atlas copco rock reinforcement products product … copco rock reinforcement products product...

Atlas Copco Rock Reinforcement Products

Product catalogue

MAI SDA self-drilling anchorsSwellex rock bolts

2

Product catalogue

Swellex rock bolts ...................................... 29

Swellex features ..........................................30

Applications ................................................31

Premium line ...............................................32

Manganese line ...........................................32

Bitumen coated ...........................................33

Plastic coated ...............................................33

Swellex Pm24C - a connectable bolt .........33

Swellex Pm24 H - a hanger ........................33

Swellex installation methods .................... 34

Installation alternatives ..............................34

Swellex product listing

Quick reference ......................................... 36

Swellex Premium line ............................... 37

Swellex Pm12 ............................................ 38

Swellex Pm16 ............................................ 39

Swellex Pm24 ............................................ 40

Swellex Pm24C ............................................41

Swellex Pm24H - a hanger .........................42

Swellex Manganese line .......................... 43

Swellex Mn12 ............................................ 44

Swellex Mn16 ............................................ 45

Swellex Mn24 ............................................ 46

Swellex face plates .....................................47

Hanging feature ...........................................47

Face plate specifications ........................... 48

Swellex installation pumps ......................... 49

How to choose the right pump ..................49

Swellex PSP 240/300 ...................................50

Swellex H1/HC1 ...........................................51

Swellex E1 ....................................................52

Quality assurance ......................................... 53

Letter of compliance ...................................53

Quality control stamps ...............................53

Quality pressure assurance gauge ............53

Pull tester .....................................................54

Steel sleeves ................................................54

Swellex accessories ..................................... 55

Mesh washer ...............................................55

Colour plugs ................................................55

Atlas Copco Rock Reinforcement ................ 3

Quality assurance means safety ................... 4

MAI SDA self-drilling anchors versus Swellex bolts .................................................. 6

MAI SDA self-drilling anchors ....................... 7

Applications ...................................................8

Sacrificial drill bits .........................................9

The selection of drill bits ..............................9

Bit specifications ...........................................9

Hollow anchor rods .....................................12

Extension couplings ....................................12

Bearing plates ..............................................13

Hexagonal nuts ...........................................13

Galvanized anchors .....................................13

MAI SDA installation methods .................... 14

Installation alternatives ..............................14

MAI SDA product listing .............................. 16

Quick reference ...........................................16

MAI SDA R32 ...............................................17

MAI SDA R38 ...............................................20

MAI SDA R51 ...............................................22

MAI SDA T76 ...............................................24

MAI SDA accessories ................................... 26

Centralizer ....................................................26

Coupling boxes ...........................................26

Shanks ..........................................................26

Grout coupling ...........................................27

MAI SDA mortar .........................................27

MAI SDA grout pump ................................... 26

3

Atlas Copco Rock ReinforcementOngoing development of faster, safer and more exotic tunnelling techniques places a constant pressure on manufacturers to provide more effi cient rock support solutions which will help the shortening of cycle time. As ground conditions get more and more demanding, emphasis is placed on fl exible and intelligent support systems in which rock and soil reinforcement is expected to contribute to the productivity and safety of the operation. The trend has been to provide rock support and reinforcement systems that are easy to install, assure effi ciency and provide safety.

For the last 25 years, Atlas Copco has been offering the SwellexTM concept as a unique, safe and reliable system of rock support. As the market leader in underground rock excavation technology, Atlas Copco has also been developing safer and more effi cient rock reinforcement products such as the Manganese line rock bolts, which are manufactured from a special type of steel. Another development is the Swellex Premium line of rock bolts, for use where high yield load and stiffness are expected from the reinforce-ment system.

When Atlas Copco bought MAI in 2001, the rock reinforcement center moved to Feistritz/Drau, Austria. This acquisition made it possible to introduce a whole new range of products for Atlas Copco customers, the MAI SDATM anchors, which are now being developed for mechanized installation by both surface and underground drill rigs, creating fresh applications in rock and soil reinforcement.

Atlas Copco’s Rock Reinforcement Center in Austria brings together the skills necessary for the develop-ment of superior rock reinforcement products to serve the tunnelling, mining and construction industries worldwide. The combined product portfolio includes Swellex rock bolts and MAI SDA anchors with all necessary accessories.

The strategy to act as “The professional supplier of specifi c and complete solutions in rock and soil re-inforcement” has paid off, and the effort to invent and commit ourselves to more productive solutions is stronger than ever.

The Rock Reinforcement center in Feistritz/Drau, Austria

The Atlas Copco Swellex plant in Canada

4

Quality assurance means safety

Quality assurance – for safer reinforcementSafety in a mine is not something Atlas Copco, takes lightly. It’s a major issue for those who own and those who work there. A minor fault in a rein-forcement bolt may prove fatal. That’s why Atlas Copco rock bolts are rigorously tested to en-sure the best possible quality and reliability. In fact our Quality assurance system is the most compre-hensive on the rock reinforcement market today.

ISO - Management systems that work harderISO standards represent the best management systems for quality and environmental issues. It’s therefore not surprising that Atlas Copco is ISO 9001 certified to systematically control overall quality. The company is also ISO 14001 certi-fied to minimise the environmental impact of the company. These are applied at every Atlas Copco manufacturing plant as well as every distribution and customer centre. They basically form the basis of the company’s Quality Assurance program.

Quality control starts at the suppliers...ISO certification is the prerequisite for every Atlas Copco supplier. Whether it’s rods for MAI self drilling anchors or steel profiles for Swellex, suppliers have to follow our specified tolerances. To ensure their quality, we test every batch for deviations and register the results.

...and ends at the clientsTo confirm that finished bolts can withstand the working pressures stipulated, we carry out destruc-tive tests on samples of Swellex bolts and MAI self-drilling anchors. And if this is not enough, eve-ry bolt is stamped with its own number. So should a problem arise, the cause can be efficiently traced back and action can be taken promptly to rectify it.

In accordance with ISO9001, Atlas Copco has developed comprehensive instruction and training material to enable end-users to install bolts and anchors correctly and safely.

5

Quality assurance means safety

MAI SDA self-drilling anchorsThere are two important quality parameters for a MAI self-drilling anchor. Firstly, that anchors can withstand the stipulated working pressure and, secondly, that couplings and bits can be easily threaded.

Ultimate load tests are carried out on 1 in 200 of the manufactured anchors. A special test bench pulls these anchors until they break and the results are monitored. Should an anchor fall short of the given tolerances, production is stopped and the fault is rectified.

Atlas Copco MAI also offers a hot dip galvanized MAI self-drilling anchor. This galvanised layer has to be the right thickness for the couplings and bits to be threaded on properly.

Again, a sample of anchors is removed from the production line during each shift and the thickness of the galvanisation is tested and registered.

Swellex rock boltsThis expandable rock bolt is more complex to manufacture than a MAI SDA. The steel profile is pressed into shape and a bushing is welded on the open end-piece. As pressurised water is used to install a Swellex bolt in the hole, leakages are not wanted. That’s why each and every bolt is tested for leakage as part of the production process. This unique operation is augmented by destructive expansion tests where 1 bolt in 200 is pressurised to the limit to ensure that the batch can withstand a minimum a working pressure of 300 bar.

In effect, one sample bolt is removed at the begin-ning of each shift and one when a new batch of steel profiles is used. This means that 1% of all bolts are sacrificed in the name of quality assur-ance.

We, at Atlas Copco, believe that assuring quality throughout the complete supply and distribution chains is the best way of ensuring the highest level of safety for our customers.

6

The Atlas Copco MAI SDA is a unique bolting solution for unstable ground conditions such as sand, gravel, silt, and clays, and in soft to medium fractured rock formations.

For projects facing such ground conditions, MAI SDA self-drilling anchors should be considered as the main productivity solution.

Atlas Copco Swellex rock bolts, which are quickly and safely installed in rock not tending to collapse, gives immediate support, speeding up operations and boosting revenues. Over the past two decades, the Swellex rock bolting solution has become world famous as the simplest, fastest and most reliable rock reinforcement technology avail-able.

MAI SDA anchors versus Swellex bolts

MAI SDA installation The MAI SDA solution is designed for optimized installation, tailored to the project’s needs. By drilling a hole in collapsing soil or loose rock, with a sacrifi cial drill bit and a hollow rod, and after the drilling operation injecting grout into the hollow rod and surrounding cavity, makes it a top produc-tivity solution.

Swellex installationThe Swellex bolt is a folded steel tube, which is inserted into a pre-drilled hole in the rock. Water is blasted into the tube at high pressure, blowing out the fold and expanding the tube into the exact shape of the hole, adapting to every irregularity.

Bolt installation takes less than 30 seconds, and provides full and immediate support along the entire hole length, in ground conditions ranging from the hardest rock to clay even non-cohesive material.

MAI SDA manual installation

Swellex manual installation

7

MAI SDA self-drilling anchors

A MAI SDA self-drilling anchor consists of:

a hexagonal nut �a bearing plate �extension couplings, if the anchor consists of �

several anchor rod sectionshollow anchor rod(s) �a sacrificical drill bit �

Nut

Rod

Coupling

Rod

Bit

Plate

8

Applications


Variation of water

level

Slop

e stab

ilization

Tunneling

Retaining wall structuresMicropiling / Underpinning

Micr

g to prevent buoyanc

yRetaining wall structures

Embankement stabilizationEmbankement stabilization

Micropiling / Underpinning

Micr

g to prevent buoyanc

y

SpilingSpiling

g ttoooo

Root pilingRoot pilingRadial systematic anchoringRadial systematic anchoring

Face stabilizationFace stabilization

Stabilization of tunnel portals

Stabilization of tunnel portals

Fore-polingFore-poling

on

Soil nailingSoil nailing

Foundations for avalanche prote

ctio

nFoundations for avalanche prote

ctio

n

Micropiling for tentioned founda

tions

Micropiling for tentioned founda

tions

Foundation with micropilesThe application circle below displays the three most important areas and industries where the MAI SDA is best utilized

Slope stabilizationIs used to stabilise mostly unstable rock/soil for-mations which are normally benched prior to the installation of the "soil nails". The unconsolidated or weathered ground conditions favour the tech-nique of Self Drilling Hollow Core Anchors (SDA) for the fast and simple method of installation com-pared to the traditional methods of cased boreholes and inserting of a suitable tendon.

Foundations with micropilesMAI SDA micro piles can be defi ned as small diameter replacements, drilled piles, composed of injected grout with the MAI SDA anchor rod as

steel reinforcement to resist the design load.

The MAI SDA micro piles can be installed in sites with limited headroom, restricted access capability with light drilling equipment which have low noise and vibration and require minimal site preparation. MAI SDA can be installed successfully into most ground conditions including rock and is suitable for tension and compression loads. The big advan-tage is the combined drilling and grouting making high piling outputs possible.

TunnellingMAI SDA anchors are the most economical solution for the reinforcement of the tunnel cir-cumference and advance roof support for tunnel excavation in overburden and soft factured rock conditions.

9


The selection of drill bitsA successful installation of the self-drilling anchor system (SDA) depends on the selection of the most suitable drill bit. Compared to conventional drill bit types offered globally for maximum stand-ing performance for rock or soil, the criteria for SDA drill bits are defined by consideration of the following factors:

High quality for a limited service life �Installed MAI SDA length �Geology �Geometry �

High quality for a limited service lifeSince the nature of the drill bit is sacrificial, the maximum stand up time is that required to install one anchor.

MAI SDA installed lengthDepending on the SDA applications, standard drilling depths would be in the range of:

Tunneling (SDA): 4-10 m �Soil and Rock Nailing (SRN): 8-20 m (30 m) �Micro Injection Piling (MIP): 10-20 m �Temporary Support Anchors (TSA): 15-30 m �

GeologyThe unique MAI Anchor system was developed over the years for the sole purpose of the drill bit to penetrate fractured and weathered rock and unconsolidated soil formations. Constantly vary-ing conditions, from clay to gravel and boulders, as well as sand and rock, require a multi-functional bit design that provides:

Optimum cutting ability in mixed ground � conditions

Adaptable flushing and grouting performance �Maximum penetration speed �

GeometryProject design for external skin friction demands a selection of various drill bit diameters. In order to maintain the functionality of the system, the fol-lowing range of diameters should be selected for the different anchor dimensions.

