minova mai self drilling systems

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Minova MAI Self Drilling SystemsInstallation Manual

THE EARTH. UNDER CONTROL.

2© 2018 MINOVA GLOBAL. ALL RIGHTS RESERVED

Preface Please read this installation manual carefully before using this product to ensure a safe and successful installation of the Minova MAI Self Drilling Systems and any applicable accessories (collectively, the “Prod-ucts”). Every person involved in the installation and assembly must strictly observe not only this manual and operating instructions but also the safety and accident prevention rules and regulations valid at the place of use.

DANGER! Incorrect storage, assembly, installation or use of the Products may endanger life and limb of the operator, support personnel and third parties or cause damage to the drill rig or other important auxiliary equipment. It could also potentially result in negative effects on the stability of the entire structure.

Warranty and Liability

• Our General Terms and Conditions apply to all Product sales and set forth Minova’s warranty and limit its liability. At the latest the purchaser will receive a copy upon conclusion of the sales contract. • Please note that the manufacturer’s warranty is no longer valid if the Products are not used in compliance with these instructions. Among others, any of the following will invalidate the warranty:

• Improper storage • Incorrect assembly • Incorrect installation • Useofanycomponentpartoranyaccessorywhichisnotidentifiedasagenuine Minova Product or which is not included in the Minova Products delivery • Failure to observe the instructions of this manual • Insufficientmonitoringofdrillingrigcomponentssubjecttowear • Unauthorized structural changes to the product, including welding, cutting, bending and/or application of any coating method (e.g. galvanization) • Unforeseendisastersduetoexternalinfluencesorforcemajeure • The installation or use of any Product that is obviously damaged or in poor condition

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Safety instructionsAny failure to follow this manual and applicable safety regulations could compromise safety and Product performanceandmustberectifiedimmediately.Usershouldkeepacopyofthisinstallationmanualavailable on site at all times.

Operating personnel

1.Qualification:Mentalandphysicalfitness,abletoresponsiblyandreliablyperformtheassignedtasks.Proofoftherequiredcapabilitiesandtheexplicitpermissionbytheexecutingcompanytocarryoutthework.Theminimumageofmachineoperatorsis18years.

2.Onlytrained,instructedandexperiencedpersonnelmayworkwiththeProducts.Thepersonor persons responsible for assembly, installation and installation procedures must be clearly definedbeforecommencingwork.

3.PersonnelintrainingmayonlyworkwiththeProductsunderthesupervisionofexperiencedspecialized personnel.

General safety instructions

1.Alwayswearapprovedpersonalprotectiveequipment(PPE)forhands,feet,eyesandears whenworkingwiththeProductsoranydrillrigorinitsvicinity.Theuserwhoisassemblingand installingtheProductsmustensureallinvolvedhaveandusetherequiredand appropriate PPE. All existing safety devices associated with the drill rig must be regularly checkedandtestedinordertoensuretheircorrectfunction. 2.DonottouchanyrotatingpartsoraccessoriesduringtheinstallationoftheProducts.Make sure that the drill hammer cannot be accidentally started during assembly and installation of the Products. 3.Ensurethattheflushingandgroutinghosesarelaidoutwithoutkinksanddonotrunover sharp edges. For changes in direction, the bending radius must be at least six times the outer hose diameter.

WARNING! Injectionpumpsarehigh-pressurepumps–useonlyreinforcedhoses and a manometer!

4.Priortocommencingwork,theusermustmakesurethataworkablegroutmixisreadyforuse,thatthehoseiscompletelyleak-freegivingspecialnoticetotheconnections,andthattheinsi-deofthehoseissufficientlymoist.

5.Priortolooseninganyconnectionswithinthegroutingandflushingsystem,e.g.pumps,hosesetc., ensure that these have been depressurized.

6.Donotoperateanyflushingorgroutingpumpwithoutamanometer.


Introduction

CAUTION! - Please note!

