dsi underground systems cable bolts us

Cable Bolts

Table of Contents Section

Mechanical Rock Bolts, Extension Bolts & Stelpipe Bolts 1

Rebar Rock Bolts 2

Cable Bolts 3

Friction Stabilizers & Expandable Bolts 4

Threadbar 5

Trusses & Slings 6

Specialty Bolts 7

Fiberglass Bolts 8

Resins & Cement Cartridges 9

Mesh, Straps & Plate Washers 10

Eyebolts, Scaling Bars & Utility Hangers 11

Tools & Hardware, Drilling Consumables 12

Lattice Girders, Steel Arches & Props 13

High Performance Grouts & Application Equipment 14

Drilling Fluids 15

Miscellaneous 16

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DYWIDAG-SYSTEMS INTERNATIONAL

DYWIDAG-SYSTEMS INTERNATIONAL

August 2012www.dsiunderground.com

DYWIDAG-SYSTEMS INTERNATIONALSection3-Page1

Minicage™ Cable Bolts (Plain & Bulb)

0.5", 0.6" and 0.7"

Plain Cable Bolt

Bulbed Cable Bolt

Dimensions

Physical Properties

Construction Details

August 2012 www.dsiunderground.com


Installation Accessories

Cable Bolts

End Holding Device - conventional style

• to hold cable bolt prior to grouting

• 2 straps 3/4" x 23/4" (19 mm x 70 mm)

• suitable for 2" (51 mm) to 2.5" (64 mm) hole

• can be ordered separately and site installed

• if factory ordered, straps removed for shipping

• not available for double cable bolts

End Holding Device - fish hook style

• hooks swaged on with steel tubing

• hooks can be bent out to accommodate

any hole size

• for single or double cable bolts

• fitting holds double cables together

0.5", 0.6" & 0.7" Machined Cable Grip - to fasten plates

• rated for full load of cable bolt

• Ø 11/4" (32 mm) for 0.5" cable bolts

• Ø 11/2" (38 mm) for 0.6" cable bolts

• c/w 2 part gripper wedges

• available galvanized

• optional plastic cap to secure wedges

during shipping

0.6" & 0.7" Cast Domed Cable Grip

- to fasten plates


• Ø 2" (51 mm) domed face

• c/w 2 part gripper wedges

• wedges available with or without

groove & retaining spring

• available galvanized

• optional plastic cap to secure wedges

during shipping



Passive Spinnable Cable Bolt - for resin installation

• 0.6" & 0.7" cable available

• resin anchored

• bulbs provide resin mixing and anchoring

• accepts 11/8" square or hex male spinner

• available plain or galvanized

• cable available in any length

• factory assembled

Strand Lok

• available with minimum 4 ton or 12 ton terminal

• easy installation, no cement to mix

• dissipates “impact shock”

• maintains bond between cable and resin grout

• enhanced one pass support

• bulge diameter and spacing variable

• ideal for confined spaces

• superior shear strength for one pass support

• higher ultimate tensile

• installed with “high strength low viscosity strand-loc resin”

• resin compressive strength exceeding 100 MPA

• Youngs modulus 11-13 GPA

• custom cartridge diameter and length

Installation Procedure

• drill a 1¼" hole to a depth which will allow the bolt to bottom out when fully inserted

• insert the Strand-Lok resin cartridges

• manually push the Strand Bolt into the resin to within 2' or 3' of full penetration

• Spin the Strand Bolt through the resin to complete the insertion and then continue spinning

for an additional 10 seconds at full insertion

• on tensioned installations allow sufficient time for the resin to gel and gain strength before torquing

Notes

• the 12 ton terminal is designed for where collar support is needed

• a recessed terminal has been designed to be used in close quarters where the

protruding termnal would be an obstruction

• a coupled extension drill steel has been designed to keep the "extension" drill

hole size at 1¼"

Installation Accessories continued



0.6" & 0.7" Dogbone Cable Coupler


• used to join cables for slings or trusses

• used to wrap failing pillars

• requires 2 sets of wedges (included)

Grout and Breather Tubing

• ¾" ID x 7/8" OD black poly tubing (400' roll)

• ¾" ID x 7/8" OD high density grout tubing (400' roll)

• ½" ID x 5/8" OD regular poly tubing (400' roll)

• 3/8" ID x ½" OD high density poly tubing (500' roll)

• black poly tubing rated for 100 psi

• yellow high density tubing rated for 200 psi

Installation Accessories continued



Cable Bolt

0.6" or 0.7" Passive and Tensionable

• 270 ksi, low relaxation cable per ASTM A416.