The sacrificial drill bit is the most crucial part of the anchoring system, and is responsible for the productivity of the installation. Atlas Copco MAI maintains a large range of drill bits to suit the changing demands of geology encountered on different projects. In order to improve on perform-ance and cost efficiency, data is collected from projects around the world, and incorporated into the design with the aim to improve penetration rate and bit quality, and to reduce manufacturing costs.

Sacrificial drill bits

Type Drill bit Ø

MAI SDA R32 51 mm, 71 mm



MAI SDA T76 130 mm, 150 mm, 175 mm

10

MAI SDA self-drilling anchorsX type

Description A forged cross-cut drill bit.

Optimum penetration

Achievable for SPT-N values of 0 - 25 N/mm2

Diameters R32 Ø 51 mm

Suitable conditions

Suitable for soft soil types such as sand and small gravel

XX type

Description A two stage cross cut bit.

Optimum penetration


Diameters

R38 Ø 110 mm

R51 Ø 110 mm

T76 Ø 130 & 75 mm

Suitable conditions

Suitable for soft soil types such as sand and small gravel.

EX type

Description A machined or cast hardened cross dill bit.

Optimum penetration


Diameters

R32 Ø 51 & 76 mm

R38 Ø 76 & 90 mm

T76 Ø 130 mm

Suitable conditions

Suitable for a majority of applications including narrow bands of soft rock.

EXX type

Description The tungsten carbide cross bit.

Optimum penetration

Achievable for UCT values of 12 - 50 N/mm2 in the range of 10 - 50%


Suitable conditions

Suitable for gravel with large boulders, soft to medium fractured rock formations, hard seams and concrete footings without seel reinforcement.

EC type

Description

Hardened tri-cresent drill bit with a unique curved shape of the blade, which results in small-sized cuttings and improves the flushing capability of the borehole.

Optimum penetration



Suitable conditions

Suitable for a majority of applications including narrow bands of soft rock.

ECC type

Description

Tungsten Carbids Tri-cresent drill bit with a unique curved shape of the blade, which results in small-sized cuttings and improves the flushing capability of the boreholes.

Optimum penetration

Achievable for UCT values of 12 - 50 N/mm2 in the range of 10 - 50%


Suitable conditions

Suitable for gravel with large boulders, soft to medium fractured rock formations, hard seams and concrete footings without seel reinforcement.

EY type

DescriptionHardened tri-blade drill bit with a drop center button face.

Optimum penetration


DiametersR32 Ø 76 mm

R38 Ø 76 mm

Suitable conditions

Offers an increased cutting performance in fills and chalk.

EYY type

DescriptionHardened tri-blade drill bit with tungsten carbide blades and a drop center configuration with hardened button face.

Optimum penetration

Achievable for UCS values of 0 - 25 N/mm2

DiametersR32 Ø 76 mm

R38 Ø 76 & 90 mm

Suitable conditions

Suitable for soft to medium cemented ground conditions incl. fills and chalk.

11


SPT-N= Standart Penetration Test,

UCT=Unconfined Compressive Strength,

RQD=Rock Quality Designation Index

ESS type

Description

Tungsten carbide hemispherical button profile drill bit. Suitable for penetrating a larger range of soils and bolders, and also soft to medium rock formations as found commonly along slopes in mountainous regions.

Optimum penetration

Achievable for SPT-N values and UCS values of 0 - 50 N/mm2

ESS-F bit ESS-D bit

Configuration Flat face Configuration Drop center

Diameters

R32 Ø 51 mm

DiametersR38 Ø 115 mmR38 Ø 76 mm

R51 Ø 100 mm

T76 Ø 120 mm R51 Ø 115 mm

Suitable conditions

Silts, sand and gravel: Compact or cemented soils or soft rock.

Suitable conditions

Silts, sand and gravel: With small boulders.

ES type

DescriptionCast and hardened hemispherical button profile drill bit. Suitable for silt, sand and gravel, but also for soft rock formations.

Optimum penetration

Achievable for SPT-N values and UCS values of 0 - 60 N/mm2

ES-F bit ES-D bit

Configuration Flat face Configuration Drop center

Diameters

R32 Ø 51 mm

Diameters R51 Ø 115 mmR38 Ø 76 mm

R51 Ø 100 mm

Suitable conditions

Silts, sand and gravel: Compact or cemented soils or soft rock.

Suitable conditions

Silts, sand and gravel: With small boulders or soft rock.

Driving head

Description

This driving head was developed for soft clay applications. NB! Consider a method of simultaneous driving and grouting for optimum grouting results.

Optimum penetration

Achievable for SPT-N values of 0 - 20 N7mm²


Suitable conditions

Suitable for soft clay applications with anchor lengths up to 8 meters.

12


Hollow anchor rodsThe anchor rod features a hollow bore for fl ush-ing, or simultaneous drilling and grouting, and has a left-hand rope thread for connection to standard drill tooling.

It is manufactured from API standard heavy wall-ing steel tubing, cold rolled to form a standard ISO rope thread profi le. The rolling process refi nes the grain structure of the steel, increasing the yield strength, and producing a durable drill rod suit-able for a range of applications. The standard rope thread of the anchor rod produces an excellent bond between the rod and grout, as well as ena-bling connection to all Atlas Copco Boomer face drilling rigs and Atlas Copco Roc surface drill rigs, and use with a wide range of drill steel accessories.

The anchor rod is produced in 12 m lengths and then cut to size depending on customer require-ments. Standard delivery lengths are 1 m, 2 m, 3 m, 4 m and 6 m. Recommended maximum rod lengths depend on diameter and can be up to 6 m. Additional lengths up to 12 m are available on request.

Extension couplingsThe coupling features a patented design that enables direct end-to-end energy transmission between each bar, reducing losses and ensuring maximum percussive energy at the drill bit.

To enable the correct seating of each bar within the coupler, all bars are chamfered with precision to enable the bar ends to have contact.

Hollow anchor rodsRendered photo on its way

An extension coupling

Rendered photo on its way

13


Bearing platesThe bearing plates are formed steel plates with a centre hole, allowing articulation of seven degrees in all directions.

All functional parts are constantly tested, in line with the Atlas Copco rigorous quality assurance policy.

Hexagonal nutsThe hexagonal nut is manufactured with cham-fered edges on both ends from high precision steel, and tempered to meet any stringent demands of the anchor specifi cations and the daily operations of underground works.

All nuts exceed the ultimate strength of the bar by 20%.

Galvanized anchorsCorrosion is a very complex process, and corro-sion rates are very hard to predict accurately. How-ever, predictive methods can be helpful to evaluate the need for corrosion protected rock bolts. For this reason Atlas Copco has developed a hot dip galvanizing corrosion protection. The full range of SDA bars with couplings and nuts are available with this corrosion protection.

Bearing plates

A hexagonal nut

Galvanized anchors

14

Manual installation

Improved quality of groutingBetter fi lling of borehole annulus due to in-situ �

mixing processConsistent load transfer over the whole bolt �

length between soil/rock and boltImprovement of corrosion protection providing �

longer service life

The option to introduce high speed stabilization with SDA versus cased borehole drilling solutions

No separate drilling equipment needed, � same crew

No subcontractors and no investments in capital � equipment

Providing technology to introduce high speed cur-ing grout formulas

Back pressures during grouting can be absorbed � by drill feed and boomer, thus enabling higher grout pressures, thus allowing lower W/C factors reducing the curing time, providing earlier load bearing of SDA resulting in a reduced excava tion cycle time.

MAI SDA installation methods

Semi-mechanized installationThe anchoring or bolting industry has a demand for increasing the effi ciency and quality of the installation of bolts. In addition increased safety by minimizing work in unprotected areas are becom-ing more important to contractors when installing bolts in diffi cult rock/soil conditions.

A change from the conventional post grouting method to a semi-mechanized installation method using an IRIA (Integrated Rotary Injection Adapt-er) method provides an adaptable installation proc-ess, which offers an improved solution and as such added value to the Customer:

SDA installation becomes one work cycle per-formed only by the drill feed

No additional work cycle for post grouting �Reduced operation cost for additional equipment �

(working platforms etc.)Better adjustment of the installation process in �

respect with the changing geologyFlexible selection and adjustment of fl ush media �

as needed (water, air or grout)

1. Drilling with water fl ushing.

2. Adding a coupling to extend the anchor with another rod.

3. Connecting to grout pump and inject the mixed grout.

4. Once grout has hardened, the anchor is perfectly installed.

15

MAI SDA installation methods

Semi-mechanized installation of anchors with a Boomer drill rig and IRIA

Manual installation of anchors with a Boomer drill rig

16

Anchor rodsDescription R32 L R32 N R32 S R38 N R51 L R51 N T76 N T76 S Unit

Outer diameter 32.0 32.0 32.0 38.0 51.0 51.0 76.0 76.0 mm

Average internal diameter 21.5 18.5 15.0 19.0 36.0 33.0 51.0 45.0 mm

Cross-sectional area 304 396 488 717 776 939 1835 2400 mm2

Ultimate tensile load (UL) 210 280 360 500 550 800 1600 1900 kN

Yield load (YL) 160 230 280 400 450 630 1200 1500 kN

Weight 2.9 3.4 4.1 6.0 7.0 8.4 15.0 19.7 kg

Description R32 L R32 N R32 S R38 N R51 L R51 N T76 N T76 S Unit

Diameter 42.0 42.0 42.0 51.0 63.0 63.0 95.0 95.0 mm

Length 145.0 145.0 190.0 220.0 140.0 190.0 200.0 200.0 mm

Weight 0.8 0.8 1.0 1.7 1.2 1.9 6.4 6.4 kg

Extension couplings


Key size 46.0 46.0 46.0 50.0 75.0 75.0 100.0 100.0 mm

Length 45.0 45.0 45.0 50.0 70.0 70.0 80.0 80.0 mm

Weight 0.4 0.4 0.4 0.4 1.6 1.6 3.6 3.6 kg

Nuts


Dimension 150x150 200x200 200x200 200x200 200x200 250x250 250x250 250x250 mm

Thickness 8.0 10.0 12.0 12.0 30.0 40.0 40.0 60.0 mm

Hole diameter 35.0 35.0 35.0 41.0 60.0 60.0 80.0 80.0 mm

Weight 1.4 3.1 3.7 3.6 8.8 18.5 18.0 26.9 kg

Anchor plates

Type of bit R32 L R32 N R32 S R38 N R51 L R51 N T76 N T76 S

X R32/51 R32/51 R32/51 - - - - -

XX - - - R38/110 R51/110 R51/110 T76/175 T76/175

EXR32/51

R32/76

R32/51

R32/76

R32/51

R32/76

R38/76

R38/90- - T76/130 T76/130

EY R32/76 R32/76 R32/76 R38/76 - - - -

EXX R32/51 R32/51 R32/51 - - - - -

EYYR32/76 R32/76 R32/76 R38/76

R38/90- - - -

EC R32/51 R32/51 R32/51 - - - - -

ECC R32/51 R32/51 R32/51 - - - - -

ES–F R32/51 R32/51 R32/51 R38/76 R51/100 R51/100 - -

ES–D - - - - R51/115 R51/115 - -

ESS–F R32/51 R32/51 R32/51 R38/76 R51/100 R51/100 T76/120 T76/120

ESS–D R38/115 R51/115 R51/115 - -

Driving head R32/65 R32/65 R32/65 - - - - -

Anchor drill bits


Quick reference

17


MAI SDA R32 anchor rodsSize Length

(m)Weight

(kg)Outer Ø

(mm)Inner Ø 1

(mm)Area 2 (mm2)

UL 3 (kN)

YL 4 (kN)