Before installing or using the Products, carefully read the section “Safety Instructions” on the preceding page of this manual so as not to endanger life and limb of the operator, support personnel or any third party,aswellastopreventdamagetothedrillingrigorotherauxiliaryequipment.

Theinstallationmanualassumesthattheoperatorhasasolidunderstandingandworkingknowledgeofdrilling and grouting operations.

Misuse or improper assembly, installation or use of the Products will invalidate all waranties and release Minova of any liability.

Proper use

For layout, assembly and installation of the Products, the standards and regulations valid at the place of use apply. All structures must be so designed to provide redundancy.

Soil and rock nailing

SoilandrocknailingisaconstructionmethodusedtomaintainorenhancethestabilityofsoilorrockmassesbyinstallingSoilorRockNails(anchors)inaccordancewiththeprovisionsoftheexecutionofgeotechnicalworks.Anchorages(sometimesincombinationwithotherelementssuchasshotcrete,drainagesystems,retainingwallsetc.)createasupportingstructureofreinforcedsoil/rockmass,whoseanchorsareprimarilysubjectedtotensilestress.Inaddition,theymayalsobesubjectedtobendingandshear stress.

ThegeneralpriniciplesfortheexecutionofsoilnailingarespecifiedinEN14490.

The Minova MAI Self Drilling System may be used for:

• TemporarySoilandRockNails:Servicelifeofupto2years• PermanentSoilandRockNails*:Servicelifeofupto50yearsandmore,dependentontheground

conditions with or without additional corrosion protection

Typicalsoilorrocknailingapplicationsinclude:

• Stabilization of slopes and construction pits• Tunnelling (forepoling, spiling, face bolting, radial bolting)

* InordertoreducethecorrosionrateMinovaMAISelfDrillingSystemsarealsoavailablewithhot-dipgalvanizationorTwinCoat coating. For additional information, please refer to the Minova MAI Product Catalogue and the Minova MAI Design Guide.

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Dimensions TypesR25 R25NR32 R32L, R32N and R32SR38 R38NR51 R51L and R51N


Micropiles

Micropiles are load-bearing elements transferring tensile, compressive or alternating loads into the ground.Inaddition,theymayalsobesubjectedtobucklingloads,inparticularinsoftground.

ThegeneralprinciplesfortheexecutionofmicropilesarespecifiedinEN14199.

The Minova MAI Self Drilling System may be used as Self Drilling Micropiles for:

• Temporary micropiles: Service life up to 2 years• Permanentmicropiles*:Servicelifeofupto50yearsandmore,dependentontheground

conditions with or without additional corrosion protection.

Typical micropile applications include:

• Foundation of new structures• Underpinning of existing foundations• Buoyancy control for structures below ground water level• Root piles in tunnelling

The system offer for Micropiles comprises the following dimensions and types:

* InordertoreducethecorrosionrateMinovaMAISelfDrillingSystemsarealsoavailablewithhot-dipgalvanization or TwinCoat coating. For additional information, please refer to the Minova MAI Product Catalogueand the Minova MAI Design Guide.

Dimensions TypesR32 R32N and R32SR38 R38NR51 R51L and R51NT51 T51S

T76 T76N and T76ST111 T111L and T111N

ThesystemofferforSoilandRockNailscomprisesthefollowingdimensionsandtypes:


The Minova MAI Self Drilling System can be used bothasSelfDrillingSoilandRockNail(SRN)oras Self Drilling Micropile (MIP). It offers reinforce-ment solutions for unstable ground conditions such as sand, gravel, silt, clay and soft to medium hard andfracturedrock.Forprojectsfacingsuchgroundconditions, the Minova MAI Self Drilling System pro-videsanefficientandcost-effectivereinforcementsolution.

The system features a hollow bar, which is used as adrillstringfordrillingeitherwithwaterflush,airflushorcementgroutflush.Thehollowbarisfittedwith a left-hand or right-hand R-thread or T-thread for easy extension and connection to conventional rockdrillingequipment.