• Supplied in any length, black or galvanized cable.

• Point anchored active bolt, tensioned after

installation utilizing the hydraulic tensioning jack.

• Point-anchored passive bolt with pre-seated

head. Wedge barrel shaped to accept 11/8" hex or

square male spinner.

• Several options for anchoring in the resin are

available: The bulbed cable bolt is designed

for point-anchoring in resin. It may also be fully

grouted with slow speed resin, or cement grouts.

Bulbing is an effective means to center the bolt

in the drill hole, to mix the resin and to develop

bond for anchoring the bolt.

• The Bond head is an additional bulb that can be

formed on the end of the cable bolt.

• Bulbs are provided to fit hole sizes:

1" hole: strip cage

13/8" hole: plunge bulb

1¾" hole: bond head

• Ultra low passive heads can be provided for low

clearance situations.



CBJ-1 Cable Bolt Tensioning Jack

For installation of bearing plates

Specifications

• for 0.6" (15.2 mm) or 0.7" (17.8 mm) cable bolts

• maximum load 25 ton @ 10,000 psi (225 kN @ 70 MPa)

• stroke = 3" (75 mm)

• double acting hollow core ram

• aluminum construction - weighs only 10 lbs (4.5 kg)

• requires double acting hydraulic pump or hand pump

• L = 11.75" (300 mm)

• D = 4" (102 mm)

Parts

Seal Kit includes:

1 - 2.25" AN wiper

1 - 2.25" x 2.75" x 3.75" rod seal

1 - 1.25" x 1.75" x 0.250" rod seal

1 - 2.31" O-ring

1 - 2.875" T-seal

1) Regularly ensure autogripper is

screwed hand tight into the hollow

core ram.

2) Ensure the cable strand is free

from mud and dust. Also regularly

clean the autogripper wedges.



Torque Tension Relationship for CB1-1

Cable Jack with 3.4:1 Intensifier

Specifications

• for 0.6" (15.2 mm) or 0.7" (17.8 mm) cable bolts

• stroke = 3" (75 mm)

• double acting hollow core ram

• aluminum construction - weighs only 10 lbs (4.5 kg)

• requires double acting hydraulic pump or hand pump

• L = 11.75" (300 mm)

• D = 4" (102 mm)

0.6" Cable Tensioner with 3.4:1 Intensifier Pressuer Vs Load (LBF)

2000 Psi Maximim Working Pressure

Note

• cylinder area = 5.01 in²

• 2000 psi is the maximum pressure allowed for use with 0.6" cable

0 250 500 750 1000 1250 1500 17500

5,000

10,000

15,000

20,000

25,000

30,000

35,000

2000



Operating Procedure

For intensified cable truss tensioner

of the dogbone/wedge barrel.

A minimum of one inch of cable tail should

protrude from the end of the autogripper

assembly. (If the cable does not protrude

from the back of the tensioner the minimum

one inch length the jaws will not grip the cable

properly. There is significant risk that the cable

will strip the wedge teeth).

• Pressurize the cylinder to the desired load

(2,000 psi/17 ton maximum for the 0.6” x 30

ton cable – see appendix 1 for a pressure

versus load plot). If the cylinder runs out of

travel before the load is reached, release the

pressure and slide the cylinder on further and

repeat the tensioning process.

• The following wear components are available

for purchase from your local DSI supplier

(appendix 2):

• Autogripper assembly

• Autogripper wedges

• O-Ring kit

• Banana Nose

• Ensure that all hydraulic fittings are tightened

before operation, and that the unit is in good

working order. Check the following:

• There are no major dents in the housing.

• That the autogripper assembly (gold in color)

is fully tightened against the face

of the piston.

• That the autogripper wedges are in good

condition and are not chipped, dented or

missing teeth.

• That there are no major leaks in the system.

• Monitor during use the following

• The autogripper remains screwed in tight

against the face of the piston

• The gripper wedges do not become too dirty

• That the wedge teeth do not wear too badly.

The autogripper wedges are designed for

reuse, but eventually need replacing.

• Before placing the tensioner onto the cable,

ensure the cable has minimal dirt and or dust on

its surface. This dirt and dust will make it harder

for the wedges to grip the cable.

