DOUBLE BIRDCAGED CABLEBOLT FAILURE CHARACTERISTICS

700

CROSS SECTION OF NODAL & ANTI-NODAL REGIONS OF DOUBLE BIRDCAGE SAMPLE SHOWING FAILED GROUT

600

ANTI-NODE
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500 400

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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

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

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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

CHUCK ADAPTOR

2 7-STRAND DYFORM CABLES SECURED TOGETHER

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 2. 2x7 STRAND DYFORM CABLE Max. Load 568kN Bond Failure
QROUTA CURE TIME: 14 DAYS HOLE SIZE : 52mm

1. 2x7 STRAND DYFORM CABLE Max. Load 574kN Bond Failure

FIOJfiE &5

FIOJAE

450mm DOUBLE EMBEDMENT TEST

TABLE

S.2

MAN.A & MAN.B DOUBLE BIRDCAGES MAN.A SINGLE BIRDCAGE

Cure Time (Days)

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 Max. Load (kN) 519 301 629 621 637 * 585 628 634 634 636 Inital Stiffness (kN/mm) 181.2 266.7 250.0 250.0 222.2 250.0 307.7 285.7 200.0 307.7 236.1 296.7 253.9 114 .3 125.0 142.9 133.3 129.0 125.0 Average INITAL Stiffness (kN/mm) 224.0 117.6 117 .6 119.7 138.1 127.0 | Working Stiffness (kN/mm) 29.0 29.0 Average WORKING Stiffness (kN/mm)

1 3 7
14 28
VD O

Grout F ailure Borehole Wall F ailure Node at Split Manufa cturer DOUBLE BIRDCAGE GROUT A Cure Time (Days) Max. Load (kN) 304 335 621 518 619 623 617 620 625 623 Inital Stiffness (kN/mm) 160.0 133.3 266.7 235.3 307.6 307.6 285.7 363.6 333.3 333.3 324.7 158.7 140.8 155.0 155.0 AVERAGE INITAL Stiffness (kN/mm) 146.7 251.0 119.8 114.3 117.6 117.6 149.8 117.1

, Working Stiffness
(kN/mm)

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

AVERAGE 1 WORKING Stiffness 1

DISPLACEMENT (mm)
MAN.B DOUBLE BIRDCAGE MAN.A SINGLE BIRDCAGE Max. Load 618kN Max. Load 302kN DOUBLE BIRDCAGE Max. Load 616kN
CURE TIME: 14 DA YB

(kN/mm) I I
-

1 3 7
14 28

GROUT A
FI OiRE 5 7

Grout failure Borehole wall failure

BULBED CABLE
SECTIONAL DIAGRAM OF TEST ASSEMBLY

DOUBLE NUTCAGES SECTIONAL VIEW OF TEST ASSEMBLY DESIGN A DESIGN

450mm DOUBLE EMBEDMENT

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

200mm INTERNAL HOLE

DIAMETER : 62mm

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

NUTCAGED LENGTH 150mm

INDIVIDUAL BULB DIAMETER 35mm

QROUTA

INDIVIDUAL CAQE DIAMETER Z*rm

BULBED LENGTH 100mm UNBULBED LENGTH - 100mm

0R0UTA

INTERNAL HOLE
DIAMETER 43mm

450mm DOUBLE EMBEDMENT

ROJRE &

& g

450mm DOUBLE EMBEDMENT TEST MAN.B DOUBLE BIRDCAGE, DOUBLE NUTCAGE BULBED CABLE
700
DOUBLE BIRDCA GE .DOUBLE NUTCA GE DESIGN

TABLE

6 3

ALTERNATIVE CABI.R ; SYSTEM PERF ORMANCI^ Mapu.pmrer , BIRDCAGE. Manufacturer DOUBLE NTCAGE 1 1 a&AmBLiajB * INITAL STIFFNESS : 0 - 200kN (kN/mm) WORKING STIF F NESS : 200kN - 400kN (kN/mm)

Cure Time (Days)

DOUBLE NUTCA QE DESIGNA

Max. Load (kN)

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 14 619 623 617 620 307.6 307.6 285.7 363.6 DOUBLE NUTCAGE 7 14 519 528 575 546
DOUBLE

117.6 117.6 158.7 140.8 149.

324.7

D E S I G N A + GROOT A 59.8 63.1 19.6 16.5 30.3

32.3

57.1 62.5 69.0 57.1

ITOTCAOE

18.1 31.3

0 L_J

I ' l l

L 7 14 606 606 598 608 166.7 153. 250.0 222.2

DESION GROOT A 160.3 236.1 61.5 51.9 81.6 56.3 56.7 69.0

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

DISPLACEMENT (mm)
MAN.B DOUBLE BIRDCAGE Max. Load 618kN Cable Failure DOUBLE NUTCAQE DESIGN A Max. Load 546kN Pull Out

BULBED CABLE + GRODT A 7 531 531 530 526 160.0 166.6 235.3 25.7 163.3 260.5 96.2 88.9 133.3 112.4

DOUBLE NUTCAGE DESIGN Max. Load 68 Wire Failure

CURE TIME: 14 DAY3 QROUTA

BULBED CABLE Max. Load 530kN Cable Failure 14

92.6 122.9

f I OURS ft IS

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 _ 28mm WIRE ROPE

600

WIRE ROPE 32mm DIAMETER CABLE 38mm HOLE 28mm DIAMETER CABLE 35mm HOLE

500

400

O
to

300

6x7 (6/1) CORELESS RIGHT HAND LANG'S LAY

200

100
GROUTA KS J L

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

6.4

450mm DOUBLE EMBEDMENT

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

MAN.B 40TONNE BIRDCAGED CABLE MAN.A SINGLE BIRDCAGED CABLE

500

Cure Time (Day)

Max. Load (kN)

Inital Stiffness (kN/mm)

AVERAGE INITAL Stiffness (kN/mm)

Working Stiffness (kN/mm)

AVERAGE WORKING Stiffness (kN/mm)

Manufacturer DOUBLE BIRDCAGE + GROUT A 7 14 619 623 617 620

307.6
307.6 285.7 363.6 324.7

117.6 117.6 158.7 140.8 149.8

28am HIRE ROPE +.GROUT A 7 f e 14 554 550 553 548 250.0 210.5 250.0 285.7 230.3 267.9 85.1 69.2 75.2 88.5

77.2 81.9

32mm WIR] i ROPE OROUT 7 14 666 668 666 665 285.7 285.7 285.7 285.7 285.7 285.7 108.7 104 .2 110.5 106.4

106.5 108.5

1 40LB 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
AT, 4449 & BIG BOLT

COMPARISON OF ROCKBOLTING SYSTEMS

700

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 J L
J I

BIG BOLT 30mm Diameter Max. Load 562kN

RE8IN TYPE : Manufacturer C AT BLOW 8ET HOLE BIZE8 : AT & 444 27mm BIG. BOLT 35mm
FIGURE & n

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

DISPLACEMENT (mm)