The hollow bar is manufactured from seamless or welded steel tubes. The R-thread according to ISO standards and the T-thread according to factory standard are formed in a cold rolling process.

The hollow bars can be extended using couplers. Our patented standard couplers ensure a safe connection of the hollow bars to optimally transfer the impact energy from the drill hammer to the drill bit.Asealingringinthecentrestopminimizesflushspillage during drilling.

The nuts are manufactured with a spherical cap on at least one end to compensate for deviations of the borehole angle with respect to the plate surface.

Thedomedorflatplatesfeatureachamferedboretoensurefirmseatingofthenut.

All system components are rigorously tested ac-cordingtostringentfactorystandardsandISO9001toensurethatthespecificationsaremet.

Thesacrificialdrillbitsignificantlyenhancestheproductivity of the installation process. In order to improveperformanceandcost-effectiveness,proj-ect data are being collected from around the world. Continuous optimization of our drill bits is a primary concern to further improve the penetration rate and bitqualitywhileatthesametimereducingmanufac-turing costs.

For an improved corrosion resistance, Minova MAI Self Drilling System components are either hot dip galvanizedorfittedwithaTwinCoatcoating(hot-dipgalvanization with an additional dual epoxy coating).

Product lines with and without technical approvals are available.

Minova MAI Self Drilling Soil and Rock Nail and Micropile Systems

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© HABAU Hoch- und Tiefbau Gesellschaft mbH

The system consists of the following components:

Nutsforanchoringandlocking

Flat plates or domed plates for connection to the structure

Protection tube

Hollow bars of various diameters with rolled continuous left-hand or right-hand thread, available in

standard lengths of 1m, 2m, 3m, 4m and 6m

Couplers to connect and extend the hollow bars, with a centre stop

for improved load transfer and sealing

Spacers

Grout or cement

Drill bits of various diameters and typestofittherespectiveground

conditions

Soil Nail Micropile


CE-certifiedsystems(withEuropeantechnicalassessments)

SoilandRockNails• EuropeanTechnicalAssessmentETA-08/0277

Micropiles• EuropeanTechnicalAssessmentETA-11/0134

Value systems (without technical approvals)

• Systems with R-threads (typically used as SoilandRockNails)

• Systems with T-threads (typically used asMicropiles)

National Technical Approvals

SoilandRockNailsAustria• BMVIT-327.120/0014-IV/IVVS2/2016

Micropiles Austria• BMVIT-327.120/0015-IV/IVVS2/2016

SoilandRockNailsGermany• National Technical Approval for temporary soil

androcknailsDlBtZ-34.713-080277

SoilandRockNails,MicropilesPoland• AT/2016-02-3278

©Geomek

Our product range of Self Drilling Systems comprises the following product lines:

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Minova MAI Self Drilling Soil and Rock Nails SRN

MinovaMAISelfDrillingSoilandRockNailsconsistofaself-drillinghollowbarwitharolledcontinuousthread as load-bearing element embedded within a grout body.

Theyarepredominantlysubjectedtotensilestress,butmayalsobesubjectedtobendingandshearloads.

Ingeotechnicalengineering,SoilandRockNailsareusedtostabilizenaturalorartificialslopesortosupport structures e.g. retaining walls.

Inordertofurtherstabilizethesurfaceoftheslopeorrock,varioussupportsystemse.g.flexiblereinforcingmeshes or geotextiles may be installed that are held in place by the head plates of the nails.

Inundergroundapplications,SoilandRockNailsarepredominantlyusedforforepoling,spiling,facebolting and radial bolting.

Inbothcases,theMinovaMAISelfDrillingSystemsprovideidealsolutionsforweak,unstableorcrackedgroundconditions.SoilandRockNailsaretypicallygroutedalongtheirentirelength.

©SST-SchusterSprengtechnikGmbH



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Minova MAI Self Drilling Micropiles MIP

Micropilesaresmalldiametergroutedpiles(typicallylessthan300mm)transferringcompressive,tensileoralternatingloadsintothesurroundingground.Inaddition,theymayalsobesubjectedtobucklingloadsin particular in soft ground.