• Slide assembly onto the tail of the cable until the

tensioner nose is fully seated against the wedges



Cable Tensioner Mark2

For tensioning cables and installing plates

Specifications

A light weight and unique way for pre-loading

cable bolts, the DSI Cable Tensioner Mark2 grips

the end of the cable bolt and tensions it, leaving

only a short tail protruding from the bearing plate

(approx. 6"). The Cable Tensioner is a single

hydraulic ram driven by an air/hydraulic pump or by

machine hydraulics.

• The jack weighs 25 lbs. The entire kit (jack

and pump) weighs 51lbs.

• Two grip handles allow for operation by

one person.

• Unit locks on the cable, until lanyard is pulled

to release spring loaded grippers.

• Can be configured for all cable bolts, from 0.6"

to 0.7" and the DSI 0.9" HITEN cable bolt.

• Capacity: 48,500 lbs

• Bleed off: 15% i.e. cable lock-off load is 85%

of pulling force due to seating loss.

(for a typical 12' bolt)

Operation

Install the plate and wedge barrel with wedge on

the end of the cable bolt.

Push the Cable Tensioner on. It will self-lock onto

the cable.

Tension bolt to the desired load per hydraulic gage

included with the unit.

After stressing, the Cable Tensioner is easily

removed by pulling on the lanyard to release the

internal grippers.



Installation Guidelines

• 28mm hole diameters are preferred.

• Hole depth is critical. Hole depth should

be approximately 155mm shorter than

the bolt length.

• This allows for sufficient tail to fit accessories,

roof plate, collar/wedges & Tensioner Unit.

• After insertion of the chemical anchors the

bolt is rotated through the anchors while

pushing the bolt, fully, to the back of the hole.

• It is important to follow the chemical

manufacturers recommended mixing and

hold times as printed on the chemical

anchor cartons. DO NOT OVER MIX.

• The tensioner unit is connected to the HI-

TEN Strand Bolt and tension applied.

• For further details refer to DSI’s Tensioner

Unit user instruction guide.

Standard Lengths & Packaging

• Standard HI-TEN Strand Bolts lengths

range from 4100 to 8100mm.

• Collar/wedge assemblies are

supplied separately to the bolt.

• Non-standard requirements are

available by negotiation.

HI-TEN Strand Bolt

General Features

• The DSI HI-TEN Strand Bolt is a cable

designed to be installed as a long rock bolt

which is capable of being post-tensioned

at the face, or out-bye, to loads of up to

27 tonnes using the DSI Tensioner Unit.

• The HI-TEN Strand Bolt is manufactured

from 21 wire strand having a 12mm square,

for mixing chemical anchors, welded to one

end of the strand.

• The HI-TEN Strand Bolt has a special collar

and segmented wedge, which can sustain

collar loads of between 57 and 60 tons.

• The HI-TEN Strand Bolt is designed for high

pre-tensioning using a point anchor system.

• If full encapsulation is required, extra

slow speed chemical anchors of 20

minutes set time are available.

• The HI-TEN Strand Bolt can also be

effectively used with cementitious grouts.

• The HI-TEN Strand Bolt concept allows a

longer than seam height bolt to be installed

at up to 30° from the vertical at the face,

or out-bye, to supplement existing strata

reinforcement. Compatible domed plates

are available to be used with the

HI-TEN Strand Bolt.

• The HI-TEN Strand Bolt system

is patent pending.



The Wedge Anchorage of the Cable Bolt

The anchorage of most cable bolts consists of a

wedge barrel and a 2- or 3-part wedge. The wedge

segments grip the cable by means of tooth shaped

threads which are forced into the surface of the

cable wires.

Warning: If friction increases (due to corrosion),

a larger F will reduce the clamping force. As V

increases all other forces can only increase if the

wedge can seat deeper into the barrel. If the wedge

is restrained to do so (i.e. by corrosion or dirt-

accumulation), the clamping force can not increase

with the pulling force causing slippage when the

load on the cable bolt gradually increases during

service life.

To avoid slippages during use, it is important that

the cable bolt is fully stressed at time of installation

to a force equal to 0.5 Fu. (i.e. 50% of the capacity

of the cable)

The clamping force W is highly dependent on

the friction between wedge and wedge hole. For

normal friction conditions, the clamping force W is

more than 4 times the cable pulling force V and it

adjusts with the pulling force V.

When a wedge is properly seated, radial cracks

may develop indicating adequate seating.

The wedge can be supplied with a rubber

O-ring or a metal spring ring holding the wedge

segments together.

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