FIOJAE a 15

DOUBLE EMBEDMENT TEST

SINGLE NUTCAGE
8ECTI0NAL VIEW OF TEST ASSEMBLY

REINFORCING TENDONS FOR 27mm HOLES AT BOLT, SINGLE NUTCAGED CABLE, MINESWEEPER ROPE 500

400

AT BOLT + RESIN CHUCKADAPTOR SINGLE NLfTCAGED CABLE 7 STRAND DYFORMED CABLE WITH NUT ON KING WIRE JOINT NUTCAOEO LENQTH 100mm NUTCAQE + Q ROUT

/ MINESWEEPER RESIN

io

NUTCAQE + RES|N

QROUTA

NUTCAQE DIAMETER 23mm

0
450mm DOUBLE EMBEDMENT INTERNAL HOLE DIAMETER 27mm

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 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

QROUTA

MULTIPLE STRAND FIBREGLASS CABLE

ID

JOINT

NODE

INTERNALLY THREADED SURFACE 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 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

8PACER

FIGURE &18

FlOJRE

ftl

DOUBLE BIRDCAGBD CABLES

SECTIONAL DIAGRAM OF TEST ASSEMBLY

ANTINODE AT SPLIT

NODE AT SPLIT

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

MNF.A DOUBLE BIRDCAGE

700
....NOce

WTINOOE

<$/

. DOUBLE BIRDCAGED CABLE 14 STRANDS

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

DOUBLE EMBEDMENT TEST

MAN.A DOUBLE BIRDCAGE + GROUT A SHEAR BEHAVIOUR

700

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

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

DOUBLE EMBEDMENT TEST

DOUBLE EMBEDMENT TEST

MAN.A & MAN.B DOUBLE BIRDCAGES ANTINODE SHEAR CHA RA CTERISTICS

700
600 -

MAN.A & MAN.B DOUBLE BIRDCAGES NODE SHEAR CHARACTERISTICS

IU\J

600 -

500 -

500 -

J2 400 Q (3 300
o o

^-y
'$%?

-s ^ 400 ** Q < Q 300 _J 200

y

f'

/ ' ' '

, ' / \ / /

/'

s/ /

200 'A

100

-fi
9

100

fi

I I I I I I

1 ' I

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

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

DISPLACEMENT (mm)
1.Man. A 2. Man. A Max. Load 448kN Max. Load 438kN 3. Man. 4. Man. Max. Load 424kN Max. Load 464kN
CURETIME:14DAYB HOLE 2 : 62mm GROUTA
FIGURE & M

DISPLACEMENT (mm)
I.Man. A 2. Man. A Max. Load 448kN Max. Load 456kN 3. Man. B 4. Man. B Max. Load 504kN Max. Load 498kN
CURE TIME :14 DAYS HOLE 8IZE : 52mm GROUTA
FIGURE &

DOUBLE EMBEDMENT TEST

DOUBLE EMBEDMENT TEST

MAN.A DOUBLE BIRDCAGE ANTINODE-NODE SHEAR CHARACTERISTICS

700

MAN.B DOUBLE BIRDCAGE ANTINODE - NODE SHEAR CHARACTERISTICS

700

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 3. NODE 4. NODE Max. Load 448kN Max. Load 456kN
CURETIME:14DAY3 HOLE 8IZE :62mm QROUTA
FIGURE &2

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

DISPLACEMENT (mm)
1. ANTINODE 2. ANTINODE Max. Load 424kN Max. Load 464kN 3. NODE 4. NODE Max. Load 504kN Max. Load 408kN
CURETIME:14DAY3 HOLE SIZE : 52mm GROUTA
FIGURE t St

DOUBLE EMBEDMENT TEST

MAN.A DOUBLE BIRDCAGE SHEAR CHARACTERISTICS 1 & 14 DAYS

700

DOUBLE EMBEDMENT TEST

MAN. A SINGLE S t DOUBLE BIRDCAGES ANTINODE - NODE SHEAR CHARACTERISTICS

700

600

600

500
HOAYQFOUT: KMPi IMP

500
/ / / /

400
WHOuROROUT:

400

3
o

300
200

, < ^ y '

40 MP. MOP.

< O 300
y'
200

/ y /' y
.\

/' y y'

/
100

S'

100

hV

10

15

20

25

30

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

L
2

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

DISPLACEMENT (mm)
SINGLE BIRDCAGE NODE Max. Load 238kN Cable Failure

SINGLE BIRDCAGE ANTINODE Max. Load 206kN Cable Failure

3. 14 DAY 4. 14 DAY Max. Load 448kN Max. Load 438kN

ANTINODE AT SPLIT HOLE 8IZE :62mm GROUTA
FIGURE &

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 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 GROUT GROUT 1 (1) GROUT 1 (2) GROUT 1 (3) GROUT 2 GROUT 6 GROUT 7 1 DAY UCS (MPa) 21.6 22.0 * 30 19.3 17.6 * 30 31.8 31.0 * 30 14.0 13.7 * 20 52.7 53.5 * 20 29.6 29.5 * 20 DENSITY (g/cc) 2.16 2.16 2.18 2.21 2.22 2.24 2.17 2.14 2.27 2.27 1.98 1.99 7 DAY UCS (MPa) 61.3 64.0 * 55 60.3 59.7 * 55 82.9 81.0 * 55 48.0 54.2 44.8 73.6 57.8 51.0 DENSITY (g/cc) 2.17 2.19 2.15 2.18 2.23 2.20 2.14 2.14 2.28 2.22 1.98 1.96 14 DAY UCS (MPa) 66.6 71.4 67.7 68.7 84.3 85.0 59.3 60.4 * 44 70.9 80.9 * 64 57.2 61.8 * 60 DENSTY (g/cc) 2.17 2.14 2.14 2.19 2.22 2.21 2.13 2.13 2.27 2.26 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. in more

The significance of grout modulus will be discussed detail in section 7.3.

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 TENSILE STRENGTH 10.66 10.10 9.18 12.08 10.17 10.13 7.15 9.24 10.46 7.73 7.53 11.20 (MPa) AVERAGE STRENGTH (MPa) 10.38

GROUT A GROUT

10.39

GROUT C

8.95

GROUT D

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

GROUT TYPE A C D E F G
**

UCS (MPa) 70 87 61 64 57 ** 63 78

MODULUS (GPa) 18 27 * 32
-

(kN/mm)
296.7 246.7 160.0
-

(kN/mm)
138.1 88.5 91.3 98.5 166.7 135.1 133.3

25 17 17

363.6 285.7 363.6

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.

120 100 a *

COMPARISON OF CABLBOLTING GROUTS GROUTS E, F & G.

120

* "*

80

. ' ^ *"

"

ol
. 60 / ' " *

U
en

CO

;.'