Product number

R32 L 2.0 5.4 32.0 21.5 304 210 160 9899 7000 50

R32 L 3.0 8.1 32.0 21.5 304 210 160 9899 7000 49

R32 L 4.0 10.8 32.0 21.5 304 210 160 9899 7000 51

R32 N 2.0 6.8 32.0 18.5 396 280 230 9899 1007 54

R32 N 3.0 10.2 32.0 18.5 396 280 230 9899 1007 55

R32 N 4.0 13.6 32.0 18.5 396 280 230 9899 1007 56

R32 S 2.0 8.2 32.0 15.0 488 360 280 9899 1007 58

R32 S 3.0 12.3 32.0 15.0 488 360 280 9899 1007 59

R32 S 4.0 16.4 32.0 15.0 488 360 280 9899 1007 60

Corrosion protected (Galvanized in accordance with EN ISO 1461:1999)

R32 L 2.0 5.4 32.0 21.5 304 210 160 9899 1013 77

R32 L 3.0 8.1 32.0 21.5 304 210 160 9899 7013 79

R32 L 4.0 10.8 32.0 21.5 304 210 160 9899 7013 81

R32 N 2.0 6.7 32.0 18.5 396 280 230 9899 1011 60

R32 N 3.0 10.0 32.0 18.5 396 280 230 9899 1018 52

R32 N 4.0 13.4 32.0 18.5 396 280 230 9899 1021 88

R32 S 2.0 8.2 32.0 15.0 488 360 280 9899 1013 67

R32 S 3.0 12.3 32.0 15.0 488 360 280 9899 1013 66

R32 S 4.0 16.4 32.0 15.0 488 360 280 9899 1024 43

1 Average internal diameter / 2 Cross sectional area / 3 Ultimate load / 4 Yield load

MAI SDA R32 extension couplingsSize Type Length

(mm)Weight

(kg)Outer Ø

(mm)Product number

R32 L&N 145.0 0.8 42.0 9899 7000 83

R32 S 190.0 1.0 42.0 9899 7000 78


R32 N&S 160.0 1.0 42.0 9899 1501 15

Products in bold are stock items, other items are produced to order.

21,5 mm“L version”

32,0 mm

18,5 mm“N version”

32,0 mm

15,0 mm“S version”

32,0 mm

MAI SDA R32

MAI SDA R38

MAI SDA R51

MAI SDA T76

Hammers Shank adapters Adapter couplings Anchor rodR32

Extension couplingR32-R32

Bit exampleR32

Bit exampleR38

Bit exampleR51

Bit exampleT76

COP 1838-R38

COP / T51

COP / T51

Krupp / HL90

Krupp / HL112

COP 1238-R38

COP 1238-R32/R38

COP 1838-R32/R38

COP 1440-R32/R38

Anchor rodR32



Anchor rodR38

Hammer Shank adapter Adapter coupling Anchor rodR51


Anchor rodR51

Hammers Shank adapters Adapter couplings Anchor rodT76

Extension couplingT76-T76

Anchor rodT76

COP 1238-R32

COP 1838-R32

R32-R32

R38-R38

R38-R32

R51-R51

T76-T76

R32-R32

R38-R32

R38-R38

T51-R51

T51-T76

HL90-T76

HL112-T76

18


MAI SDA R32 nuts & platesNut

Size Type Length (mm)

Weight (kg)

Key size (mm)

Product number

R32/SW46 L&N&S 45.0 0.4 46.0 9899 1007 67


R32/SW46 L&N&S 45.0 0.4 46.0 9899 1011 61

Anchor plate

Size Type Dimension (mm)

Thickness (mm)

Weight (kg)

Hole Ø (mm)

Product number

R32 L 150x150 8.0 1.3 35.0 9899 1007 97

R32 L&N 200x200 10.0 3.1 35.0 9899 1007 98

R32 S 200x200 12.0 3.7 35.0 9899 1007 99


R32 N 200x200 10.0 3.2 35.0 9899 1011 63

R32 S 200x200 12.0 3.9 35.0 9899 1013 69

MAI SDA R32 accessoriesRIA-Kits

Description Type Weight (kg)

Product number

RIA-Mono "ext R32/ext R32" L&N&S 6.5 9899 1007 94

RIA-Mono "Seals 55x67x6 NBR 70" L&N&S 0.1 9899 1516 08

RIA-Combi "Body" L&N&S 0.6 9899 1514 98

RIA-Combi "Shank ext. R32/ ext. R32" L&N&S 2.5 9899 1516 02

RIA-Combi "Shank int. R32/ int. R32" L&N&S 3.5 9899 1516 01

RIA-Combi "O-ring/ Ø39,2x5,7 NBR 70" L&N&S 0.01 9899 1516 05

RIA-Combi "Seals S605 45x55x8" L&N&S 0.05 9899 1516 04


MAI SDA R32 bits Size Type Weight

(kg)Outer Ø (mm)

Product number

Drill bit R32 L&N&S X 0.5 51.0 9899 1007 79

Drill bit R32 L&N&S EX 0.3 51.0 9899 1007 81

Drill bit R32 L&N&S EX 1.2 76.0 9899 1012 67

Drill bit R32 L&N&S/L74 EXX 0.5 51.0 9899 7004 09

Drill bit R32 L&N&S EY 1.2 76.0 9899 1510 37

Drill bit R32 L&N&S EYY 1.0 76.0 9899 1503 54

Button bit R32 L&N&S ES-F 0.4 51.0 9899 1500 30

Button bit R32 L&N&S ESS-F 0.4 51.0 9899 1500 31

Button bit R32 L&N&S ESS-F 0.9 51.0 9899 1509 63

Split arc bit R32 L&N&S EC 0.4 51.0 9899 1500 83

Split arc bit R32 L&N&S ECC 0.4 51.0 9899 1507 52

Ram head R32 L&N&S Driving head 0.6 65.0 9899 1500 36

19

Coupling box – Adapters – Shank adapters


Product number

Quick coupling NW25 1" IT "female" L&N&S 0.5 9899 1003 73

Coupling box R25-R32 with middle stop L=200 mm L&N&S 1.7 9899 1018 30



Coupling box R32-T45 with middle stop L=200 mm L&N&S 3.1 9899 1501 37

Drill bit adapter R38/R32 L&N&S 0.01 9899 1500 08

Injection adapter R32/1" L&N&S 0.6 9899 1019 52

Shank R25 male/SK22 L&N&S 1.2 9899 1015 03

Shank R25 male/SK25 L&N&S 1.4 9899 1015 00

Centralizer R32/ Ø72 L&N&S 0.3 9899 1515 32

Pull test equipment

Description Type Weight (kg) Product number

Load testing unit Max load 300 kN, stroke 63 mm, bore 53 mm

L&N 67.0 9899 1019 65


S 86.0 9899 1512 75


IRIA-Kits and parts

COP Conversion kit Type Reference Product number

COP 1238 L&N&S Rock Drills AB Örebro 3128 3124 80



BSH 110 Type Reference Product number

BSH 110 SDA L&N&S Rock Drills AB Örebro 3128 3106 50

BSH 110 Bushing halves Type Reference Product number

R32 L&N&S Rock Drills AB Örebro 3128 2021 22

Shank adapters Type Reference Product number

COP 1238-R32F L&N&S Secoroc AB Fagersta 7403 0305 01



Integrated injection adapter Type Reference Product number

IRIA kit for COP 1238, 1838 and 1440 L&N&S Rock Drills AB Örebro 3115 3230 00

IRIA seals kit, complete for COP 1238 and COP 1838

L&N&S Rock Drills AB Örebro 3115 3230 90

IRIA Shank adapters Type Reference Product number




20


MAI SDA R38 extension couplingsSize Type Length

(mm)Weight

(kg)Outer Ø

(mm)Product number

R38 N 220.0 1.7 51.0 9899 7000 34


R38 N 220.0 1.8 51.0 9899 1020 42

MAI SDA R38 bitsSize Type Weight

(kg)Outer Ø

(mm)Product number

Drill bit R38 N XX 1.4 110.0 9899 1025 43

Drill bit R38 N EX 1.2 76.0 9899 1007 82

Drill bit R38 N EX 1.3 90.0 9899 1500 16

Drill bit R38 N EY 0.9 76.0 9899 1510 17

Drill bit R38 N EYY 0.9 76.0 9899 1026 23

Drill bit R38 N EYY 2.2 90.0 9899 1500 41

Button bit R38 N ES-F 1.0 76.0 9899 1500 28

Button bit R38 N ESS-F 1.0 76.0 9899 1500 29

Button bit R38 N ESS-D 1.3 115.0 9899 1506 22

MAI SDA R38 nuts & platesNut


Weight (kg)

Key size (mm)

Product number

R38/SW50 L&N&S 50.0 0.4 50.0 9899 1007 68


R38/SW50 L&N&S 50.0 0.4 50.0 9899 1019 81




(m)Weight

(kg)Outer Ø

(mm)Inner Ø 1

(mm)Area 2 (mm2)

UL 3 (kN)

YL 4 (kN)

Product number

R38 N 2.0 12.0 38.0 19.0 717 500 400 9899 1007 63

R38 N 3.0 18.0 38.0 19.0 717 500 400 9899 1007 64

R38 N 4.0 24.0 38.0 19.0 717 500 400 9899 1007 65


R38 N 2.0 12.0 38.0 19.0 717 500 400 9899 1026 65

R38 N 3.0 18.0 38.0 19.0 717 500 400 9899 1020 43

R38 N 4.0 24.0 38.0 19.0 717 500 400 9899 1026 66


38,0 mm

MAI SDA R32

MAI SDA R38

MAI SDA R51

MAI SDA T76



Bit exampleR32

Bit exampleR38

Bit exampleR51

Bit exampleT76

COP 1838-R38

COP / T51

COP / T51

Krupp / HL90

Krupp / HL112

COP 1238-R38

COP 1238-R32/R38

COP 1838-R32/R38

COP 1440-R32/R38

Anchor rodR32



Anchor rodR38



Anchor rodR51



Anchor rodT76

COP 1238-R32

COP 1838-R32

R32-R32

R38-R38

R38-R32

R51-R51

T76-T76

R32-R32

R38-R32

R38-R38

T51-R51

T51-T76

HL90-T76

HL112-T76

21




Product number

RIA-RotoJec "Body" N 15.8 9899 1505 29

RIA-RotoJec "Shank int. R38 / int. R38" N 11.5 9899 1508 68

RIA-RotoJec "Seals S605 75x90x13" N 0.1 9899 1516 03



Product number

Quick coupling box R25-R38 with middle stop L=200 mm N 2.6 9899 1027 02



Quick coupling box R38-T45 with middle stop L=200 mm N 3.1 9899 1510 59

Quick coupling NW25 1" IT "female" N 0.5 9899 1003 73

Shank R25 male / SK22 N 1.2 9899 1015 03

Shank R25 male / SK25 N 1.4 9899 1015 00

Drill bit adapter R51 / R38 N 0.03 9899 1510 92

Injection adapter R38 / 1" N 0.9 9899 1025 42

Pull test equipment


Product number


N 86.0 9899 1512 75

IRIA-Kits and parts

COP Conversion kit Type Reference Product number

COP 1238 N Rock Drills AB Örebro 3128 3124 80



BSH 110 Type Reference Product number

BSH 110 SDA N Rock Drills AB Örebro 3128 3106 50

BSH 110 Bushing halves Type Reference Product number

R38 N Rock Drills AB Örebro 3128 2021 22

Shank adapters Type Reference Product number

COP 1838-R38F N Secoroc AB Fagersta 7403 0914 01


Integrated injection adapter Type Reference Product number

IRIA kit for COP 1238, 1838 and 1440 N Rock Drills AB Örebro 3115 3230 00

IRIA seals kit, complete for COP 1238,1838 and 1440

N Rock Drills AB Örebro 3115 3230 90

IRIA Shank adapters Type Reference Product number




Anchor plate


Thickness (mm)

Weight (kg)

Hole Ø (mm)