Minova MAI Self Drilling Micropiles consist of a self-drilling hollow bar with a rolled continuous thread as load-bearing element that is embedded within a grout body. Dependent on the ground conditions, Self Drilling Micropiles are designed either as end-bearing or friction piles.

The main areas of application include:

• Foundation of new structures• Underpinning of existing foundations• Minimizing settlements• Buoyancy control for structures below groundwater level

Self Drilling Micropiles are typically installed via simultaneous drilling and grouting using cement grout as theflushingmedium.Particularlyincohesionlessorunstablegroundconditionse.g.sand,clayorgravel,thisisthefastestandmostefficientinstallationmethodformicropilesystems.Comparedtoothermethods,smallerdrillingequipmentcanbeused.ThusSelfDrillingMicropilesareideallysuitedforprojectswithlimit-edaccess,confinedspacesorlowheadroomconditions.

©Geomek© HABAU Hoch- und Tiefbau Gesellschaft mbH

© 2018 MINOVA GLOBAL. ALL RIGHTS RESERVED

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Minova MAI offers two product lines, the CE-line or nationally approved products and the Value-line.

The CE-line is based on the European Technical AssessmentsforSoilandRockNails(ETA-08/277)andMicropiles(ETA-11/0134).Inaddition,anumberof national technical approvals have also been granted. For more detailed information, please refer tothechapter“Certification”onpages23and24.

TheValue-linemeetsrequirementsatareasonableprice. The products of the Value-line do not have technical approvals. Both product lines are produced in compliance withtheregulationsofISO9001.Inbothlines,thecouplersandnutstransfertheloadsspecifiedforthe respective system.

Hollow barsThe system consists of one or several coupled hollowbarsfordrillingwithwaterorairflushorfor simultaneous drilling and grouting. The hollow bar features a left-hand or right-hand R-thread (rope thread) or T-thread (trapezoidal thread) for easy extension and connection to all conventional drill rigs. It is manufactured from seamless or welded steel tubes. The R-thread according to ISO standards and T-thread according to factory standard are both formed in a cold rolling process.

CE-line and approved systems: Only seamless tubes are used. We purchase the tubes from European suppliers approved according toETAG013.

Value-linie: For the Value-line, seamless or welded tubes are used. The material is purchased exclusively from carefully selected suppliers with proven expertise in quality.

Extension couplersThe couplers are used to extend the hollow bars. Therequiredlengthoftheload-bearingelementcanthus be achieved also in cases of limited feed length of the drill rig or low headroom conditions. All couplers are designed to safely transfer the specifiedsystemload,withthefacesofthehollowbars bearing against each other to ensure safe energy transfer between the hollow bars and the drill bit without affecting the couplers mechanically.

CE-line and approved systems: Only seamless tubes are used. We purchase the tubes from European suppliers approved according toETAG013.ThecouplersarefittedwithanR-thread or T-thread to ensure safe connection ofthe hollow bars.

Value-line: For the Value-line, seamless or welded tubes are used. The material is purchased exclusively from carefully selected suppliers with proven expertise in quality.

Minova MAI Self Drilling Systems - Components



For the Value-line, the designer/customer is free to choose between two options:

• Standard couplers with an R-thread or T-threaddependent on the thread of the bar used.

• Anewthreaddesignallowstosignificantlyreduce the length of the coupler for R-threadsthus offering improved economy withoutimpairingthespecifiedsystemperformance(LCcoupler).

PlatesThe steel plates feature a chamfered bore allowing an angle of deviation of 5 degrees in all directions.

CE-line and approved systems: Thetechnicalapprovalsprescribetheuseofspecificplates for each type of hollow bar dependent on its useasSoilandRockNailorMicropile.

Value-line: The designer/customer is free to choose from among a variety of plates dependent on the requirementsofthespecificproject.

NutsThe nuts transfer the load from the plate into the hollow bar. They feature a spherical cap on at least one end to compensate for angle deviations. All nuts are so designed as to ensure safe transfer of the specifiedsystemload.