'lr"'x~"

"~

40

ivy 7

'

/ / " ^

20

'k ili
!

it

12

18

20

(Days)
GROUT A GROUT BRITISH COAL LOWER ACCEPTABLE LIMIT GROUT C

24

28

12

16

20

24

28

TIME (Days)
GROUT E GROUT F

GROUT D

GROUT G

BRITISH C 0 A L

LOWER ACCEPTABLE LIMIT

T.8.RE. 67mm DIAMETER CYLINDICAL SAMPLES

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

FIGURE

11

f icunE }

TABItB ? . . 2

CABLEBCLT aB0DT3 TABLE 7 .3

T.3.R.E. UNIAXIAL C0WPRES3IVK STRENGTH (MPa) 57mm DIAMETER BOTTLE SAMPLES

TIME (Days) GROUT A GROUT GROUT C GROUT D GROUT E GROUT

CABLBOLTING GROOTS
1 41.1 21.7 47.3 B6.9 41.1 39.7 3 5B.1 64.4 52.1 66.0 51. 51. 7 63.9 79.3 59.3 65.2 57.1 55.0 14 70.3 87.0 60.7 63.5 57 .1 62.9 28 82.5 95.4 67.1 71.1 64 .4 74 .9 GROUT A BAG SIZE (Kg) WATER (Lt) W.S.R. MANF. DENS. (g/cc) TSRE DENS, (g/cc) BAG PRICE (El 25Kg PRICE (E) YIELD 25 Kg (Lt) PRICE lOLt (E) 25.00 GROUT 13.75

WATER SOLIDS RATIOS. DENSITIES & YIELDS

GROUT C 14.00

GROUT D 25.00

GROUT E 25.00

GROUT F 16.40

7 .7S 0.31 2 .09

2.50 0. 18 2.30

2.50 0. 18

3 .90 0. 16 2.20

5.00 0. 20

5.00 0.30 2 .00

Average of 3 samples, S7mm diameter bottles, one sample subcored for Youngs Modulus. MANFACTUERERS UNIAXIAL COMPRESSIVE STRENGTHS (MPa) CUBE SAMPLES
TIMB

2.22

2 .13

2.07

2 .27

2 .19

2 .01

(Days)
GROUT A 100mm CUBES GROUT 50mm CUBBS GROUT C CUBBS GROUT D 100mm CUBES GROUT

9.58

5.24

1 40

3 50

7 60

4 .20

9.00

14

6.38

5.74

28 80

53

9.58

9.53

7 .50 approx. 13

9 .00 , approx. 12

6.38 approx. 14

0.75

40

60

75

80

15.6

12.7

16.3

20

55

42

57

6 . 10

7 .50

5.80

7 . 50

4 .50

5.30

40

65

70

Prices June 1994, excluding VAT. Grout A is now available 5.OOLts. TSRE Density = 14 day cure in 16Kg bags, added water

.
70 80

85 -

GROUT ? 50mm CUBBS

30

55

TABLE

7 J

TABLE

7.6

GROUTS A t SYSTEM PERFORMANCE WITH DOUBLE BIRDCAOEP CABLE INITIAL STIFFNESS 0 - 200kN (kN/mm) WORKING STIF F NESS : 200kN-400kN (kN/mm) GROUT A Cure Time (Days) 1 3 Max. Load (kN) 519 * 301 629 621 637 585 62 634 634 636 Inital Stiffness (kN/nm) 181.2 266.7 250.0 250.0 222.2 250.0 307.7 285.7 200.0 307.7 263.1 296.7 253.9 114 .3 125.0 142.9 133.3 129.0 125.0 AVERAGE INITAL Stiffnenn (kN/nm) 224.0 117.6 117.6 Working Stiffnees (kN/mra> 29.0 2 9.0 AVERAGE WORKING Stiffness (kN/nm)

GROUTS C ft SYSTEM PERFORMANCE HITH DOUBLE BIRDCAGED CABLE INITAL STIFFNESS : 0 -200kN (kN/mm) WORKING STIFFNESS : 200kN-400kN (kN/mm) GROUT C Cure Time (Days) 1 3
7

Max. Load (kN) 330 487 17 6 618 620 627 80 620 604 590

Inital Stiffness (kN/mm)

AVERAGE INITAL Stiffness (kN/mm) 114.3 173.9 _ 160.0 -

working Stiffness (kN/mm)

AVERAGE WORKINO Stiffness (kN/mm)

114.3 173 .9

1 1 i4
28
CO

49.4

49.4

119.7 14 138.1 28 127.0

160.0 -

98 .5

98.5 -

Grout F ailure Borehole Wall F ailure Node at Split GROUT Cure Time (Daye) 1 3 7 14 28 Max. Load (kN) 293 * 518 620 626 629 630 620 ** 363 598 623 Inital Stiffness (kN/mm) 166.7 111.1 250.0 222.2 307.6 142.9 160.0 333.3 AVERAGE INITAL Stiffness (kN/mm) 138.9 236.1 225.3 246.7 Working Stiffness (kN/mm) AVERAGE HORKING Stiffness (kN/mm) 44.0 98.1 Cure Time (Days) 1 44.0 99.0 97.1 163.9 64.5 88.5 88.5 3 7 14 28

Grout Failure Borehole wall failure GROOT D Max. Load (kN) U 607 F 629 U 608 F 625 U 619 F 625 U 607 F 619 U 610 Inital St i C f ness (kN/mm) U 363.6 F 266.7 U 333.3 F 210.5 U 235.3 F 333.3 U F 250.0 U 137.9 137.9 INITAL Stiffness U (kN/mm) 363.6 333.3 235.3

Working Stiffneos (kN/mm) U 122.0 F 118.3 U 122.0 F 127 .4 U 98.5 F 183 .5 U 91.3 F 181.8 U 77.5

WORKINO Stiffness U (kN/mm) 122.0 122.0 98.5 91.3 77.5

114.7 J

Grout failure Borehole wall failure

Grout D was supplied in two developmental formulations: U Universal & F Flowable Formulation U was subsequently approved for underground use.

450mm DOUBLE EMBEDMENT TEST

450mm DOUBLE EMBEDMENT TEST

COMPARISON OF CABLEBOLT GROUTS GROUTS A, B, C, & D.

COMPARISON OF CABLEBOLT GROUTS GROUTS E, F, & G.

700

IO

DISPLACEMENT (mm)
GROUT Max. Load 620kN

8 10 12 14 1 18 20 22 24 26 28 30
GROUT C Max. Load 624kN

DISPLACEMENT (mm)
GROUT F Max. Load 615kN

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

QROUTA Max. Load 628kN

GROUT E Max. Load 642kN

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 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
-.r."'

450mm DOUBLE EMBEDMENT

MNF.A DOUBLE BIRDCAGE + GROUTA SYSTEM PERFORMANCE WITH TIME

700

600

J I 2 4

J J I I l 8 10 12 14 16 18 20 22 24 26 28 30 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

DISPLACEMENT (mm)
BRITISH COAL LOWER ACCEPTABLE LIMIT 2. GROUT Max. Load 640kN Cable Failure
CABLE TYPE : Manufacturer A DOUBLE BIRDCA GE CURETIME:14 0A Y8 HOLE SIZE ; 62mm Fioune r

1. GROUT Max. Load 640kN Cable Failure

24 HOURS Mx. Loud 518kN Q(out Fallute

DISPLACEMENT (mm)
3 DAYS 7 DAYS Max. Load SBkN Cable Failure Max. Load e07kN Cable Failure

MDAY9 Max. Load fl26f<N Cable Failure HOLE SIZE : 52mm ANTINODE AT SPLIT

28 0AY9 Max. Load o34kN Cable Failure

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 INITAL STIFFNESS WORKING STIFFNESS 0 200kN (kN/mm) 200kN400kN (kN/mm)

24HOUR & 14 DAY GROUT CURE CHARACTERISTICS GROUT A & GROUT D 700 AVERAGE WORKING Stiffness (kN/mm) 37.4

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

J C ure
Time (Days)

Max. Load (kN) 392 * 409 547 555 554 550 553 548 555 553

Inital Stiffness (kN/mm)

AVERAGE INITAL Stiffness (kN/mm) 114.3 160.0 230.3 267.9 276.2

Working Stiffness (kN/mm)

600 -

yC*

jf
500 -

1 3 7 14 28

114.3 160.0 160.0 250.0 210.5 250.0 285.7 266.7 285.7

37.4 58.8 74 .1 85.1 69.2 75.2 88.5 90.5 81.6

il;

66.5 77.2

/// 400
//.'