Product number

R38 N 200x200 12.0 3.6 41.0 9899 1008 00


R38 N 200x200 12.0 3.8 41.0 9899 1019 80

22



(m)Weight

(kg)Outer Ø

(mm)Inner Ø 1

(mm)Area 2 (mm2)

UL 3 (kN)

YL 4 (kN)

Product number

R51L 2.0 14.0 51.0 36.0 776 550 450 9899 1500 57

R51 L 3.0 21.0 51.0 36.0 776 550 450 9899 1500 52

R51 L 4.0 28.0 51.0 36.0 776 550 450 9899 1500 64

R51 L 6.0 42.0 51.0 36.0 776 550 450 9899 1500 47

R51 N 2.0 16.8 51.0 33.0 939 800 630 9899 1500 62

R51 N 3.0 25.2 51.0 33.0 939 800 630 9899 1500 61

R51 N 4.0 33.6 51.0 33.0 939 800 630 9899 1500 35

R51 N 6.0 50.4 51.0 33.0 939 800 630 9899 1500 63


R51 L 2.0 14.0 51.0 36.0 776 550 450 9899 7000 41

R51 L 3.0 21.0 51.0 36.0 776 550 450 9899 1509 88

R51 L 4.0 28.0 51.0 36.0 776 550 450 9899 7000 42

R51 N 2.0 16.8 51.0 33.0 939 800 630 9899 1513 12

R51 N 3.0 25.2 51.0 33.0 939 800 630 9899 1509 89

R51 N 4.0 33.6 51.0 33.0 939 800 630 9899 7000 45


MAI SDA R51 extension couplings Size Type Length

(mm)Weight

(kg)Outer Ø

(mm)Product number

R51 L 140.0 1.2 63.0 9899 7000 35

R51 N 220.0 1.9 63.0 9899 7000 36


R51 L 120.0 1.2 63.0 9899 1509 84

R51 N 200.0 1.9 63.0 9899 1509 85

MAI SDA R51 bitsSize Type Weight

(kg)Outer Ø

(mm)Product number

Drill bit R51 L&N XX 1.8 110.0 9899 1500 42

Button bit R51 L&N ES-F 1.8 100.0 9899 1500 22

Button bit R51 L&N ESS-F 1.8 100.0 9899 1507 53

Button bit R51 L&N ES-D 2.0 115.0 9899 1508 92

Button bit R51 L&N ESS-D 2.0 115.0 9899 1500 59


51,0 mm


51,0 mm

36,0 mm“L version”

MAI SDA R32

MAI SDA R38

MAI SDA R51

MAI SDA T76



Bit exampleR32

Bit exampleR38

Bit exampleR51

Bit exampleT76

COP 1838-R38

COP / T51

COP / T51

Krupp / HL90

Krupp / HL112

COP 1238-R38

COP 1238-R32/R38

COP 1838-R32/R38

COP 1440-R32/R38

Anchor rodR32



Anchor rodR38



Anchor rodR51



Anchor rodT76

COP 1238-R32

COP 1838-R32

R32-R32

R38-R38

R38-R32

R51-R51

T76-T76

R32-R32

R38-R32

R38-R38

T51-R51

T51-T76

HL90-T76

HL112-T76

23

MAI SDA self-drilling anchorsMAI SDA R51 nuts & platesNut


Weight (kg)

Key size (mm)

Product number

R51 L&N 70.0 1,6 75.0 9899 1500 23


R51 L&N 70.0 1,6 75.0 9899 1512 61

Anchor plate


Thickness (mm)

Weight (kg)

Hole Ø (mm)

Product number

R51 L 200x200 30.0 8.8 60.0 9899 1500 96

R51 N 250x250 40.0 18.5 60.0 9899 1500 97


R51 L 200x200 30.0 8.8 60.0 9899 7000 09

R51 N 250x250 40.0 18.5 60.0 9899 1511 64



Product number

RIA-RotoJec "Body" L&N 15.8 9899 1505 29

RIA-RotoJec "Shank int. R38 / int. R51" L&N 10.5 9899 1512 85

RIA-RotoJec "Shank int. T45 / int. R51 L&N 8.0 9899 1508 67

RIA-RotoJec "Shank int. H55 / int. R51 L&N 8.3 9899 1508 72

RIA-RotoJec "Seals S 605 75x90x13 L&N 0.1 9899 1516 03



Product number

Coupling box R51-R38 with middle stop L=235 mm L&N 5.1 9899 1500 26

Coupling box R51-T38 with middle stop L=235 mm L&N 5.1 9899 1500 25

Coupling box R51-T45 with middle stop L=235 mm L&N 4.7 9899 1500 27

Quick coupling NW25 1" IT "female" L&N 0.5 9899 1003 73

Centralizer R51 / Ø 100 mm L&N 0.5 9899 1515 31

Injection adapter R51 / 1" L&N 1.0 9899 1500 67


24


MAI SDA T76 anchor rods


MAI SDA T76 extension couplingsSize Type Length

(mm)Weight

(kg)Outer Ø

(mm)Product number

T76 N&S 220.0 6.4 95.0 9899 1506 46


T76 N&S 220.0 6.4 95.0 9899 7003 25

MAI SDA T76 bitsSize Type Weight

(kg)Outer Ø

(mm)Product number

Button T76 N&S EX 6.0 130.0 9899 7000 54

Button T76 N&S XX 3.2 130.0 9899 7000 03

Button T76 N&S XX 3.8 175.0 9899 1522 81

Button T76 N&S XX 4.0 200.0 9899 7000 94

Drill bit T76 N&S ESS-F 4.6 120.0 9899 7000 93

Size Length (m)

Weight (kg)

Outer Ø (mm)

Inner Ø 1 (mm)

Area 2

(mm2) UL 3 (kN)

YL 4 (kN)

Product number

T76N 2.0 30.0 76.0 51.0 1835 1600 1200 9899 1506 44

T76N 3.0 45.0 76.0 51.0 1835 1600 1200 9899 1506 50

T76N 4.0 60.0 76.0 51.0 1835 1600 1200 9899 1506 51

T76N 6.0 90.0 76.0 51.0 1835 1600 1200 9899 1506 52

T76 S 2.0 39.4 76.0 45.0 2400 1900 1500 9899 1511 02

T76 S 3.0 59.1 76.0 45.0 2400 1900 1500 9899 1511 03

T76 S 4.0 78.8 76.0 45.0 2400 1900 1500 9899 1511 04

T76 S 6.0 118.2 76.0 45.0 2400 1900 1500 9899 1511 05


T76 N 2.0 30.0 76.0 51.0 1835 1600 1200 9899 7003 19

T76 N 3.0 45.0 76.0 51.0 1835 1600 1200 9899 7003 20

T76 N 4.0 60.0 76.0 51.0 1835 1600 1200 9899 7003 21

T76 S 2.0 39.4 76.0 45.0 2400 1900 1500 9899 7003 23

T76 S 3.0 59.1 76.0 45.0 2400 1900 1500 9899 7003 24

T76 S 4.0 78.8 76.0 45.0 2400 1900 1500 9899 7002 02


76,0 mm

45,0 mm“S version”

76,0 mm


MAI SDA R32

MAI SDA R38

MAI SDA R51

MAI SDA T76



Bit exampleR32

Bit exampleR38

Bit exampleR51

Bit exampleT76

COP 1838-R38

COP / T51

COP / T51

Krupp / HL90

Krupp / HL112

COP 1238-R38

COP 1238-R32/R38

COP 1838-R32/R38

COP 1440-R32/R38

Anchor rodR32



Anchor rodR38



Anchor rodR51



Anchor rodT76

COP 1238-R32

COP 1838-R32

R32-R32

R38-R38

R38-R32

R51-R51

T76-T76

R32-R32

R38-R32

R38-R38

T51-R51

T51-T76

HL90-T76

HL112-T76

25


MAI SDA T76 accessoriesRIA-Kits


Product number

RIA-RotoJec "Body" N&S 5.8 9899 1505 29

RIA-RotoJec "Shank int. H55 / int. T76 N&S 11.5 9899 1512 28

RIA-RotoJec "Seals S 605 75x90x13 N&S 0.1 9899 1516 03



Product number

Coupling box H55-T76 with middle stop L=220 mm N&S 5.2 9899 1518 29

Injection adapter T76 / 6/4" N&S 3.0 9899 1518 30

Anchor plate


Thickness (mm)

Weight (kg)

Hole Ø (mm)

Product number

T76 N&S 250x250 60.0 27.0 80.0 9899 1510 47


T76 N&S 250x250 60.0 27.0 80.0 9899 7003 27

MAI SDA T76 nuts & platesNut


Weight (kg)

Key size (mm)

Product number

T76 N&S 80.0 3.6 100.0 9899 1506 45


T76 N&S 80.0 3.6 100.0 9899 7003 26


26

MAI SDA accessories

Centralizer A centralizer is available for specialist applica-tions. For general use the centralizer is not re-quired as it snags during rotation and interferes with grout circulation in the borehole. The use of a centralizer does not guarantee comprehensive grout cover along the length of the bar as it's is im-possible to control the grout within the borehole.

Coupling boxesManufactured from thick-wall steel which is machined and case hardened. Coupling boxes are used at high wear locations, typically just below the hammer drive. A locking torque is normally applied to the coupling box at the permanent joint, to avoid release when additional anchor bars are added.

All the coupling boxes are supplied with a bridge to act as a centre stop.

When a step down (reducer) drive arrangement is used i.e. R38 shank to drive to install R32 anchor bar, a locking torque should be applied at the R38 end to prevent the R32 bar climbing into the R38 chamber.

Step up drive arrangements are not recommended as the additional torque overloads the smaller drive.

ShanksRotary percussion is the preferred method of in-stallation. Either hydraulic or air hammer is suit-able. To transfer the rotation and percussion from the hammer to the bar's system there is a need for the special tool named shank adapter. Atlas Copco is providing a full range of different shank adapt-ers for different hammers.

Centralizer

Coupling boxes

A common shank adaptor

27

MAI SDA accessories

The MAI anchor mortar is mostly used for grout-ing of anchor bore holes or for consolidation grouting of fractured rock formation and loose unconsolidated ground. Depending on the work environment the MAI anchor mortar is available as standard or sulphate-resistant type cement.

ProcessingMAI anchor mortar is mixed with clean water; ap-proximately 5.0 l/bag are needed. For processing, standard mortar mixing pumps, especially the MAI pump m400 NT are suitable.

StorageThe MAI anchor mortar is delivered in bags of 25 kg each. The bags should be kept in dry condi-tions, a max. shelf life of 6 months can be expect-ed.

SafetyAs per international chemical substance law the MAI anchor mortar is not considered as a danger-ous substance.

MAI SDA mortar

Technical dataDescription Product number

MAI mortar, sulfat resistant 9899 1500 20

MAI mortar, normal/standard 9899 7000 80

Description data

Max. grain size 0.3 mm

Bulk weight ~ 1200 kg/m3

Water consumption ~ 20% of dry mass

Cube strength 1d 15 N/mm2





MAI SDA anchor mortar

Grout couplingAfter using standard fl ushing media - water or air, grouting has to be done. For connecting the grout-ing hose from the pump with the anchor bar, the grout coupling is used. The grout coupling will be removed and reused after the grouting process is done.

Grout coupling

28

MAI grout pump

The MAI pump m400 NT is a proven high quality pump which is used successfully around the world in tunnel construction, civil engineering, mining and shoring of building excavations, slopes and hill sides.

Areas of useThe proven mixing and pumping technology is especially suitable for:

Injection work �Re-injection grouting �Drill hole filling �Back filling �Anchor mortar �

Description

Spur-wheel gear motor 6 kW/200 rpm

Worm pump MP 3 "L" (Standard) 600 l/h

High pr. mortar hose with quick-release coupl. Dia. 25 mm

- Vibrator

- Automatic reverse drive

- Automatic screen safety feature

- Tools

- Cleaning equipment

- Water pump optional

- Automatically polarity control

Accessories

MAI SDA grout pump m400 NT

Technical dataDescription Product number

MAI pump m400 NT (standard) 9899 1226 07

Other pump constructions available on request

Description data

Delivery rate 400-2000l/h

Delivery distance 40-60 m max.