CE-line and approved systems: The technical approvals prescribe the use of specificnutsforeachtypeofhollowbar.Thenutsfeature an R-thread or T-thread to securely connect to the hollow bars.

Value-line: The material is purchased exclusively from carefully selectedsupplierswithprovenexpertiseinquality.For the Standard-line, the designer/customer is free to choose between two options:

• Standard nuts with R-thread or T-threaddependent on the thread of the bar used.

• A new thread design enables nuts for R-threadsto be produced more economically withoutimpairingthespecifiedsystemperformance(LCnut).

Nail and pile neck protection tube• Protectiontubesforsoilandrocknails(plastic

tubes)areavailableuponrequest.

• Pileneckprotectiontubes(plasticorsteeltubes)areavailableuponrequest.

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Minova MAI Self Drilling Systems - AccessoriesSacrificial drill bitsThe correct selection of the drill bit dependent on the geological conditions on site is essential to ensuring a productive and cost-effective installation of the Self Drilling System.

Conventional drill bits are designed for longevity. Drill bits for the Minova MAI Self Drilling System mustmeetthefollowingrequirements:• The stability of the drill bits enables safe drilling

oftheboreholedowntotherequireddepth.• Since the drill bit is used for one borehole only

(sacrificialdrillbit),theservicelifeshouldmeetbutnotsignificantlyexceedtherequirementssoas to ensure cost-effectiveness.

• The drill bit type used and, in particular, theinserts are dependent on the geologicalconditions on site.

• The drill bit diameter is dependent on the designrequirementsandthespecificationsdefinedinthe approvals.

Minova MAI offers a wide range of drill bits suitable for diverse geological conditions.

Drill bit adaptersDrillbitadaptersincreaseflexibilitybyallowingtheuse of drill bits designed for other dimensions of hollow bars.

Spacers/CentralizersSpacers are used to centre the hollow bars within the borehole and to ensure the correct grout cover of the load-bearing element according to therelevantstandardsandasspecifiedintheapprovals.

Coupling boxesCoupling boxes (crossover couplers) must be installedbetweentheshankadapterandthehollowbar during the drilling operation. Since this section of thedrillstringisdirectlyandcontinuouslysubjectedto the impact energy of the drill hammer, our coupling boxes are manufactured from hardened steel and are intended for multiple use.


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All coupling boxes feature a centre stop to ensure the direct transfer of the impact energy to the face ofthehollowbaraswellasflatsforeasylooseningof the connection. Extension couplers may not be used as coupling boxes, since a damaged thread of ashankadaptercancausedamagetothethreadinthe extension coupler and negatively affect the load-bearing capacity of the system.

Grout swivelsThe grout swivels consist of a grout body and a swivelshaftandareattachedtotheshankadapter.A large variety of grout swivels for all standard types ofshankadaptersisavailable.Thegroutswivelsare suitable for simultaneous drilling and grouting.

Pull test equipmentA CE-approved pull tester is available to test the self-drilling nails and piles after installation of the system and curing of the grout body.

MAI M400NT und M440GE grout pumpsMinovaMAIrecommendstheuseoftheM400NTgrout pump or, for geotechnical applications, M440GEtoproduceagroutmixturewithacontrolled water/cement ratio.

TheM400NTpumpisgloballythemostwidelyusedpump in tunnel construction.

• Proven technology for a long service life• Easy handling and maintenance• User-friendly operation• Robust design

TheM440GEgroutpumpistheresultofdecadesof experience and sets new standards in process security.