81.9 86.1

* /

F a i l u r e of Grout

O 300 / / . / -I

li ii ;
-

BULBED CABLE + GROOT A Cure Time (Days) Max. Load (kN) * 449 388 Inital Stiffness (kN/mm) 222.2 133.3 250.0 250.0
7

200 AVERAGE INITAL Stiffness (KN/mm) 177.8 90.9 90.9 96.2 88.9 133.3 112.4 121.2 111.1 Working Stiffness (kN/mm) 29.2 29.2 AVERAGE WORKING I Stiffness (kN/mm)

li
I I

1 3

100 | /

551
531 531 530 526 530 529

160.0 166.6 235.3 255.7 250.0 285.7

92.6 122.9 116.2

I 4

163 .3 260.5 267.8

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

!s
14

DISPLACEMENT (mm)
QROUTA QROUTA GROUT D QROUTD 24 HOURS 14 DAYS 24 HOURS 14 DAYS
CABLE TYPE : Manufacturer A DOUBLE BIRDCAGE HOLE SIZE 52mm
FiOURE ?

F a i l u r e of grout

CABLBOLTING A SSESSMENT: GROUT COMPA RISON

450mm DOUBLE EMBEDMENT TEST

ORDINARY PORTLAND CEMENT WSR 0.31 & 0.37

120

ORDINARY PORTLA ND CEMENT WSR 0.31 & 0.37

700 600

500 -

400

O
rvj

300

200

100

10

20

10 12 14 16 18 20 22 24 26 28 30

TIME (Days)
BRITISH COAL LOWER LIMIT OPC WSR 0.31 57mm Bottl89 57mm Bottles OPC WSR 0.37 100mm Cubes OPC WSR 0.31 100mm Cubes

DISPLACEMENT (mm)
BRITISH COAL LOWER LIMIT Max. Load 602kN 1. OPC WSR 0.31 Max. Load 636kN Cable Failure

OPC WSR 0.37 57mm Bottles

Bone Data: 2x57mm 1x44mm Subcor Cub Data: 100mm Av. 2 Sample All Sampl Wet Curad

2. OPC WSR 0.37 Max. Load 614kN Cable Failure

CABLE TYPE : Mabufectur A DOUBLE BIRDCAGE CURE TIME: 14 0AY3 HOLE SIZE 52mm

FIOURE

FIOJRE re

QROUT STRENGTH : EFFECT OF 8AMPLE GEOMETRY

GROUT STRENGTH : EFFECT OF SAMPLE GEOMETRY

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

IU

57mm BOTTLES, & 44mm SUBCORED SAMPLES ORDINARY PORTLAND CEMENT WSR 0.31
120

100

100

80
,."' .."ittfoo. ' Qu

, . ' 'OOgrcc OTeOc ^ ^ ^ " ^_^""^^

^ ^ ^ " ^

D _
60

ISJ

<

_J
40

Q < O

1
1 1 10 20

20

10 20 TIME (Days)

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

57mm Bottle samples 44mm Suboore 29mm Subcore Av. 2 samples 1 sample A v. 3 samples
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

120

57mm BOTTLE SAMPLES & 50mm CUBE SAMPLES GROUT F

120

(0 CL

100

H 100 I
ltfce

80

Ztltfcc

h O UJ

or
\~

80
2(<xyoc

6 0 200tfoo

LU >
2 0 2 : _ _ZCXffoc _ /-

<

ZCne/oa

60
Z20(ycc

LU

cr
L

40

o
10 20
20

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

D
5 10 15 20

25

50mm CUBES Average of 2 Samples

A U 8AMPLES WET CURED

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

firxjBE M J

FlOuRE 1 15

UCS & DENSITY OF GROUT WITH ADDED WATER GROUT

13 s 100
ajotfcc

UCS & DENSITY OF GROUT WITH ADDED WATER GROUT D

I uu

<*. * .
*

rt Q_ .,' . .
% \
217f>oo

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80
2IPOOC

% * *^*^

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^V

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\^ >v I \

75

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>

60
2I7O/0C " ~ " " . . . ^ 2 21 ota:
s ,t;ycc N

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C O C O LU C C 40
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' " . *> 2MO/0C

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1 20 1 40 1 60
I.OVcc 1

<

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.,
.900

D
0
I I I I

80

100

20

40

60

80

100

ADDED WATER (%)

3 DAYS 7 DAYS 14 DAYS

ADDED WATER (%)

3 DAYS 7 DAYS 14 DAYS

Averag of 2 tempi 29mm 8UBCORED SAMPLES

Average of 3 eample9 57mm BOTTLE 8AMPLE3

FIGURE M A

FiouflE n s

FIELD & LABORATORY GROUT STRENGTH GROUTA

7 DAYS CURE 120 (0 Q2

FIELD & LABORATORY GROUT STRENGTH GROUTA

14 DAYS CURE
120

1.0

2.1

2.2

DENSITY g/cc
LABORATORY FIELD *

2.3

2.4

2.1

2.2

DENSITY g/cc
LABORATORY FIELD *

2.3

2.4

MANUFACTURERS DATA 100mm CUBES D

LAB DATA : 57mm Diameter Botti Samplee FIELD DATA : 67mm Botti S a m p l 6 V 20mm 8uboor SAMPLE DATES ; Jan-Dec 1993
FIGURE ?

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 1 1

MODULUS OF GROUT WITH VARIABLE WATER CONTENT QROUTA

20

UCS OF GROUT WITH VARIABLE WATER CONTENT GROUTA

100

18 -

(3

a . 16

co .

C O

D =J D O
co

14

NJ ^1

12

C U

1 0

10

15

20

ADDED WATER %
44mm Subcored Samples
CURETIME:14DAYS AVERAGE OF 3 SAMPLES
FIGURE 7.IS

10

15

20

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

DENSITY OF GROUT WITH VARIABLE WATER CONTENT

FIELD & LABORATORY GROUT STRENGTH

GROUTA
2.12

GROUTA
14 DAYS CURE

1. LABORATORY 5 10 15 20

2.1

2.2 FIELD

DENSITY g/cc

2.3

2.4

ADDED WATER %
57mm Bottle Samples 44mm Subcore
CURE TIME: 14 DAYB AVERAGE OF 3 SAMPLES
FIGURE 7 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
FICURE 7 21

ROUTINE LABORATORY GROUT TESTING GROUTA

14 DAYS CURE 120 CO LU CO LU > CO

GROUT QUALITY CONTROL EFFECT OF UNDERWEIGHT BAGS GROUTA 14 DAYS CURE

100 -

io

co LU oc
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
FIGURE 7 22

D
1.0 2 2.1 2.2

DENSITY (g/cc)

2.3

2.4

1004 LAB DATA 100mm CUBES

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 23

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 Prince of Wales Bentley Asfordby Welbeck Daw Mill Longannet Manufacturer 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 1 3 3

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 kN 53
M24 660 YIELD

VARIATION IN BENDING PERFORMANCE

GOOD METALLURGY HEAT TREATED

MANUFACT.

