Atlas Copco Geotechnical Engineering Products

Roofex rock bolts

With Roofex, peace of mind

comes as standard
When rock moves, its comforting to know that
youve chosen the markets only predictable rock
bolt system.
Roofex is unique. It is a new and highly advanced
rock bolt designed to dissipate and control
high amounts of energy liberated from the rock
mass deformation process. Roofex provides a
predictability to the system behaviour and allows
you to accurately adjust the support needed to
keep the excavation from caving in.
3

Roofex rock bolts

Tunnelling or drilling mining shafts in deep unstable rock conditions has
always been a challenge for the geomechanical designers. With rock
movements being difficult to predict, controlling them can be a headache. Whatever the type of support system, the deformation must be
controlled and the tunnel or shaft kept from collapsing. Thats where
Atlas Copco comes in! With years of experience in rock reinforcement,
we have developed a new rock support system Roofex.
Safety in extreme conditions

Roofex is a unique rock bolt that can

absorb energy from rock mass movement. It is designed to dissipate large
amounts of energy liberated from the
rock mass deformation process. This
process can be a static phenomenon,
as in the case of large convergence in
yielding ground, or extremely sudden
and violent as in a rock burst event.
Roofex is designed to accommodate
the whole spectrum of rock mass
behaviour as well as being a solution
for extreme conditions potentially
occurring at depth.
Once convergence forces exceeds
80kN, this ingenious frictional system starts to extend along the rock
deformation, dissipating the energy of
the rock. The bolts sliding function
allows the rock to move a predefined
sliding length, up to 600 mm, before

stopping. Once sliding length has been

consumed, Roofex acts as a stiff rock
bolt, with an ultimate load capacity of
100 kN. By allowing a certain amount
of rock movement, Roofex releases the
energy of the rock mass in a controlled
manner.
An ingenious design

The Roofex rock bolt mechanism consists of a frictional steel to steel sliding
system built up by a high strength steel
bar, an energy absorber, a mixing /stop
element, two insulating steel sleeves,
a calibrated lock-nut and a steel face
plate.

absorbing element, creating friction

which absorbs the energy released
from rock movement. The energy
absorber is also designed to provide
enhanced mixing of the bonding agent.
The mixing /stop element facilitates
bolt installation by shredding and mixing the resin cartridges. This feature
also ensures that the inner steel bar,
sliding through the energy absorber,
stops at the end of the sliding length,
and allows for the reserve load capacity to cope with residual loads. The two
insulating steel sleeves act as decoupling agents and corrosion protection.
Easily adapted to your operation

The unique energy absorber is the

heart of the system that allows the
inner steel bar to move towards the
excavation at a stable and precise load.
Once the rock starts to move, the inner
steel bar is pulled through the energy

Roofex uses common rock bolting

equipment for installation. Once the
hole has been drilled and resin cartridges have been installed, the Roofex
bolt is inserted while rotating. This
action punctures the cartridges and

Sliding length,
pre-calculated
maximum
deformation

Sliding length,
pre-calculated
maximum
deformation

Roofex rock bolt

at installation

Rock mass
movement energy absorbing
phase

Roofex rock bolt

at max load and
max deformation

Energy absorber
(anchoring point)
Mixing/stop element travelling
inside steel sheathing

evenly distributes the resin around

the rock bolt. The energy absorber is
now fixed to the rock while the inner
steel bar is free to slide inside the steel
sleeves and the core of the energy
absorber. This also minimizes the
chances of the bar being pinned down
by a rock burst. Installed at an early
stage, Roofex still allows for extended
rock movement. This means the life
span of the support system is extended,
the total cost of operation are reduced
and the gallery can be opened for a
longer period of time.
Primary or secondary support system

Roofex is mainly used as a primary

bolting support. However, a situation
when Roofex can be used as a secondary suport, is where a tunnel has been
reinforced with rock bolts, such as
Swellex, with wire mesh and sealed
with shotcrete. Roofex can then be
installed as a secondary precaution.
It is not only ideal for new tunnelling
or mine shaft work, Roofex can also
be used in existing installations where

theres a risk of a collapse.

Predictable time and time again

Roofex is a powerful tool in the hands

of the geomechanical designers.
Thanks to rigorous testing in several
places around the world, as well as
in lab tests, we have shown that the
extension and final load characteristics
are consistent. The energy released
by the rock deformation process is
absorbed by the steel to steel interaction of the energy absorber and the
inner steel bar. Being preset at the
manufacturing stage, this means that
these bolts are insensitive to the external conditions.
With Roofex, the designers can predict
the bolts behaviour and use it in their
mathematical models. This optimises
the rock reinforcement design of deep
mines or tunnels and can also facilitate
higher levels of safety and productivity.