Delivery pressure 40 bar, approx.

Electricity supply 400 V, 50 Hz

Amperage 12.1 A

Main supply fuse 25 A

Power requirement Min. 16 KVA

Normal output 6.2 kW

Dimensions

Total length 1730 mm

Total width 570 mm

Length without motor and pump 1040 mm

Total height 960 mm

Weights

Total weight 217 kg

Weight without dismantled parts 125 kg


Productivity characteristicsS � turdy construction.Galvanized frame guarantees optimum corro- �

sion protection and can withstand even the toughest treatment.

Simple to dismantle and quick to clean and � maintain.

29

Swellex rock bolts

Since its introduction 25 years ago, the Swellex rock bolting system has gained wide recognition in mining and tunnelling works. It is a unique rock bolt, as it is made out of a welded tube folded on itself and sealed at one extremity. It is re-expanded using a high pressure water flow provided by a spe-cial pump and adapter. The bolt is expanded inside a borehole drilled into the excavation wall, why the installation process is easy and very similar as other rock bolts, making Swellex accessible to all opera-tors. The speed and quality of installation and the exten-sive application range have solved support problems and increased profitability for contractors and mine operators all over the world. As mine and tunnel safety requirements have become more stringent, the prompt, reliable and versatile support available with Swellex rock bolts has made them the best for most problem solving, and one of the best for rock reinforcement in general.Through a process of continuous improvement, Atlas Copco has refined Swellex to offer the most versatile portfolio of rock bolts available on the market. Swellex rock bolts from Atlas Copco ex-ist in two typical versions, one being the Swellex Premium line, a relatively stiff rock bolt for tunnel-ling and mining in moderate stress conditions, and the other one called the Swellex Manganese line, a highly deformable rock bolt for large rock deforma-tion situations.Another improvement is the line of corrosion protected Swellex. From the well accepted rubber bitumen coating to the new Plasticoated Swellex for highly corrosive environments, Atlas Copco cov-ers all demands for corrosion protection and long life rock bolts. And again, for special applications like hangers and deep reinforcement, Atlas Copco has perfected versions of Swellex to perform these tasks with the same easy system. With the Swellex Hanger Pm24H, the operator can install its serv-ice hanger in the same reinforcement operation as the primary support. The Connectable Pm24C is a modern replacement to medium length cable bolts, with high productivity, quality control and safety components.

30

Swellex featuresThe Swellex rock bolt is made out of a welded steel tube folded on itself and sealed at one extrem-ity, while the other extremity is set with a special head bushing used for inflation and retaining of the face plates typically used in rock bolting.

The expansion of the bolt, inside the drilled bore-hole, creates a friction and interlocking anchor, which provides instant reinforcement and support.

Swellex rock bolts can be considered as a full column support as they provide reinforcement and support on the whole length of the borehole, what-ever happens at the collar area. Due to its unique anchorage mechanism, the Swellex bolt can adapt to a wide variety of ground conditions and provide good to excellent anchor-age capacity in most rock types. The steel profile can also adapt to shear movements, and in softer materials the Swellex bolt accommodates large shear displacements without failure.

The simplicity of the system can explain its per-formance. The operator simply drills a hole in the rock, inserts the bolt and then inflates it to a pre-determined pressure using a dedicated inflation system. The pump stops when reaching the rec-ommended inflation pressure that guarantees the quality of the installation.

Swellex rock bolts can easily be pull tested. In fact, a Swellex rock bolt has the easiest pull test operation of any rock bolt type.

As the anchorage principle of Swellex is a tight interlock with the asperities of the borehole sur-face, corrosion can develop if the environment is prone to corrosion processes. In order to provide a solution for long term reinforcement, and handle particularly aggressive situations, Atlas Copco provides two versions of protected Swellex bolts, the Bitumen coated Swellex and the Plastic coated Swellex. These two products extend the normal life of a Swellex by many years.

Friction and interlocking support of the whole length

Swellex net washer for screening Bridges gaps in the rock Allows major shear movements in medium to soft rocks Adapted to the bore hole’s irregularity A 50 cm long inflated bolt can develop 100 kN friction

Swellex rock bolts

A Swellex rock bolt before inflation

An inflated Swellex rock bolt adapted to the bore hole’s irregularity

31

ApplicationsSwellex rock bolts are extremely versatile and can be used in a variety of excavation, from tunneling to mining. A very typical application in tunneling is to use Swellex as pattern bolts to support, rein-force or consolidate the periphery of an excava-tion. The density of bolting depends of the size of the excavation and the self-supporting qualities of the rock mass. In mining, common applications

Swellex rock bolts

Tunn

elling Mining

Hag wall boltin

gHag wall boltin

g

nn

Radial systematic boltin

gRadial systematic bolting

a

Roof boltingRoof bolting

like roof and hanging wall bolting have adopted Swellex as a rapid and performing stabilisation de-vice. Because Swellex is expanded inside a bore-hole smaller than the folded tube circumference, it is not sensitive to hole diameter, rock quality or water conditions and provides a good anchorage capacity in most tunneling and mining conditions.

32

Swellex rock bolts

Atlas Copco offers a versatile portfolio of rock bolts that provides reinforcement solutions for ground conditions varying from easy to very dif-fi cult. With three typical capacity ranges, at 120 kN, 160 kN and 240 kN, the Swellex rock bolts can be used in most reinforcement and support ap-plications. They can also be used either in mines or in civil engineering applications and their specifi c mechanical properties will provide the needed safety and performance. Selection of a rock bolt is usually done during the design phase of an excava-tion, and is the prerogative of the design engineer as it involves geological and structural knowledge and engineering computation. However, the fol-lowing sections can help understand the specifi c mechanical properties of the Swellex bolts and ease the selection process.

Premium lineThe Premium line is a typical tunnelling bolt, with a high yield load and good deformability. It pro-vides a competitive strength combined with the classic Swellex system performance. Pm rock bolts can also be used in mining when low to medium stress conditions require a stiff Swellex rock bolt with a high yield load. However, Pm line Swellex are deformable enough to provide a safe behaviour in rising stress conditions and can be used in most typical mining environments.

Manganese lineThe Manganese line was developed to suit large stress changes occuring in some mining and tun-neling projects. Made from a very specifi c steel type, Mn rock bolts receive a heat treatment to im-prove their mechanical properties. Manganese line Swellex rock bolts have a unique yielding behav-iour that can be matched only with the proper steel manufacturing. As a result, they provide a high ultimate load and a large deformation capability. Because of these outstanding mechanical proper-ties and the quality assurance associated with the Swellex system, the Manganese line has been amining success.

Swellex Manganese line rock bolts

Swellex Premium line rock bolts

33

Swellex rock bolts

Plastic coatedPlastic coated Swellex is providing its long term corrosion protection through a thick plastic coating that is impervious to water and current. The dam-age resistant coating is very effective in very corro-sive environments and its resistance and effective-ness is proven over years of application in highly acidic conditions.

Swellex Pm24C – a connectable boltFurther to the typical pattern rock bolting appli-cation, the Swellex Pm24C offers the possibility of deeper reinforcement without grouting opera-tion. The Swellex Pm24C is a connectable rock bolt, which consists of individual sections that are joined together via “R” thread connections. The required bolt length is achieved by adding one or more sections. Swellex Pm24C bolts are very competitive against short and medium length cable bolts.

A Swellex connectable rock bolt

Swellex Pm24H – a hangerThe Swellex Pm24H is a new generation of hanger that provides a high anchorage capacity hanger with a fl anged head with a female M36 thread. The rock bolt has a static axial load carrying capacity of 200 kN and is designed for hanging services. The fi nal hanging capacity is determined by the eye bolt capacity. After the Pm24H bolt has been installed by using an infl ation adapter, a forged eye – bolt with M36 thread is screwed on. Utilities can then be suspended directly from the eye – bolt. As the Pm24H is not designed for excentric loading, the design load should always be coaxial to the bolt profi le, and the bolts installed as vertical as pos-sible. The end sleeve should be inside the borehole in rock and shotcrete. Swellex Pm24H can be installed using standard Swellex installation equipment combined with a small infl ation adapter.

The Swellex hanger system

Bitumen coatedBitumen coated Swellex is created by coating a Swellex bolt with a thick rubber bitumen paint, to provide medium term corrosion protection against most corrosive conditions.

A plastic coated Swellex rock bolt

34

Swellex installation methods

Manual installation

Mechanized installation

Rock bolting for mining and tunnelling has reached a phase of performance never attained in the past. While spot bolting is still used to stabilize individual blocks in roofs and walls of excavations, the trend is to use rock bolting as a systematic mean to provide a global reinforcement mechanism that will allow longer and safer use of underground excavations.

Along these changes, mechanization of rock bolt-ing has become a preferred way for many tunnel and mining operators. Not only does a mechanized installation provide a higher productivity, it also helps to maintain a safer working environment. However, since the demand for manually installed rock bolts is still high, support systems must be fl exible and allow manual as well as mechanized installation operations.

Over the last decade, it has been recognized that the installation operation is a critical step in as-suring the effectiveness of a rock support system. If not properly installed, the best rock bolt will behave poorly and provide a false sense of security that is detrimental to the reinforcement purpose. Better bolting operation and quality control of the raw materials is now a basic component of a good reinforcement system.

Fully mechanized installation of Swellex with a Boltecdrill rig

1. Drill the hole. 2. Insert the bolt. 3. Connect and start the pump to expand the bolt.

4. Installation completed.

35

Swellex installation methods

Manual installation of Swellex Connectables

Manual installation of Swellex Hangers

1. Drill the hole 2. Install bolt 1 and add bolt 2

3. Add bolt 3 with face plate

4. Connect the infl ation chuck and install all the bolts

5. Infl ate the bolts 6. Installation completed

1. Drill the hole 2. Mount the infl a- tion adapter

3. Connect the chuck to the bolt

4. Infl ate the bolt 5. Dismount the adapter

6. Mount the eye- bolt

36

Swellex Manganese line

* Typical values** A5. According to SS-EN 10 002 - 1 where applicable.

Swellex Premium line

DescriptionBolt type

UnitPm12 Pm16 Pm24 Pm24C Pm24H

Type of steel S275JR / S355MC

Minimum breaking load 110 160 240 200 200 kN

Minimum yield load 100 140 200 190 190 kN

Minimum elongation ** 10 10 10 10 10 %

Inflation pressure 300 300 300 300 300 Bar

Profile diameter 27.5 36.0 36.0 36.0 36.0 mm

Original tube, diameter 41.0 54.0 54.0 54.0 54.0 mm

Material thickness 2.0 2.0 3.0 3.0 3.0 mm

Upper bushing, diameter 28.0 38.0 38.0 38.0 38.0 mm

Inflation bushing, diameter 30.0/36.0 41.0/48.0 41.0/48.0 41.0/48.0 - mm

Optimal hole diameters* 35.0 - 38.0 45.0 - 51.0 45.0 - 51.0 48.0 - 51.0 45.0 - 51.0 mm

Range hole diameters 32.0 - 39.0 43.0- 52.0 43.0 - 52.0 48.0 - 54.0 43.0 - 52.0 mm

Connection diameter including welds - - - 45.0 - mm

Recommended collar diameter - - - - 53.0 - 55.0 mm

Bitumen coated option Yes Yes Yes Yes Yes

Plastic coated option Yes Yes Yes Yes Yes

Swellex rock bolts

Quick reference

DescriptionBolt type

UnitMn12 Mn16 Mn24

Type of steel S355JR

Minimum breaking load 110 160 200 kN

Minimum yield load 90 120 180 kN

Minimum elongation ** 20 20 20 %

Inflation pressure 300 300 300 Bar

Profile diameter 27.5 36.0 36.0 mm

Original tube, diameter 41.0 54.0 54.0 mm

Material thickness 2.0 2.0 3.0 mm

Upper bushing, diameter 28.0 38.0 38.0 mm

Inflation bushing, diameter 30.0/36.0 41.0/48.0 41.0/48.0 mm

Optimal hole diameters* 35.0 - 38.0 45.0 - 51.0 45.0 - 51.0 mm

Range hole diameters 32.0 - 39.0 43.0 - 52.0 43.0 - 52.0 mm

Recommended collar diameter - - - mm

Bitumen coated option Yes Yes Yes

Plastic coated option - - -

* Typical values** A5. According to SS-EN 10 002 - 1 where applicable.