• Multi-purpose machine• Intelligent control system• Innovative water and dry material management


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Product specification and caracteristic load-bearing capacities of the hollow bar system

Line ParameterType R Type T

R25 R32L R32N R32S R38N R51L R51N T51S T76N T76S T111L T111N

1 Nominal diameter Da, nom

mm 25 32 32 32 38 51 51 51 76 76 111 111

2 Outer diameter Da mm 24.7 31.3 31.3 31.3 38.0 50.0 50.0 51.9 75.4 75.4 111.0 111.0

3 Inner diameter Di 1) mm 14.0 20.6 18.5 15.0 19.0 33.3 30.2 26.6 51.0 44.0 85.0 75.5

4Nominal cross sectional erea S0

2)mm2 300 350 430 520 750 900 1070 1325 1870 2400 3185 4395

5 Nominal mass m 3) kg/m 2.35 2.75 3.4 4.1 5.9 7.05 8.4 10.4 14.7 18.85 25.0 34.5

6 Relative rib area fR - 0.12 0.24

7 Nominal yiel load Fp0.2,nom

kN 150 160 230 280 400 450 630 750 1200 1500 2000 2750

8Nominal tensile load-bearing capacity Fm, nom

4)kN 200 210 280 360 500 550 800 1050 1600 1900 2640 3650

9 Yield strength Rp0.2 5) N/mm2 500 460 530 530 530 500 590 570 640 630 630 630

10 Tensile strength Rm 5) N/mm2 670 600 650 690 660 610 750 790 860 790 830 830

11 Rm / Rp0.26) - ≥1.15

12 Total elongation at maximum load Agt

% ≥2.5 ≥5.0

13 Fatiquestrength2σa 7) N/mm2 ≥120 ≥100

14Notch effect according to EN 1993-1-9

N/mm2 90 70

15 Bond strength tak8)

N/mm2 ≥2.8 ≥5.3

16 Moment of inertia I 9) mm4 11200 25800 29800 33300 75700 179000 211000 215000 863000 977000 3580000 4110000

17 Thread - ISO10208 ISO1720 Factory Standard

Legend1) Mean value2) Calculated based on nominal mass m,

S0=103m/7.853) Allowabledeviation-3%to+9%4) Characteristic value as 5% fractile5) Calculated based on nominal force and nominal cross

sectional area, rounded value6) Characteristicvalueas10%fractile

ModulusofelasticityE≈205000N/mm2

7) DeterminedatanupperloadofFup=0.7*Fp0.2,nomforthehollowbar,couplerandanchorage80N/mm2

8) Characteristic value, determined in pull-out tests. Thevaluesarebasedonameanvaluewithaslipof0.01,0.1and1.0mmandacylindercompressivestrengthofcementgroutof≥40N/mm2

9) Determined in bending test. Relative to a modulus ofelasticityof205000N/mm2 and reduction by 5% to takeintoaccountdeviationsinthemasstolerances

Technical Data of the approved systems



Couplers and nuts

Type R

Type T

Type R - LC Coupling and nuts

1) Locknutsofhalftheheightmaybedesigned2) Hexagonal nut3) Ringnutø160mmwith4flats

ComponentType R

R25N R32L R32N R32S R38N R51L R51N

Coupler

Outer diamter mm 33.7 42.4 42.4 42.4 51.0 63.5 63.5

Length mm 150 145 145 190 220 170 220

Minimum torque Nm 300 500

Nut

Height 1) mm 35 45 45 45 60 85 85

Width across flats AF mm 462) 462) 462) 462) 502) 752) 752)


ComponentType T

T51S T76N+S T111L+N

Coupler

Outer diameter mm 70 95 140

Length mm 160 220 250

Minimum torque Nm 500

Nut

Height 1) mm 70 80 120

Width across flats AF mm 752) 1002) 1503)

Minimum torque Nm 500

ComponentType R - LC


Coupler

Outer diameter mm 33.7 42.4 42.4 42.4 51.0 63.5 63.5

Length mm 90 90 90 110 100 120 140


Nut

Height 1) mm 35 45 45 45 60 85 85

Width across flats AF mm 462) 462) 462) 462) 502) 752) 752)