DIN24 660 YIELD

45 60

47 300 280 232

350 MAX 300

AVERAGE

Ul IO

250

AVERAGE

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O 2 LU

200

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150

100

50

AVERAGE

MIN

MAX

M24 660 YIELD

,,PrYHEAT u METALLURGY

TREATED

DIN24 660 YIELD MANUFACT H

BOLT TYPE

INSTALLING C O U P L E D BOLT INSERT RESIN TO TOP OF H O L E 1 RED 4- 1 GREEN INSERT FINAL RESIN SEPARATELY 1 GREEN CAPSULE

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 i 3.6m

PUSH

PUSH

STAGE 3 STAGE 4

SPIN STAGE 5

F i g u r e '3

140

FORGED/BENDABLE ROC KBOLTS MANUFACTURER A

Test No 1 2 3
4

Test Type Tensile only

Failure Load kN 152.0 162.0 150. 5 152 . 0 152. 0

Waist Norma 1
II

Remarks

j
I

tt

| |i Surface crack before test

5 90 bend/ straightened 6
7

tl

156.0 160. 4 7 0 bend/ stra ightened 90 bend/ straightened /4 0 bend/ straightened 160.2 160.0 161. 7 161.9

Radiused Normal
tt

8 9 10 11

It

11

NOTE: Normal waist Radiused Waist Radiused sides and flat surface Forms arc of a circle

TABLE 1

1 4 1

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. C abla bol tod sect lon. F i lo Station A. 20m MM. Roof C centr-o) S203RAX2

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146

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147

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STRATA SECTION

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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.

1 5 1

152

BARNSLEY SEAM (DEEP)

Mudstones & Sillslones

X XX
LH W

x x x x
XX

Slip plane within bolted height

X X

high vertical stress lower horizontal stress moderate rib displacement

slip plane within bolted height high bolt loads - yield some rool movement
RM/AA/7.

OK provided immediate roof can be controlled and vertical stress minimised

Figure 2

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

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

ROOrBOLIINC k MONITORING
10 S C 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
4 WOICS ro CUOWCt. Suiro! 0 ' ui( PW)JV$ "C A 0I.C OOltINC TOR ROf SUPPOT!' (rr eoc0<XIS'

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

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
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.

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

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

I +

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)

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' V"* f / ) ' l ' *1> *&*< * ( ( \ il O C H 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 B - B
NORUA). HOOINC SUPPONI (SlACt 1 BOvtINO)

SECTION A - A
I Jm 10 0>
3UCM

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

0
oex
I HA I :,<cv

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^"o7^{

IASI R O * or BOUS

^ ' 2t rF^cFE;
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tecun COMOHiONS

3|

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

iNOiCAc A RC R I O U I R C D

-
Cl o

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ta.

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J O ' I rA Cf CAOINO

LOOIION

PLAN

j
Figure 3

C D ~ th" 0?
t . ;.m Rooreous
0.6m I.Om cil. SCI errxCCN CKIIIMC SIRA PS

& Q G G S

^ : "?

* G
ORHiSH COA I. NORIHCUN CROUP

:..

C D G G B j j g ^ g gj B C D *fe C DC Dcfj^ C D
b /=i U i RO" Of BOUS 9 OU A l MtlCHl I t U t A U ( W im) SONIC CXItNSOuntR ().Jm) UAIN CA TC 1 illmr

RlCCALL MINE

JUNCTION PLAN
H54S MAIN CATE /
coie 1 /

cTrPOl Q

. HEADING

OOuBlC BiROCA CC OS IC BOU ( t m )

NORMAL HCA OINC SUPPORI (SUCt S B O U I N C )

fS

S'CNtO uANiccr: O'iC

~im THIS

PLAN TO BE READ IN CONJUNCTION WITH HEADING SUPPORI RULES

PLAN RCrCRCNCC ilo

SJ 1 0 7

i
I

ROOFBOLIING k MONITORINO
'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 C O O C O PRCICt i HOICS roR CUiOA C(. 'SUPPORI Of umi e0rs o< locuaous' U 'CA BI.C BOLlINC rOR RCOr SUPPORT'

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

I I -+-

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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 +

1 1 1 1 1 1 + + tu

1 1 1 +

1 1 1 1 1 1 1 1 1 + 4- + Q m Q

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

I ! i I +

BOLTING SPECIFICATION
C*Hn P 0 \ ' 10 'nlKUO ". * t\j>( .O OOWO *<\&H(k l.roiK/< 10 fl( 1 ir* SIOJB ( ( *1 < 0*U/(. vt*n<xir

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'.LAM

sec rACC MOO SIJPPO! u n i roR s e t ooi oc u n :

ra Q

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r . ower^, ue~ ( * > > < tc*i>>) ' . :iv. <oi \|i (ini gflUKM> '0 *M*KO IO H V**f *ICinc*IONS

SECTION A - A
?
NORuAl HCAOIN'", SuPPORI (SIACC J BOUiNCI
CNCJ or JUNCTION

SECTION B - B

l Jm f./-)") ' ! 1 0 SK>viMC O" / . r\ >_ lOO-m ( C ( M l C * ' 0 l ( K S . 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

UH*CCI*ei(

-A- -A-

oiRCCiiON o r ORIVACC

*
Figure 4

-A-

cnzrc U o" G M G" G G

1
UI UI

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

G G G G G G G
| |

G fa G

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

QQfi^ a cfa a

Y7?i

ci

a tb a G a a a a a a
G g G G*G G G,G cff.G G
SCC TACC HOC. SUPPORT RUICS

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.l3
, , Otfl-

G G G G
BRI1ISH COAL NOR'HERN GROUP

G G B B ^ B B

B
IO ROOrOOLlS li PIAICS O 0 6m ci> m SIRAP CxtCNSiOV WIIM 2 OOroOi.15 . 9 ROOreOUS * PLA1C5 O 0 6m cil ROOroOUS 4 PuMCS O 0 6m cl STARI 0 JUNCTION m nil. KY DUAL MCICHI TCll-l*lC (Sm/ Jm|

RICCALL MINE

Btb B

B B B G G
0 lw

F2F

B B

B'DfG B

ya-

JUNCTION PLA
H504S TAIL GATE /
SONiC CTCN!,OunCl ( ) Sm) >

FACE HEADING

Sede
SiCNCO

- 1/

PLAN

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

OOUOU OIRDCACC CAdiC (lOlt (6m) IJANACC

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

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
e e

125

100
Ln

2 LU LU U < -J

100

a. co

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 (metres) ABOVE ACTION LEVELS

BOLTED HEIGHT 'A'

g|

ABOVE BOLTED HEIGHT 'B'

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

ILI3o

||

t
l/l

WP

C)

vi

O u 2 O
X L U ' X
gh

\f

10

20

30

40

50

60

70

DISPLACEMENT (mm)
Station 1 4 MM Station 2 20 MM Station 3 70 MM Station 4 120 MM A Station 5 170 MM O

Figure

ROCK MECHANICS. TSRE : ROOF STRATA ASSESSMENT Colliery: Seam: Oistrict: Riccall Barns ley H430's Tail Gate Metre Mark: Date: Logged by: Cored by: Sept 1992 D J leigh Group

Log

Sample s No MPa

E GPa

/E

Bond Strgth

SILTSTONE

lant debris. Rare, sandy laminae top. Generally hard. ? ovaras

Grey, fine-grained. Micaceous. Scattered

73.8

18.3

4.03

7.09 to 9.18 82.8 18.8

4.40

2.4 2.1 1.8 1.5 1.2 ".90

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

5.5 to 9.18 8.76 to 9.18

67.7

19.2

3.52

IRONSTONE MUOSTONE Grey/dark grey. Abundant plants. Quite eat. MUOSTONE Dark grey, caroonaceous. Abundant plants, very weak and broken.