Combined mixing / stop

element

Steel sheathing

Energy absorber
(with inserted steel pins)

Resin or cement

Steel sheathing

Face plate
Nut (hemispherical, with
lock/nut effect)
High quality steel bar
(partly threaded)

Range of products

Roofex rock bolt

static or dynamic applications
Roofex rock bolts are universally applicable to a large variety of ground conditions and load applications.
The Roofex rock bolts are designed either for static or dynamic applications. The
energy absorber consists of a hollow steel cylinder with inserted metallic pins
deforming the inner steel bar sliding through it in a cold rolling process. For
static applications of the Roofex rock bolts, ordinary steel pins are inserted into
the energy absorber, whilst for the dynamic applications, because of heat generation during the rapid movement along the steel bar, hard metal pins made from
carbide have to be used. The system also includes face plates that are matched
to each application - either static, as in yielding ground or for violent dynamic
events.

Roofex rock bolts Rx8S and Rx8D

Yielding ground conditions are characterised by relatively weak or broken ground

with high stresses. With Roofex rock bolts designed for static applications, the
sliding process is initiated by the rock mass expansion and the bolt slowly stretches under the prevailing rock mass pressure along the pre-defined sliding length
until equilibrium is reached again.
Dynamic events such as rock bursts typically occur in massive hard rock with high
stress. The Roofex rock bolt designed for dynamic applications is able to dissipate
the sudden energy release and transfer it directly into movement along the predefined sliding path, without receiving major damages.

Roofex monitor bolts

The Roofex concept also offers two types of monitor bolts that directly monitor
rock mass movements and therefore provide predictability to the rock reinforcement system.
Once Roofex bolts are installed, the actual rock mass deformation at the roof and
sidewalls of the excavation can only be determined by monitoring with surveyors.
This will not always be an indication that the bolts work properly or that they are
well bonded to the rock mass. By using Roofex monitor bolts, the effective movement of the inner steel bar through the energy absorber can be clearly monitored.
In fact, using Roofex rock bolts together with Roofex monitor bolts is the reliable
way to verify that the bolts function correctly in a given rock mass environment.

Roofex monitor bolts Rx8M and Rx8M+

Roofex monitor bolt (Rx8M)

The rigid external version of the monitor bolt, with the green-yellow-red coded
bar is very simple in terms of monitoring. The colours on the bar will be consumed by the sliding process, and the magnitude of the rock mass deformation can
be easily observed.

Roofex monitor bolt

Rx8M at installation
Roofex Rx8M

Anchoring point

Rock mass
movement

Rock mass movement

close to bolt capacity

Deformation

Roofex monitor bolt with added features (Rx8M+)

As a consequence from customers feedback and additional enquiries from our customers
center we have also developed a monitoring bolt that has a flexible telltale for safety and
offers plate tensionability. The flexible telltale can also be replaced once it gets damaged or
lost.
This model of the monitor bolt has also a thread to mount the anchor plate directly on the
excavated rock mass. As an added value it is furthermore possible to perform a pulltest of
the monitor bolt. Once the predefined deformation is consumed, the monitor bolt will still
work as an ordinary rock bolt.

Roofex Rx8M+

Anchoring point

Deformation

Roofex monitor bolt

Rx8M+ at installation

Rock mass
movement

Rock mass movement

close to bolt capacity

Roofex testing program

In the course of the development of the Roofex rock bolts,
Atlas Copco has conducted an extensive laboratory and field
testing program, to commit to our high quality standards.
Static pull test

At the Atlas Copco in-house laboratory

in Feistritz, Austria, static pull testing
on fully assembled Roofex rock bolts
was performed. Various pre-set sliding
lengths from 150 to 600 mm pulling
length were used. The test successfully
confirmed a constant load capacity of
80 kN over the full sliding length of
the bolt.
In order to secure quality of Roofex
rock bolts, pull test are still performed
for quality control issues. A reasonable
ratio of bolts is tested before bolts are
available for delivery.

Dynamic drop test

At the CANMET-MMSL laboratories

in Ottawa, Canada, the dynamic capability of Roofex rock bolts were tested.
The tested bolts were installed in simulated bore holes, with variations of the
loading parameters, drop mass and the
fall height, to achieve variations of the
impact energy. The dynamic load was
simulated by dropping a mass over a
selected distance onto the bolts.
The tests showed that the peak load of
the bolts is easily predictable and show
little variations. The performance can
be used to predefine the bolts sliding
length adequately for a given dynamic
event.