37

Swellex rock bolts

Swellex rock bolts for applications where high-er yield and breaking strength are required.

Swellex Premium line is engineered to provide safety and productivity in areas where stiff rock bolting is expected to work within its elastic range and to minimize the deformation in and around the excavation. Improved yield and breaking load val-ues extend the use of well-known Swellex concept into applications where the design requires higher work load from a bolt. A special steel composition coupled with the inherent Swellex advantages offer perfect installation, im-mediate support on the entire length and an ideal bolt for demanding excavations.

Swellex Premium line

38

Swellex Pm12

Size Length(m)

Weight(kg)

Product number incl. colour plugs

Product number

SWX Pm12 1.2 2.5 On request 9899 7001 26

SWX Pm12 1.5 3.1 9899 7004 78 9899 7001 27

SWX Pm12 1.8 3.7 9899 7004 79 9899 7001 28

SWX Pm12 2.1 4.3 9899 7004 80 9899 7001 29

SWX Pm12 2.4 4.9 9899 7004 81 9899 7001 30

SWX Pm12 2.7 5.5 On request 9899 7001 31

SWX Pm12 3.0 6.0 9899 7004 82 9899 7001 32

SWX Pm12 3.3 6.6 On request 9899 7001 33

SWX Pm12 3.6 7.2 9899 7004 83 9899 7001 34

SWX Pm12 3.8 7.6 On request 9899 7001 35

SWX Pm12 3.9 7.8 On request 9899 7001 36

SWX Pm12 4.0 8.0 9899 7004 84 9899 7001 37

SWX Pm12 4.5 9.0 9899 7004 84 9899 7001 38

SWX Pm12 5.0 9.9 9899 7004 84 9899 7001 39

SWX Pm12 6.0 11.9 On request 9899 7001 40

SWX Pm12 6.5 12.9 On request 9899 7001 41

Bitumen coated

SWX Pm12 1.8 3.7 On request 9899 7013 01

SWX Pm12 2.1 4.3 On request 9899 7013 02

SWX Pm12 2.4 4.9 On request 9899 7013 03

SWX Pm12 3.0 6.0 On request 9899 7013 04

SWX Pm12 3.6 7.2 On request 9899 7013 05

SWX Pm12 4.0 8.0 On request 9899 7013 06

SWX Pm12 5.0 9.9 On request 9899 7013 24

SWX Pm12 6.0 11.9 On request 9899 7014 52

Plastic coated

SWX Pm12 1.5 3.3 On request 9899 7004 74

SWX Pm12 1.8 3.8 On request 9899 7004 75

SWX Pm12 2.1 4.4 On request 9899 7004 76

SWX Pm12 2.4 5.0 On request 8394 0101 81

SWX Pm12 3.0 6.2 On request 9899 7004 34

SWX Pm12 3,6 7.5 On request 9899 7004 64

Swellex rock bolts

General information

Minimum breaking load 110 kN

Minimum elongation* 10%

Minimum yield load 100 kN

Inflation pressure 300 bar

For further information, see also Technical data page 36 * A5. According to SS-EN 10 002 - 1 where applicable.


For suitable face plates, see page 48

39

Swellex rock boltsSwellex Pm16

Size Length (m)

Weight (kg)

Product number

SWX Pm16 1.8 5.1 9899 7001 42

SWX Pm16 2.0 5.6 9899 7001 43

SWX Pm16 2.1 5.8 9899 7001 44

SWX Pm16 2.4 6.7 9899 7001 45

SWX Pm16 2.7 7.4 9899 7001 46

SWX Pm16 3.0 8.2 9899 7001 47

SWX Pm16 3.3 8.9 9899 7001 48

SWX Pm16 3.6 9.7 9899 7001 49

SWX Pm16 4.0 10.7 9899 7001 50

SWX Pm16 4.5 12.0 9899 7001 51

SWX Pm16 5.0 13.3 9899 7001 52

SWX Pm16 6.0 15.9 9899 7001 53

SWX Pm16 6.5 17.2 9899 7001 54

Bitumen coated

SWX Pm16 2.1 5.8 9899 7015 12

SWX Pm16 2.7 7.4 9899 7013 28

SWX Pm16 3.0 8.2 9899 7013 29

SWX Pm16 3.6 9.7 9899 7013 26

SWX Pm16 4.0 10.7 9899 7013 07

SWX Pm16 4.5 12.0 9899 7013 27

SWX Pm16 6.0 15.9 9899 7013 18

Plastic coated

SWX Pm16 3.6 9.7 9899 7005 19

General information








40

Swellex Pm24

Size Length(m)

Weight(kg)

Product number

SWX Pm24 1.8 7.2 9899 7001 55

SWX Pm24 2.1 8.4 9899 7001 56

SWX Pm24 2.4 9.5 9899 7001 57

SWX Pm24 2.7 10.6 9899 7001 58

SWX Pm24 3.0 11.8 9899 7001 59

SWX Pm24 3.3 12.9 9899 7001 60

SWX Pm24 3.6 14.0 9899 7001 61

SWX Pm24 3.9 15.2 9899 7001 62

SWX Pm24 4.0 15.6 9899 7001 63

SWX Pm24 4.5 17.4 9899 7001 64

SWX Pm24 4.9 18.9 9899 7001 65

SWX Pm24 5.0 19.3 9899 7001 66

SWX Pm24 5.5 21.2 9899 7001 67

SWX Pm24 6.0 23.1 9899 7001 68

SWX Pm24 6.5 25.0 9899 7001 69

SWX Pm24 7.0 26.9 9899 7001 70

Bitumen coated

SWX Pm24 2.1 7.2 9899 7014 94

SWX Pm24 2.4 9.5 9899 7013 08

SWX Pm24 2.7 10.6 9899 7013 09

SWX Pm24 3.0 11.8 9899 7013 00

SWX Pm24 3.6 14.0 9899 7013 25

SWX Pm24 4.0 15.5 9899 7013 11

SWX Pm24 4.5 17.4 9899 7013 12

SWX Pm24 4.9 18.9 9899 7013 13

SWX Pm24 5.0 19.3 9899 7013 14

SWX Pm24 6.0 23.1 9899 7013 15

Plastic coated

SWX Pm24 2.1 7.2 9899 7014 95

SWX Pm24 2.4 9.5 9899 7012 84

SWX Pm24 3.0 11.8 9899 7005 72

SWX Pm24 3.6 14.0 9899 7004 77

Swellex rock bolts

General information








41

Swellex Pm24C – a connectable boltSize Description Length (m) Weight

(kg)Product number

Assembled Overall

"NR" (Connectable)

SWX Pm24C Blind 1.62 1.62 6.3 9899 7013 89

SWX Pm24C Injection 1.52 1.62 6.4 9899 7013 90

SWX Pm24C Intermediate 1.62 1.72 6.6 9899 7013 91

SWX Pm24C Blind 1.92 1.92 7.8 9899 7013 83



SWX Pm24C Blind bushing 2.22 2.22 8.5 9899 7013 95

SWX Pm24C Injection hole 2.12 2.22 8.5 9899 7013 96


SWX Pm24C Blind 2.52 2.52 9.7 9899 7013 30



SWX Pm24C Blind 3.12 3.12 12.0 9899 7013 36



SWX Pm24C Blind 4.12 4.12 15.9 9899 7013 92



"NR" Plastic coated (Connectable)

SWX Pm24C Blind 1.62 1.62 6.4 9899 7014 08



SWX Pm24C Blind 1.92 1.92 7.8 9899 7014 03






SWX Pm24C Blind 2.52 2.52 9.7 9899 7014 00






SWX Pm24C Blind 4.12 4.12 15.9 9899 7014 15



Swellex rock bolts



42

Swellex Pm24H – a hangerSize Description Length

(m)Weight

(kg)Product number

M36 "NG" (Hanger)

SWX Pm24H M36 thread 1.5 6.8 9899 7006 67

SWX Pm24H M36 thread 2.1 9.1 9899 7006 68

SWX Pm24H M36 thread 2.4 10.2 9899 7006 69

SWX Pm24H M36 thread 3.0 12.5 9899 7006 17

SWX Pm24H M36 thread 4.0 14.4 9899 7006 70

Swellex rock bolts


43

Swellex rock bolts

Rockbolts for applications where high energy absorbency in tensile and shear loading is re-quired.

Swellex Manganese line is engineered to provide safety and productivity in areas where improved elongation capability at maximum load capac-ity are required. Made from a very specific type of steel the Swellex Mn rock bolts also receive a heat treatment to improve their mechanical proper-ties. Swellex Manganese line rock bolts are a high quality product with extraordinary work absorb-ency.

Swellex Manganese line

44

Swellex Mn12

Size Length (m)

Weight (kg)

Product number incl. colour plugs

Product number

SWX Mn12 1.2 2.5 9899 7014 67 9899 7013 42

SWX Mn12 1.5 3.1 9899 7014 68 9899 7013 45

SWX Mn12 1.8 3.7 9899 7014 64 9899 7013 48

SWX Mn12 2.1 4.3 9899 7014 69 9899 7013 49

SWX Mn12 2.4 4.9 9899 7014 65 9899 7013 51

SWX Mn12 2.7 5.5 9899 7005 97 9899 7013 53

SWX Mn12 3.0 6.0 9899 7014 66 9899 7013 55

SWX Mn12 3.3 6.6 9899 7014 39 9899 7013 56

SWX Mn12 3.6 7.2 9899 7014 70 9899 7013 57

SWX Mn12 4.0 8.0 9899 7014 71 9899 7013 59

SWX Mn12 4.5 9.0 9899 7014 72 9899 7013 60

SWX Mn12 5.0 9.9 9899 7014 73 9899 7013 62

SWX Mn12 6.0 11.9 On request 9899 7013 64

SWX Mn12 6.5 12.9 On request 9899 7013 65

Bitumen coated

SWX Mn12 1.8 3.7 On request 8394 0176 04

SWX Mn12 2.1 4.3 On request 8394 0176 05

SWX Mn12 2.4 4.9 On request 8394 0176 06

SWX Mn12 3.6 7.2 On request 8394 0176 10

SWX Mn12 4.0 8.0 On request 8394 0176 11

Swellex rock bolts

General information

Minimum breaking load* 110 kN







45

Swellex Mn16

Size Length(m)

Weight(kg)

Product number

SWX Mn16 1.8 5.1 8394 0173 06

SWX Mn16 2.0 5.6 8394 0173 30

SWX Mn16 2.1 5.8 8394 0173 07

SWX Mn16 2.4 6.7 8394 0173 08

SWX Mn16 2.7 7.4 8394 017309

SWX Mn16 3.0 8.2 8394 017310

SWX Mn16 3.3 8.9 8394 0173 11

SWX Mn16 3.6 9.7 8394 0173 12

SWX Mn16 4.0 10.7 8394 0173 40

SWX Mn16 4.5 12.0 8394 0173 45

SWX Mn16 5.0 13.3 8394 0173 50

SWX Mn16 6.0 15.9 8394 0173 60

SWX Mn16 6.5 17.2 8394 0173 65

Bitumen coated

SWX Mn16 4.0 On request 9899 7003 43

Swellex rock bolts

General information








46

Swellex Mn24

Size Length(m)

Weight (kg)

Product number

SWX Mn24 1.8 7.2 9899 7013 47

SWX Mn24 2.1 8.3 9899 7013 50

SWX Mn24 2.4 9.4 9899 7013 52

SWX Mn24 2.7 10.5 9899 7013 54

SWX Mn24 3.0 11.7 9899 7013 58

SWX Mn24 3.3 12.8 9899 7013 61

SWX Mn24 3.6 13.9 9899 7013 63

SWX Mn24 3.9 15.2 9899 7013 66

SWX Mn24 4.0 15.4 9899 7013 67

SWX Mn24 4.5 17.3 9899 7013 68

SWX Mn24 5.0 19.2 9899 7013 69

SWX Mn24 5.5 21.1 9899 7013 70

SWX Mn24 6.0 22.9 9899 7013 71

SWX Mn24 6.5 24.8 9899 7013 72

SWX Mn24 7.0 26.7 9899 7013 73

Bitumen coated

SWX Mn24 2.4 9.7 8394 0170 33

SWX Mn24 2.7 10.8 8394 0170 43

SWX Mn24 3.0 12.0 8394 0170 53

SWX Mn24 4.0 15.4 8394 0170 83

SWX Mn24 4.5 17.8 8394 0170 93

SWX Mn24 6.0 23.6 8394 0171 24

Swellex rock bolts

General information








47

Swellex rock bolts

Swellex face platesFace plates are used to create a local surface sup-port around the borehole collar area. With point load anchor bolts, the plate is used to transfer the displacement of the rock mass into the rock bolt, without it no load transfer can take place. Full col-umn support like grouted bolts and friction bolts need a face plate to maintain rock mass loading on the area of the collar only as most of the loading occurs along the bolt body. Face plates are used to maintain local roof stability, to prevent keyblock movement, and retain surface support like mesh.