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ComponentType R


Domed plate

A mm 150 150 200 200 200 - -

B mm 8 8 8 10 12 - -

ø C mm 30 35 35 35 41 - -

D mm 25 25 28 28 28 - -

Flat plate

A mm - - 95 120 140 150 180

B mm - - 25 30 35 40 45

ø C mm - - 35 35 41 56 56

ComponentType T

T51S T76N T76S T111L T111N

Flat plate

A mm 200 250 250 300 350

B mm 50 60 60 80 90

ø C mm 60 90 90 130 130

A-A ( 1 : 1,3 ) B-B ( 1 : 1,3 )

A AB B

C C

A

A A

ABB

D

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Protection tubes

Soil and rock nails

Micropiles

Component DimensionType R

25 32 38 51

Plastic tube (smooth or corrugated)

Outer diamteterA mm >32 >32 >38 >51

Wall thickness d mm 0.8 0.8 1.0 1.0

Length L mm >200 >200 >200 >200

Component DimensionType R Type T

32 38 51 51 76 111

Steel tube

Outer diameter A mm 76.1 76.1 88.9 88.9 114.3 159.0

Wall thickness d1) mm 2.9 2.9 3.2 3.2 4.5 4.5

Length L mm 420 480 610 450 630 650

Plastic tube (smooth or corrugated)

Outer diameter A mm ≥63 ≥75 ≥ 80 ≥ 80 ≥ 100 ≥ 160

Wall thickness d mm ≥ 1.0 ≥ 1.0 ≥ 1.5 ≥ 1.5 ≥ 1.5 ≥ 2.0

Length L mm 300 300 300 300 300 300

1) For temporary micropile applications, the wall thickness of the steel tube may be reduced by 1.0 mm.


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Installation of Minova MAI Self Drilling Systems

Inunstablegroundconditions,conventionalsoilandrocknailsandmicropilesaretypicallyinstalledusingcasing drilling whereby the casing is retrieved during grouting.

MinovaMAISelfDrillingSystemsofferamoreefficientalternative,particularlyinunstablegroundconditions. The hollow bars serve as drill strings and after drilling as supporting elements. The hollow bars canbedrilledusingwaterorairflushorbymeansofsimultaneousdrillingandgrouting.

SoilandRockNailsaretypicallydrilledusingwaterorairflushandgroutedafterinstallation(postgrouting).

Micropilesaretypicallyinstalledusingsimultaneousdrillingandgroutingwiththegroutservingasaflushingmediumthatimmediatelystabilizesthesurroundinggroundbyfillingvoidsandcracks.Afterreachingthefinaldepth,thewater-cementratioisdecreasedinordertofilltheannularspacebetweenthehollowbarand borehole wall thus ensuring optimal load transfer.

Manual, mechanical and automated installation methods are available.

• The selection of the suitable drill bit is dependent on the planned length of the nail or micropile,expectedgeologicalconditionsonsiteandintendedgroutcover.Ifrequired,anexpertpossessingtherequiredexpertiseandexperiencemustbeconsultedorloadtestsonsamplenails or micropiles must be carried out.

• The corrosive effect of the ground on metallic materials must be evaluated and assessed in thedesigninadvanceinordertoprovidetherequiredcorrosionprotection(groutcover,corrosionallowance, hot-dip galvanization or TwinCoat. Combinations of the aforementioned alternatives arepossible).

• Using the selected drill bit, the hollow bar is installed by means of rotary or rotary percussivedrillingusingacouplingboxbetweentheshankadapterandhollowbar.Air,waterorgroutmaybeusedasdrillflush.Thehollowbarcanbeextendedusinganextensioncouplerscrewedonbyhand.Thetorqueisappliedviatheinstallationprocess.Guidevaluesfortorqueandimpactenergyarelistedonpages20and21as50%valuepairs,thepathsareshownintorque-impactenergydiagrams.

• Simultaneously to drilling the nail or micropile, the annular space around the hollow bar may befilledwithcementorcementgroutcreatingagroutbodyusingarotaryinjectionadapter(groutswivel).Postgroutingmaybecarriedoutusinganinjectionadapteriftheboreholeisofsufficientstability.