50.4

5.42 to 6.26

.60 .30

-1

Table

158

ROCK

MECHANICS,

TSHE

: ROOF

STRATA

ASSESSMENT

Metre

Mark:

RICCALL COLLIERY
BARNSLEY SEA M 473'S MA INGA TE (L\H) HEIGHT OF SOFTENING (M)

58

Colliery.

Ricca))

Date: Logged y: C.P.Eaton

Seam:

Barnsley

Cored 0y:

Oistrlct:

473's

T/G

Log

ample No

3 MPa

E GPa

Dond Strqth

X r JD

->

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

t?;
10 59. 1 52.4 1 . 12 4 4

Z
9 37.5 32.6 1 . 15

3 3 YnON^tONE 0NO 5ILI5II!WCUVIO5I0W[ Cooilinl In D i r t i SMIISINEHUOSIONE' '

?3 3
34.9

1 ) ""
4.6 .710 2.4

~ Z

Ln LO

6 VKONSTONE NO HuOSTOUE S'ootn '" / ' -*' 2 4

93.0' 43.6

0 31.5 1 .38

Z?~I 5

2.1

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

i.e

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

40.5

0 1 .5

Z
1

1.2 3 41.6 0 .90

20

40

60

80

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

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 *

3
torn I

37.9

17.6

2 . 15

.60

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

b
0

29. 1

.30

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

A
Seam Depth (m) 6 5 0 Oct'90Ocf91

Table 2

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' A A A > < > 15mm 15mm 15mm TELL TALE 'B' < 10mm Coupled bolts Coupled bolts Cable bolts

10mm < < 2 0mm > 20mm

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

LU O
> O

EFFECT OF ROADWAY WIDTH ON ROOF STABILITY CASTLEBRIDGE.

100 90 0
70 60 50 40 C) 3.5m 30 20 2.5m,
<7

<
2

LU
LL

7m HEIGHT OF SOFTENING > 7m

< I

8
cr

(a u.
2
<
E
Z LU

LU

Q.

u. O O oc
_J

Ii
10 0 ROADWAY WIOTH (m) -

(B

Figure 2

B05"$ M J G 30 > 4 .210

SF

3.9m Wide

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

25

20

iJ IS

12

IO

sa
72 % 133 2 148 fi 182 4
T E L L T A L F . A (2 lm)

^
S s

LTS
324 366 411

rrra pr?
4M) S06

201.6 2*2.4 266 4 Measure Mark 'm) y

(2 I Sm)

BOSs T/G 100

4.2m Wide

7 Bolts/strap + spot

bolts

80

60

Junction

40

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)

(2.1 Sm)

Figure 3

165

British Coal flock Mechanics No: 44838189611 at 09: 54 30/JUN/92 CASTLEBRIOGE Bl'S File: C SB15X2 M/G STATION ROOF EXTO. 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
en en

OISTANCE INTO STRATA (m) 8

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

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

4295 HH-5.mgg5S^

i^srfa

1 M

bi U ^ x
t i l l
I I I I

""*

100 90

BO

70 60 50 40 30 STRAIN (mm/m)

20

10

10

20

30

40

_ L

_ L

50

60

70

90 100

DISPLACEMENT [mm)

Figure 4

BO's Maingate Mid Roof Extenso meter Analysis

8
9

>

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

2000

Distance Along Maingate from C31's (m)

Tell-Tale Disp. Hi. of Softening

Figure 6

C r l l i e r j : Lc.f06ftuio&r Dare: ( / s / ^ /
Desrrip.ion

Seam uPP&jg. H I R S T Logged by: NToMSS

D i r t r i e t : B lS"k Cored bv: K

< ^

[tetrc Mark: 174"

JRCKSON

~3
o;
1 bl

Log

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

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

b'

I
//

I Stiffness Streng th rife

11'

02

.""~

/O

75

?3*
fi/l osjr>ftAj"r AJSTC J S

1
1

|
i i

! M Su+m-v SJry

_I

1
~=r

? .8
~

55 I 36-8

'
J

!
-

ft 2

I
U-U

U^-5

IM

3~~"

25

i
6

I
82

^^~ _"z.r_

S 1
3

19 333

91

WM, r////
'
' '

1 13

' 1 i.

/ / / / / /

/M

SU?***

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

2
/

58 ' 90

f I S "

I rco
!

level

7///

UPPER.

HIKST

^W

I 1 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 . 1

Table

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. A uniform pattern of bolts is the best design where stress is at a high angle to the drivage. Important to keep gate width to a minimum. 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

b) c) d)

e) f)

Local seam topography can have a significant effect on the stress field and support conditions. 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

m/g

34

t/g

Max. Horizontal Stress Direction

KTVETON PARK

STRESS MAP

Figure
174

KIVETON PARK

N36

LOADERGATE

ROOF FAILURE CHARACTERISTIC

5 -

2 LU

4 -

O
u.

3 -

o
L

2 -

I 1 -

ROOF DEFORMATION (MM)

Figure 3

mm
100 80 60

KIVETON N36's M/G TELL TALES

^1

en

START OF PRIMARY SUPPORT ON BOLTS

80 60
40 20

10/FEB/92

CABLE BOLTING ONGOING

JLgggiJflUvti*
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DISTANCE INTO STRATA (m)

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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 1 8 1

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

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1.8m sleel Rib Bofts

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186

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188

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OLLERTON COLLIERY, 19's LOADER GATE Suggested rib cable pattern

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5m double birdcaged steel cable bolts

5m double birdcaged GRP 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. The yellow colour was very distinctive different from either the red or green. and obviously

c) 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. 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. There were no failed bolts within the test length. 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. 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. 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. The cost per hole of the resin was not insignificant, 27 pence more compared to the twin capsule system.

e)

f) g)

h)

i)

j)

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. 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.

ii)

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. 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. 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.

v)

vi)

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. 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

x)

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

xvi) Application of the Strata and the implementation materials and equipment maintained of consumables

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 and Monitoring, ISRM

201

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

CODE of PRACTICE
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. 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. Cable bolts should be full column grouted using a grout which has gained acceptance through the SRME scheme. 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. 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. All cable bolts should be installed as near to vertical as is practicable, unless the design specifies otherwise. 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 .

3.2

3.3 3.4

3.5 3.6 3.7

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. 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. 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.