The Swellex face plates are manufactured from high quality steels, and meet or exceed the prop-erties stated in the individual specifications. All face plates are designed, manufactured and tested according to ASTM F432-95 standards.The face plate’s capacities are designed to meet the custom-ers’ requirements.

Hard rock conditionsIn hard rock, where the anchorage capacity is often exceeding 200 kN per metre of anchorage length, the load that is transferred on to the face plate is rarely more than 50 kN, as friction on the profile takes over most of the loading from the rock mass.

Hanging featureMost face plates types can be specified with a hole or notch to be used to hang light and non-vibrating or oscillating services. The suffix “L” is then added to the plate description to indicate the presence of such a hole or notch. This added feature does not reduce strength specifications, but it should not be attempted to hang heavy or vibrating services as the long term capacity of the rock bolt could be dramatically reduced.

Face plates with lance Face plates with a bent corner

Soft ground conditionsIn softer ground conditions and broken rock masses, the load transferred onto the plate is much higher as the rock mass close to the borehole collar tends to yield more freely and exert a direct load-ing over the plates.

Accordingly, the high strength face plates are de-signed for high convergence conditions and poten-tially dynamic conditions. In low stress or loading conditions, regular strength face plates can be used efficiently and safely as proven by years of usage in the tunneling and mining industries.

Swellex face plates

48

Swellex Pm12, Mn12 face platesRegular strength ¬ ¬ ¬Name General Suitable conditions Data Product numbers

Std SWX plate

Traditional spherical domed plates

Normal ground conditions with low to medium stress level & small convergence

Steel: Domex 600 / Plate size: 151x151 mmHole size: 29x39 mm ± 5 mmMin. mtrl. thickness: 3,8 mmMin. breaking load: 89 kN ASTM grade 2

Standard 3125 5655 03

Bent corner 3125 5655 01

Lance -

VR12 / VR12L

Domed plates Normal ground conditions with medium stress levels & small convergence.

Steel: HSLA Gr 75 ksi / Plate size: 151x151 mm Hole size: 30,2 mm ± 0,3mmMin. mtrl. thickness: 3,8 mmMin. breaking load: 110 kN ASTM grade 2

Standard 9899 7006 32

Bent corner -

Lance 9899 7012 90

D12/D12L Low profile plate with a ridge

Normal duty applications.Normal ground conditions with low stress levels & small convergence.

Steel: HSLA Gr 75 ksi / Plate size: 151x151 mmHole size: 30,2 mm ± 0,3mmMin. mtrl. thickness: 3,8 mmMin. breaking load: 100 kN ASTM grade 2

Standard 9899 7006 31

Bent corner -

Lance 9899 7012 89

NR12 Low profile domed plates

Mining & tunnelling applica-tions. Normal ground conditions with low to medium stress levels & small convergence.

Steel: S355JR / Plate size: 151x151 mmHole size: 30,2 mm ± 0,3mmMin. mtrl. thickness: 4,0 mmMin. breaking load: 70 kN

Standard 9899 7014 18

Bent corner -

Lance -

F12 Flat plate Mining and tunnelling ap-plications and relatively even rock surfaces

Steel: S355JR / Plate size: 151x151 mmHole size: 30,2 mm ± 0,3mmMin. mtrl. thickness: 4,0 mmMin. breaking load: 70 kN

Standard 9899 7012 91

Bent corner -

Lance 9899 7012 92

High strength ¬ ¬ ¬ ¬ ¬

VS12 Domed plates Normal ground conditions with high stress levels & important convergence.

Steel: HSLA Gr 75 ksi / Plate size: 151x151 mmHole size: 30,2 mm±0,3mmMin. mtrl. thickness: 4,8 mmMin. breaking load: 142 kN ASTM grade 3

Standard 9899 7006 33

Bent corner -

Lance 9899 7012 97

NS12 Low profile domed plates

Mining & tunnelling applica-tions . Normal ground condi-tions with high stress levels & important convergence.

Steel: S355JR / Plate size: 151x151 mmHole size: 40 mm±0,3mmMin. mtrl. thickness: 5,0 mmMin. breaking load: 100 kN ASTM grade 2

Standard 9899 7014 20

Bent corner -

Lance -

Swellex Pm16, Pm24, Mn16, Mn24 face platesRegular strength ¬ ¬ ¬

Name General Suitable conditions Data Product number

Mn face plate

Traditional spherical dome plates

Normal ground conditions with low to mediuim stress levels & small convergence

Steel: Doomex 600 / Plate size: 151x151 mm Hole size: 39x44 mm ± 0,5 mmMin. mtrl. thickness: 3,8 mmMin. breaking load: 89 kN ASTM grade 2

Standard 3125 5655 13

Bent corner -

Lance -

NR24 Domed face plates Normal ground conditions with low to medium stress levels & small convergence.

Steel: S355JR / Plate size: 151x151 mmHole size: 40 mm ± 0,3mmMin. mtrl. thickness: 4,0 mmMin. breaking load: 100 kN ASTM grade 2

Standard 9899 7014 21

Bent corner -

Lance -

VR24 / VR24L

Domed face plates Normal duty applications. Normal ground conditions with low stress levels & small convergence.

Steel: HSLA Gr 80 ksi / Plate size: 151x151 mmHHole size: 40 mm ± 0,3mmMin. mtrl. thickness: 4,1 mmMin. breaking load: 90kN ASTM grade 2

Standard 9899 7012 95

Bent corner -

Lance 9899 7012 96

High strength ¬ ¬ ¬ ¬ ¬

VS24 / VS24L

Domed face plates developed for the North American market

All ground conditions and especially for high stress & convergence.

Steel: HSLA Gr 75 ksi / Plate size: 151x151 mm Hole size: 40 mm ± 0,3mmMin. mtrl. thickness: 5,4 mmMin. breaking load ASTM: 144 kNMin. breaking load, bushing: 200 kN ASTM grade 3

Standard 9899 7006 34

Bent corner -

Lance 9899 7012 98

Swellex rock bolts


49

Swellex installation pumps

The installation system for Swellex rock bolts con-sists of a high pressure water pump coupled with an inflation chuck that is pushed over the bolt’s head bushing to conduct the water flow from the pump to the inside of the bolt. The water pumps used for this operation are high pressure pumps that can rapidly and safely deliver the 300 bars constant pressure specified for a perfect instal-lation. The inflation chuck is a safe and simple system that grips and injects the water inside the bolt. Once the inflation is completed, the pressure is released manually, or automatically, like with the electric and hydraulic versions of the pump.

How to choose the right Swellex pumpWhen choosing between a pneumatic, electric or hydraulic pump, the user should know the avail-ability of water, air and electricity in the locations where the pumps will be used. Comparison of the various input requirements with the available services is necessary in order to make an educated choice on the best type of pump to use. Installation with a hydraulic rig tends to favor the hydraulic pumps but the electric and pneumatic pumps can still be an option as they can be easily installed on most rigs and more rudimentary bolting equip-ment. Flexibility requirements can also affect the choice of the pump as the operator may need a pump that can be used in various environments that do not always have all the same service avail-ability.

Finally, hydraulic and electric Swellex pumps have the lowest maintenance costs of the three types available at Atlas Copco.

The diagram provided to the right can help to evaluate the pump that best suits the performance requirements of the bolting operations, in term of inflation time.

Inflation chuck

Comparison of performance between different Swellex pumps

for Pm/Mn24

75

100

125

e [S

ec.]

PSP

0

25

50

75

1,5 2,4 3 4 6

Infla

tion

time

Bolt length [m]

E1H1/HC1

50

Swellex pump PSP 240/300The pneumatic Swellex pump PSP 300 is a well-proven high pressure water pump for Swellex rock bolt installations. It has an integrated pump unit, which is a pressure booster consisting of a double acting air cylinder connected to a water pump by means of a common piston rod. It requires an inlet air pressure of 5 bar to inflate bolts up to 300 bar. The expansion time for a 4.0 m long Standard Swellex rockbolt is about 70 seconds.


Description Weight (kg)

Product number

PSP 300 Std. (No inst. arm incl.) 30.0 8613 2421 30

PSP 300 (Inst. arm, 1.6 m incl.) Manometer and Chuck Pm/Mn12 38.5 8613 2411 32

PSP 300 (Inst. arm, 1.6 m incl.) Manometer and Swellex Chuck for Pm/Mn16, Pm/Mn24 incl.

39.0 8613 2411 33

Description data

Max. working pressure for water 300 bar

Max. working pressure for air 5 bar

Air consumtion at 5 bar, average 53 l/s

Max. inlet water pressure 3 bar

Connections air Claw coupling (1/2")

Connections water Hose coupling (1/2")

Noice level at op. ear, 4 m away Below 96 dB (A)

Vibrations in the installation arm Not measureable

Depth x width x height 280 x 850 x 320 mm

Weigth installation arm with valve and chuck

6.5 kg

Technical data



Product number

Chucks

Swellex chuck Pm/Mn 12 1.0 8613 2441 05

Swellex chuck Pm/Mn 16 & 24 1.4 8613 2440 07

Installation arms with chucks

L=1,6 m for Pm/Mn 12 11.0 8613 2431 07

L=1,6 m for Pm/Mn 16 & 24 12.0 8613 2430 09

L=1,6 m with manometer for Pm/Mn 12 12.0 8613 2430 18

L=1,6 m with manometer for Pm/Mn 16 & 24 13.0 8613 2430 19

Accessories

Productivity characteristicsS � turdy, yet light construction.Suitable for work in hard and demanding under �

ground conditions. High availability / reliability. �

Areas of useThis simple and yet high performance pump is especially suited for:

Bolting where electricity is not widely available �Manual installation of Swellex rock bolt with �

various equipmentsRelatively low bolts consumption �

51



Productivity characteristicsTo be used with hydraulic rigs. �Short inflation time. �Simple and robust. �Quality of installation is assured with the HC1. �

Swellex pump H1 and HC1The hydraulic Swellex pump H1 is designed to be used with hydraulic bolting rigs. The H1 is robust and reliable. It can be used with a manual instal-lation arm or it can be integrated with the rig's installation system. Swellex H1 hydraulic pumps are only available in stainless steel version to resist corrosion, provide a long life expectancy and low operating costs. The HC1 version has been designed to assure the quality of installation by controlling the inflation until the required pressure is reached. It then maintains this pressure for a set period of time so the bolt is fully expanded around the irregularities inside the borhole and the best anchorage capacity and a perfect installation is granted.