Mixing test

At the Atlas Copco laboratory in

Feistritz, mixing tests were also performed in order to confirm proper
shredding of the resin cartridges,
subsequent mixing effect of the resin
or mortar and distribution of the resin
in front of the energy absorber to
provide bonding inside the drill hole.
The tests were performed by inserting
the Roofex rock bolts under rotation
into resin cartridge filled steel and
plexiglass tubes, and was followed by
pull out tests. The tests successfully
proofed even mixing and consistent
anchorage performance.

An extensive field testing program

with several test installations has been
conducted throughout the development
phase of Roofex.
Static field testing

After an agreement with the mine

management of Iberpotash, a test
installation was performed in Vilafruns
mine in Spain. Important convergences
had been noticed in the roadways of
this salt and potash mine, making it
very suitable for testing Roofex rock
bolts for static applications. Around
300 pieces of Roofex rock bolts and
Roofex monitor bolts were installed.
While performing these tests, Atlas
Copco also got the opportunity to be a
part of a study at the School of Mines
UPM in Madrid.

Dynamic field testing

Within Altas Copcos extensive field

testing program for Roofex rock bolts,
also real time dynamic testing, using
simulated rock bursts through blasting
have been conducted. The test procedure was carried out in an abandoned
drift at IAMGOLD Mine Doyon,
Rouyn-Noranda, Quebec in Canada.
The aim of this simulated testing was
proving the Roofex bolt capacity under
dynamic impact conditions.

Technical specifications

Quick reference
Model

Description

Rx8S

Roofex rock bolt / 80 kN sliding load / Static application

Rx8D

Roofex rock bolt / 80 kN sliding load / Dynamic application

Rx8M

Roofex monitor bolt / 80 kN sliding load / Static application*

Rx8M+

Roofex monitor bolt with added features/ 80 kN sliding load / Static application*

Rx8 Plate

Roofex plate suitable for 80 kN sliding load / Static and Dynamic applications

Rx8 Mesh washer

Roofex mesh washer

*Dynamic on demand

Combined
Mixing / stop
element

Technical data
Ultimate load of failure

100 kN

Sliding load

80 kN 10 %**

Static energy absorption

~800 J/cm sliding length

Dynamic energy absorption

~290 J/cm sliding length (for first event)

Steel
sheathing

General data
Energy absorber
(with inserted steel pins)

Steel bar

12.5 mm

Lock nut

28 mm (square)

Steel bar thread

left hand thread (right hand optional)

Energy absorber outer

30 - 34 mm

Recommended drill bit

33 - 36 mm

Anchoring method

resin /cement

Recommended resin cartridge

28 mm

Recommended Resin column support

500 mm

Overall length

1500-6000 mm (300 mm staggering)*****

Pre-set sliding length

150-600 mm (150 mm staggering)

***

****

** Sliding loads might be adjusted to customer needs

*** Other dimensions on demand
****Adjustments might be possible due to installation conditions
*****For Rx8M refer to Length index on page 11

Steel
sheathing

High quality steel bar

(partly threaded)
Face plate
Nut
(hemispherical, with
lock/nut effect)

10

Load performance
120

Load - Displacement Diagram

15 kJ Impact

80

100

60

80
Load (kN)

Load (kN)

100

40
20

60
40
20
0

400

300

200

100

100

200

300

400

Displacement (mm)

Displacement (mm)
Static load performance (example)

Dynamic performance for 15kJ impact (example)

Length index
Model

Overall length (mm)

Sliding length (mm)

Rx8S + Rx8D 2400/300

2400

300

Rx8M 2400/300

2700

300

Rx8M+ 2400/300

2700

300

Other model lengths accordingly

Roofex Rx8S and Rx8D

Sliding length

Overall length

Roofex Rx8M

Roofex Rx8M+
Sliding length

Overall length

Sliding length

Flexible/removeable
telltale

Overall length

11

Atlas Copco Geotechnical Drilling and Exploration

www.atlascopco.com

6991 1629 01a

Mrsta, Sweden, February 2011

Copyright 2011, Atlas Copco Craelius AB, Mrsta, Sweden. All rights reserved. Atlas Copco is committed to comply or exceed all applicable laws, rules and regulations.
Photos in this publication may show situations which complies with such laws, rules and regulations in the country where the photo has been taken but not necessarily
in other parts of the world. In any case think safety first and always use proper ear, eye, head and other protection to minimize risk of personal injury. This publication, as
well as specifications and equipment, is subject to change without notice.