5.3

5.4

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

b.

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. 2. 3. 4. 5. 6. 7. 8.

Demonstrate the ability to read and comprehend the appropriate Codes of Practices concerned with Rockbolting and Cablebolting. Read and interpret the Manager's Support Rules and demonstrate a specific knowledge of the cable bolting requirements. Demonstrate awareness and understanding of the safeguards associated with Cablebolting Systems. Demonstrate ability in the application of pre-start checks, close down procedures and daily maintenance requirements. Demonstrate ability in the process of safe drilling. 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. 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. 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.

ii.

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. b. weighing of the sample, determination of density and hence water/solids ratio. 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. ANI Amali or Dywidag Systems

150 150 10 single tail bearing plate c/w barrel and wedge assembly. Supplier: ANI Amali or Dywidag Systems

3.

200 150 10 double tail bearing plate c/w barrel and wedge assembly. Supplier: ANI Amali or Dywidag Systems

4.

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

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DOUBLE BIRDCAGED CABLE SECTION
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FIGURE 2
214

DOUBLE BIRDCAGED CABLE SECTION

SEALING TUBE INJECTION TUBE

FIGURE 3
215

BREATHER TUBE

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. 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. 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. An example of the numbering system is given below:Acceptance Status POA Product Category 10 Serial Number 057

2.0

3.0

4.0

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

6.0

218

BRITISH COAL OPERATIONS DEPARTMENT

APPENDIX A

Notes of Guidance on the Acceptance Scheme for Strata Reinforcement Materials and Equipment 1. 1.1 Introduction 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. 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. The Acceptance Scheme does not apply to materials and equipment within the scope of British Coal Specifications. Special care shall be taken to ensure that operation of the Acceptance Scheme does not impede development of materials or equipment by the manufacturer. Procedure for Acceptance 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. 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. 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. 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. 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.

1.2

1.3

1.5

2. 2.1

b.

c.

d.

e.

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) ii) Cablebolting practice, control aspects. The behaviour of coal influence of stress. standards measures and strata and

quality and the and

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

The second stage of the package involves underground assessment at a cablebolting site, the focus of attention being: i) ii) Operators demonstrating good practical skills. 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 How cables work Application/Installation Design

Afternoon

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

Cure Time (Days) 1

U.C.S. (MPa) 42.4 48.4 32.4 58.2 55.4 * 60.6 60.1 65.3 * 66.2 70.6 64.5 * 75.8 84.1 84.7 * 78.7

Average U.C.S. 41.1

Density (gm\cc) 2.04 2.05 2.04 2.05 2.07 2.06 2.05 2.07 2.06 2.08 2.06 2.07 2.08 2.09 2.09

Average Density 2.04

58.1

2.06

63.9

2.06

14

70.3

2.07

28

82.5

2.09

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) 3 7 14 UCS (MPa) 51.4 40.1 67.7 66.7 72.8 63.6 AVERAGE UCS 45.8 67.2 68.2 DENSITY (g/cc) 2.07 2.06 2.06 2.08 2.07 2.08 AVERAGE DENSITY 2.07 2.07 2.08

225

GROUT UNIAXIAL COMPRESSIVE STRENGTH AND DENSITY 57mm DIAMETER BOTTLE SAMPLES

Cure Time (Days) 1

U.C.S. (MPa) 20.3 23.2 21.6 71.3 70.6 * 54.4 82.6 80.0 * 75.3 90.7 86.2 * 84.0 85.1 99.3 * 101.9

Average U.C.S. 21.7

Density (gm\cc) 2.22 2.23 2.22 2.25 2.27 2.26 2.28 2.26 2.27 2.28 2.26 2.28 2.25 2.26 2.28

Average Density 2.22

64.4

2.26

79.3

2.27

14

87.0

2.27

28 1_

95.4

2.26

Sample subcored to 30mm diameter for Youngs Modulus

YOUNGS MODULUS YOUNGS MODULUS CURE TIME (Days) 3 7 14 28 YOUNGS MODULUS (GPa) 23.0 27.1 27.2 28.1

226

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

Cure Time (Days) 1

U.C.S. (MPa) 46.9 47.7 47.2 54.5 50.8 50.8 56.4 63.1 58.3 61.4 62.4 58.4 65.7 64.6 * 71.0

Average U.C.S. 47.3

Density (gm\cc) 2.21 2.22 2.18 2.21 2.21 2.18 2.19 2.22 2.19 2.20 2.24 2.21 2.22 2.22 2.21

Average Density 2.20

52.0

2.20

59.3

2.20

14

60.7

2.22

28

67.1

2.22

Sample subcored to 3 0mm diameter for Youngs Modulus

YOUNGS MODULUS YOUNGS MODULUS CURE TIME (Days) 3 7 14 28 YOUNGS MODULUS (GPa)
_

31.9

227

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

Cure Time (Days) 1

U.C.S. (MPa) 56.7 54.7 59.1 67.3 62.4 68.4 66.3 64.1 65.5 61.5 69.9 72.4

Average U.C.S. 56.8

Density (gm\cc) 2.21 2.18 2.21 2.23 2.19 2.22 2.20 2.20 2.18 2.19 2.22 2.20

Average Density 2.20

66.0

2.21

65.2

2.21

14

63.5

2.19

28

71.1

2.21

YOUNGS MODULUS YOUNGS MODULUS CURE TIME (Days) 3 7 14 28 YOUNGS MODULUS (GPa)
-

228

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

Cure Time (Days) 1

U.C.S. (MPa) 46.8 38.3 38.2 55.0 49.6 51.1 55.3 58.8 57.1 53.9 60.9 * 56.6 64.7 61.7 66.7

Average U.C.S. 41.1

Density (gm\cc) 2.15 2.12 2.12 2.13 2.12 2.13 2.13 2.13 2.15 2.13 2.14 2.11 2.14 2.12 2.15

Average Density 2.13

51.9

2.13

57.1

2.14

14

57.1

2.13

28

64.4

2.14 1

Sample subcored to 3 0mm diameter for Youngs Modulus

YOUNGS MODULUS YOUNGS MODULUS CURE TIME (Days) 3 7 14 28 YOUNGS MODULUS (GPa) 24.9 -

229

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

Cure Time (Days) 1

U.C.S. (MPa) 44.1 33.5 41.4 50.3 56.6 48.4 57.8 57.4 49.6 63.5 64.7 60.6 71.7 * 79.8 * 73.2

Average U.C.S. 39.7

Density (gm\cc)
-

Average Density
-

51.8

2.00 2.01 2.04 2.01 1.99 2.00 1.98 2.03 2.03 2.05

2.02

55.0

2.00

14

62.9

2.01

28

74.9

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) 3 7 14 UCS (MPa) 61.5 62.7 59.0 63.2 73.2 73.8 AVERAGE UCS 62.1 61.1 73.5 DENSITY (g/cc) 2.02 2.03 2.04 2.03 2.01 2.00 AVERAGE DENSITY 2.02 2.04 2.01

230

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

Cure Time (Days)

1

U.C.S. (MPa) 66.6 59.4 61.8 67.3 68.1 * 73.1 80.3 77.6 * 78.9 62.1 85.3 * 86.0 84.0 * 95.1

Average
U.C.S. 62.6

Density (gm\cc)
2.02 2.03 2.03 2.04 2.04 2.02 2.04 2.04 2.03 2.04 2.04 2.04 2.04 2.05