When Swellex HC1 is used with a drill rig equipped with the CANBUS control system, an optional function is available for recording number of bolts installed and inflation pressure.

Technical data Description H1 HC1

Product number 8613 1101 87 8613 1100 42

Weight 36 kg 38 kg

Max. inlet water pressure 20 bar

Max. otlet water pressure 320 bar

Max. water temperature 70 ºC

Max. water consumtion 17 litres/min.

Hydraulic pressure 150 - 250 bar

Hydraulic flow 40 litres/min.

Vibrations in the instal. arm Not measureable

Electric voltage - 22V max. 28V DC

Power consumption Max. 2A

CE marked yes yes

Dimensions (L x W x H) 550 x 280 x 270 mm

Weight installation arm with valve and chuck

6.5 kg

Areas of useSwellex hydraulic pumps are preferred when high bolting performance is required.

To be used with hydraulic rigs. �With the HC1, the inflation process is fully con �

trolled by the pump system and is not affected by human factors.


Product number

Chucks

Manual installation chuck for Pm/Mn 12 1.0 8613 2441 05

Swellex chuck Pm/Mn 16 & 24 1.4 8613 2440 07

Installation arms with chucks for manual installation

L=1.6 m for Pm/Mn 12 11.0 8613 2431 07

L=1.6 m for Pm/Mn 16 & 24 12.0 8613 2430 09

L=1.6 m with manometer for Pm/Mn 12 12.0 8613 2430 18

L=1.6 m with manometer for Pm/Mn 16 & 24 13.0 8613 2430 19

L=1.6 m HC1 arm for Pm/Mn 12 13.0 8613 1102 10

L=1.6 m HC1 arm for Pm/Mn 16 & 24 14.0 8613 1102 20

Upgrade kit for conventional Swellex arm 2.0 8613 1102 07

Hydraulic Hose/cable set 5 m for HC1 2.0 8613 1102 12

Accessories

52

The electric Swellex pump E1 is a fast and quiet, high pressure water pump. It has an electrically driven Triplex plunger pump for up to 320 bar installation pressure. The main advantage is that the flow delivered by the pump is independent of the water pressure and thus speeding up the bolt expansion process. The expansion time for a 6.0 m long Mn24 or Pm24 rockbolt is less than 60 seconds. The pump is equipped with electric main switch, a pressure sensor on the incoming water side and an outlet pressure sensor with signal light. The outlet pressure from the pump can easily be adjusted via a pressure switch. The pump can also be used as a high pressure washing unit when used with Atlas Copco dedicated washing nozzle.

Swellex installation pumpsSwellex E1



Product number

E1 400 VY Europe 80.0 9899 7007 07

E1 200/220 VD Japan 80.0 9899 7007 06

E1 440 VY, CE-60Hz Japan 80.0 9899 7007 08

E1 480 VY, CSA 60 Hz 80.0 9899 7007 09

E1 525 VD, CE 50 Hz South Africa 80.0 9899 7007 10

E1 575 VD, CSA 60 Hz 80.0 9899 7007 11

Ext. hose for arm, 5 m long 2.0 8613 1100 06

Description data

Max. working pressure for water 320 bar

Suppy water pressure 2 - 20 bar

Max. supply water temperature 40 ºC

Flow rate 12 litres/minute at 50 Hz

Connections water Claw coupling (1/2")

Noice level at op. ear, 4 m away Below 60 dB (A)

Vibrations in the installation arm Not measureable

Depth x width x height 450 x 775 x 450 mm

Weigth installation arm with valve and chuck

6.5 kg

Technical dataDescription Weight

(kg)Product number

Chucks

Manual installation chuck for Pm/Mn 12 1.0 8613 2441 05

Manual installation chuck for Pm/Mn 16 & 24 1.4 8613 2440 07

Installation arms with chucks for manual installation

L=1.6 m for Pm/Mn 12 11.0 8613 2431 07

L=1.6 m for Pm/Mn 16 & 24 12.0 8613 2430 09

L=1.6 m with manometer for Pm/Mn 12 12.0 8613 2430 18

L=1.6 m with manometer for Pm/Mn 16 & 24 13.0 8613 2430 19

Accessories

Productivity characteristicsCan be used with any types of rigs or equipment �

where electricity is available.Can be ordered with required current and voltage �

requirements.Robust with short inflation time. �

Areas of useSwellex Electric pump E1 is the favourable tool when high performance bolting is required with various types of rigs and equipment.

Can be used with hydraulic rigs or others. �Can be used for manual or mechanized bolting. �The pump is equipped with a time control system �

so the inflation process is unlikely to be affected by human factors.

53

Quality assurance

The quality assurance consists of:Letter of compliance �Quality control stamps �Pressure gauges �Pull testers �Steel sleeves �

Quality control stampsThe alphanumerical code stamped on the bushing of every Swellex rock bolt manufactured by Atlas Copco allows the product to be quality con-trolled from the steel mill up to the manufacturing day. Quality control stamp on each head


Atlas Copco Swellex products are all manufactured according to strict ISO rules. Stringent incoming quality control assures high quality materials are used. Extensive quality testing is performed to assure that the products are adequate for the Atlas Copco brand.

Letter of complianceThe letter of compliance is Atlas Copco's guaranty to the customer that the quality and performance of the products meet the required standards and specifi cations. If required by a customer, the letter of compliance can be issued for a particular order but Atlas Copco also provides a standing letter of compliance that states that all our products meet the specifi cations they are built for. It is a promise that Atlas Copco delivers what it claims. And it is the fi nal step of the quality assurance process, as it seals the whole QA process into one fi nal certify-ing document.

Letter of complicance

Letter of compliance No.

Buyer: Date:

Order:

Shipment number:

Swellex ® Pm12 rockbolts

Swellex Pm12 rockbolts are manufactured with a specially developed steel within the S355MC specifications according EN 10 149. Swellex Pm12 rockbolts meet or exceed the breaking load, yield load and elongation specifications stated below.

The production quality is continuously monitored and evaluated. Each bolt is marked with an individual batch number. The documentation system makes it possible to trace the bolt all the way back to the steel mill.

Swellex rockbolts are designed, manufactured and tested to meet ASTM F 432 Standard. Swellex rockbolt production is ISO 9001 certified.

Specification - Swellex® Pm12

Technical data

Type of steel............................. ……………S355MC Minimum breaking load……………………….120 kN* Minimum elongation A 50..……….…………….. 15 % Minimum yield load......……………………….100 kN Installation pressure..…………..……………..30 MPa

* According to EN 10 002

General data

Profile diameter………………….…………. 27 mm Material thickness……………………………..2 mm Original tube diameter……………………….41 mm Upper bushing………………………….…… 28 mm Recommended bore hole diameter.…32 – 39 mm

ATLAS COPCO MAI GmbH

Werkstrasse 17 A-9710 Feistritz/Drau

Quality pressure assurance gaugeThe pressure gauge for quality assurance is a simple tool designed to be used by the operator to verify the pressure delivered by the pump. It is to be used at the beginning of the shift or at any time when there is a doubt regarding the infl ation pres-sure delivered to the Swellex.

Pressure gauge for Pm12, Mn12


Product number

QA pressure gauge Ø 30 mm 0.9 8613 1101 01

Pressure gauge for Pm16, Pm24, Mn16, Mn24


Product number

QA pressure gauge Ø 40 mm 0.9 8613 1101 02

Gauge

54

Pull testerHydraulically operated test equipment with digitally displayed test results.

Atlas Copco Swellex products are the easiest to test for installation quality and random quality testing thanks to the original adapter that allows to pull-test any Swellex bolt at anytime, without spe-cial set up during the bolt installation. Accordingly, new and old Swellex bolts can be tested with the same ease. Atlas Copco provides a complete pull tester set for the customer's convenience.

The Swellex pull-tester is designed to meet the highest demands on accuracy and portability that professional users in the mining and tunnelling industry put on a measuring instrument of this type. With Swellex pull-tester you can test any installed Swellex bolt. The adapter sleeve grips around the head of the bolt when you set up the equipment and you do not have to prepare a bolt for pulltesting prior to installation. This means that you can easily pull test bolts installed a long time ago. You can pull-test bolts with or without face plates.

Pull test equipment


Product number

Pull tester complete 62.0 8613 1108 00

Mechanical parts for pull tester 22.3 8613 1108 01

Pull tester hose, 700 bar, 6m 2.1 8613 1108 80

Quality assurance


Pull tester

Steel sleevesWhen performing non destructive sliding tests to estimate the specific anchorage capacity of Swellex bolts in a given rock type or rock mass conditions, it is customary to use steel sleeves passed over the profile to reduce the effective anchored length, thus enabling to slip out the bolt without failure. Atlas Copco can also provide those sleeves for the customer convenience.

Steel sleeves are an important tool when perform-ing anchorage capacity pull tests. These tests are done to verify that the rock bolt can provide the necessary retaining force to hold the rock in place.

Steel sleeves provided for performing anchorage capacity estimation

Swellex Pm12 bolts


Product number

Sleeve, length 300 mm 0.5 9899 7014 54

Swellex Mn12 bolts


Product number

Sleeve, length 300 mm 0.5 9899 7014 54

Swellex Pm16, Pm24, Mn16, Mn24 bolts

Description Weight(kg)

Product number

Sleeve, length 300 mm 1.0 9899 7006 76

55

Mesh washersThe Swellex Mesh Washers are used for instal-lation of wire mesh on already installed Swellex rock bolts. This special friction washer is pushed over the inflation bushing head and can carry over 10 kN. Care must be taken that the washer is pushed straight over the bushing head and that the teeth of the hole are not broken or bent during the process.

Swellex accessories

Mesh washer installation

Mesh washers

Swellex mesh washers

Description Adapted to Outer Ø(mm)

Capacity(kN)

Product number

Circular mesh washer

Swellex Pm12Swellex Mn12 100 10 3125 5400 00

Description Adapted to Dimensions(mm)

Capacity(kN)

Product number

Square Mesh Washer

Swellex Pm12Swellex Mn12 125 x 125 10 3125 5492 00

Square Mesh Washer


Square Mesh Washer


Color plugs are designed to help differentiate the length of Swellex bolts once the bolts are installed in the excavation. When more than one length of Swellex bolts are used in the same excavation, col-our plugs are an easy and efficient way to perform quality control on the reinforcement system as they allow rapid identification of the bolt.

Colour plugs

Description Indicated bolt length

(m)

Product number

Colour plug, orange 1.2 - 1.5 9899 7004 19

Colour plug, natural 1.8 9899 7004 22

Colour plug, blue 2.1 9899 7004 20

Colour plug, green 2.4 9899 7004 21

Colour plug, red 3.0 9899 7004 23

Colour plug, white 3.6 9899 7004 25

Colour plug, yellow 4 - 5 9899 7004 24

Swellex colour plugs

Colour plugs

Atlas Copco Geotechnical Drilling and Explorationwww.atlascopco.com

6991

157

1 01

b M

ärst

a, S

wed

en, D

ecem

ber,

2008

© C

opyr

ight

200

8, A

tlas

Cop

co C

rael

ius

AB

, Mär

sta,

Sw

eden

. Any

una

utho

rized

use

or c

opyi

ng o

f the

con

tent

s or

any

par

t the

reof

is p

rohi

bite

d. T

his

appl

ies

in

parti

cula

r to

trade

mar

ks, m

odel

den

omin

atio

ns, p

art n

umbe

rs a

nd d

raw

ings

. Illu

stra

tions

and

pho

tos

in th

is b

roch

ure

may

sho

w e

quip

men

t with

opt

iona

l ext

ras.

S

peci

ficat

ions

and

equ

ipm

ent s

ubje

cts

to c

hang

e w

ithou

t not

ice.

Con

sult

your

Atla

s C

opco

Cus

tom

er C

ente

r for

spe

cific

info

rmat

ion.

atlas copco rock reinforcement products product … copco rock reinforcement products product...

Documents