Average Density
2.03

69.5

2.03

78.9

2.04

14

77.8

2.04

28
*

89.6

2.05

Samples subcored to 44.5mm diameter for Youngs Modulus Sample lost on preparation 15.5 15.5 16.8 17.9 GPa GPa GPa GPa 100mm CUBES

YOUNGS MODULUS 3 Days 7 Days 14 Days 28 Days

CURE TIME

(Days)
3 7 14

U.C.S. (MPa) 68.9 62.2 69.9 62.2 82.5 77.9

Average
U.C.S. 65.6 66.1 80.2

Density (g/cc)
2.03 2.03 2.04 2.04 2.05 2.01

Average Density
2.03 2.04 2.03

231

ORDINARY PORTLAND CEMENT

WSR 0.31

UNIAXIAL COMPRESSIVE STRENGTH AND DENSITY 57mm DIAMETER BOTTLE SAMPLES

Cure Time (Days) 1

U.C.S. (MPa) 35.9 33.7 42.4 58.7 54.8 * 62.6 63.3 67.1 * 73.6 82.3 73.4 * 81.3 82.9 87.8 * 87.6

Average U.C.S. 37.3

Density (gm\cc)
-

Average Density

58.7

2.13 2.13 2.12 2.12 2.14 2.13 2.15 2.14 2.14 2.15 2.14 2.15

2.13

68.0

2.13

14

79.0

2.14

28

86.1

2.15

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) 3 7 14 UCS (MPa) 58.4 49.5 47.4 49.0 80.0 79.7 Average UCS 54.0 48.2 79.9 Density (g/cc) 2.16 2.14 2.14 2.14 2.15 2.15 Average Density 2.15 2.14 2.15

232

ORDINARY PORTLAND CEMENT

WSR 0.37

UNIAXIAL COMPRESSIVE STRENGTH AND DENSITY 57mm DIAMETER BOTTLE SAMPLES

Cure Time (Days) 1

U.C.S. (MPa) 32.3 27.4 29.1 39.6 42.2 * 44.6 51.8 48.7 * 58.9 64.6 45.3 * 58.9 71.3 44.3 * 75.1

Average U.C.S. 29.6

Density (gm\cc) 2.02 2.01 2.O0 2.03 2.04 2.05 2.06 2.06 2 .06 2.09 2.08 2.09 2.06 2.06 2.06

Average Density 2.01

42.1

2.04

53.1

2.06

14

53.1

2.09

28

63.6

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) 3 7 14 UCS (MPa) 48.0 46.7 58.3 59.5 64.3 68.6 Average UCS 47.4 58.9 66.5 Density (g/cc) 2.07 2.07 2.06 2.07 2.10 2.09 Average Density 2.07 2.07 2.10

233

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

Cure Time (Days) 1

U.C.S. (MPa) 54.2 54.3 46.3 66.8 63.0 * 60.2 67.3 70.3 * 59.9 79.3 79.2 * 82.4 81.4 79.1 * 88.5

Average U.C.S. 51.6

Density (gm\cc) 2.08 2.07 2.07 2.08 2.09 2.11 2.09 2.10 2.10 2.11 2.08 2.12 2.09 2.11 2.11

Average Density 2.07

63.3

2.09

65.8

2.10

14

80.3

2.10

28
*

83.0

2.10

Samples subcored to 44.5mm diameter for Youngs Modulus Sample lost on preparation 17.2 18.1 19.4 21.4 GPa GPa GPa GPa 50mm CUBES

YOUNGS MODULUS 3 Days 7 Days 14 Days 28 Days

CURE TIME (Days) 3 7 14

U.C..S. (MPa) 61.3 60.6 68.2 72.5 80.8 83.1

Average U.C.S. 61.0 70.4 82.0

Density (g/cc) 2.10 2.09 2.12 2.11 2.13 2.13

Average Density 2.10 2.12 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 SECTION 2 SECTION 3

Introduction Technical Considerations Special Purpose Bolts Installed as Anchors for the Sole Purpose of Lifting or Suspension of Equipment Lifting Equipment/Suspension Brackets

239 240

241

SECTION 4 SECTION 5

243 244

- Typical Installation Procedures (Becorit, BRC etc)

238

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. 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. 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).

1.2

1.3

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. 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. It is important that Special Purpose Anchor Bolts should be installed in accordance with the bolt and resin manufacturers instructions (see Section 5 ) . 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. Improvisation using unsuitable lifting, suspension or pulling equipment/devices is not permitted, and must not be practised.

2.2

2.3

2.4

2.5

240

SECTION 3 SPECIAL PUTRPOSE ANCHOR BOLTS INSTAI I . F D 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 ) . 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. 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. This type of Anchor Bolt complete with shackle or bow nut shall be colour coded green. 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). 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). 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.

3.1.2

3.1.3

3.1.4 3.1.5

3.1.7

3.1.8

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. 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. 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. 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. 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 ) . 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.

3.2.2

3.2.3

3.2.4

3.2.6

3.2.7

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. Each lifting/suspension bracket shall be marked (preferably by stamping) with its maximum Safe Working Load in suitably sized letters/numbers. The ultimate strength of the lifting/suspension bracket shall not be less than five times its Safe Working Load. 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. 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".

4.2

4.3 4.4

4.5

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. 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". (3) (4) (5) (Red capsules).

(2)

Using drill and spinner tool adaptor, spin the fully assembled bolt into hole. (Approximately 4 sees) . Hold bolt spinning at final depth for 5 sees. 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

HUKFUbt tULI S

.:*:'' /' '

i.

:'

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

<

i.

a.

SUSPENSION

CHAiN^

FG

i a BECORIT

FIG Ib SECORJ MUL T f-SUSPENSIN AND PijRf

MOA/O.A/L.

I
',

ROLLED THREAD ANCHOR END

1
ALTERNATIVE BOW NUT TAPED PLAIN DIA FIG /HONORA/L SUSPENSION FIG 2.0 3

s r\j

0. I

BECORIT SPECIAL PURPOSE BOLT

A4-12037-U8

SHACKLE SPINNER

ALTERNATIVE

BOW NUT SPNNER

o o m r^

:*:. .
. * 'U

1 . . .

* t "

a 4 * .

A4-2037-U7
SPINNER TOOLS FIG 4.0

fr* V '

19 A/F

SHACKLE

SOW NUT PARAMETERS FIG 5.0

BOLT ASSEMBLIES
A4-7 2 0 3 7 - U 2 SHACKLE A4-12037-U3 BOW NUT M24 V\2A

LIFTING

kA-}2037-US AA-12037-U6

SHACKLE H27 BOU NUT M27

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. 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. Anchor bolt length is to be the same (nominally) as the strata bolts being used, i.e. 1.8m, 2.1m, 2.4m, etc. 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. 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). 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 5.2.7 (One Capsule) (Two Capsules)

5.2.2

5.2.3 5.2.4

5.2.5

5.2.6

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

5.2.8 5.2.9

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

Slow Set (Green) AT Resin

o o

. E E

Q.

Full Column Bonded Anchor Bolt

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

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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.

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