• A plastic or steel protection tube, dependent on the type of loading acting on the soil nail ormicropileandonthetypeofjoint,mustbeinstalledintothestillflowablegrout.Forsoilnails,theprotectiontubeprotrudes200mmbeyondthenailshaft,formicropilesatleast100mmintothefoundationbody.Theannularspacebetweenhollowbarandprotectiontubemustbefilledwithcementgrout.Therequireddimensionsoftheprotectiontubesarelistedonpage18.

• The anchorage is installed after the grout or cement grout has set. Dependent on the type ofloading, the head plate must be tightened via the load-bearing nut (in the case of micropiles also viathelocknut),withaminimumtorqueof500Nm.

• Duetotheriskofmacro-elementformation,anelectricallyconductivecontactbetweenthereinforcement of the foundation body and the micropile must be prevented by installingsuitable insulation. The exact design of the anchor head is carried out during the planningand design of the structure.


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Torque Mt and impact energy Es during the installation process

Duringinstallation,theimpactenergyEsandtorqueMtmustbelimitedtothespecifiedvaluepairs.Forapplicationsbeyondthesespecifications,thetorque-impactenergydiagramsmustalsobetakenintocon-sideration.

Type R

Type T

Range ParamterType R


Es, max2

Es Joule 90 80 130 160 230 220 380

Mt Nm 350 500 700 750 1300 1850 2500

Mt, max2

Es Joule 130 120 200 250 330 320 550

Mt Nm 250 400 500 550 950 1350 1800

Range ParamterType T

T51S T76N T76S T111L T111N

Es, max2

Es Joule 395 500 680 320 730

Mt Nm 3550 8950 10000 14800 21500

Mt, max2

Es Joule 555 690 950 400 970

Mt Nm 2700 7000 7700 12300 17600

0

200

400

600

800

1000

1200

0 100 200 300 400

Mt i

n N

m

Es in J

R32L R32SR32N

R25N


21

0

2000

4000

0 200 400 600 800

Mt i

n N

m

Es in J

R51NR51L

R38N

0

5000

10000

15000

20000

25000

30000

35000

40000

0 200 400 600 800 1000 1200 1400 1600

Mt i

n N

m

Es in J

T76S

T51S

T111NT111L

T76N



Packaging, transport and storage of Minova MAI Self Drilling SystemsPackaging sizes

MinovaMAISelfDrillingSystemsarepackedindifferenttypesofpackagingforeasyhandling:• Hollow bars in bundles• Couplers, nuts and drill bits in cardboard boxes on pallets (R25 - T63)• Couplers, nuts and drill bits in wooden crates on pallets (T76 - T111)• Plates on pallets

Hollow bars

R25 50 bars per bundle

R32 L, N, S 50 bars per bundle

R38 N 50 bars per bundle

R51 L, N 25 bars per bundle

T51 S 25 bars per bundle

T76 N, S 10 bars per bundle

T111 L, N 5 bars per bundle

Nuts

R25 100 nuts per box

R32 L, N, S 65 nuts per box

R38 N 48 nuts per box

R51 L, N 12 nuts per box

T51 S 12 nuts per box

T76 N, S 8 nuts per box

T111 L, N loose

Couplers

R25 40 to 60 couplers per box

R32 L, N 30 couplers per box

R32 S 25 couplers per box

R38 N 12 couplers per box

R51 L 12 couplers per box

R51 N 12 couplers per box

T51 S 9 couplers per box

T76 N, S loose

T111 L, N loose

Drill bits and plates

Drill bits Up to 90 drill bits per box

Plates Up to max. 800 kg per pallet

Transport and storage

A. Deliver the components (hollow bars, couplers, nuts, drill bits and head plates) to the construction siteinundamagedmanufacturerpackaging–includingtheinstallationinstructions.

B. Use suitable lifting means, hoists and transportation.

C. StoreProductssuchthattheyareeasilyaccessibilityforinspectionandidentificationpurposes.

D. Store the Products such that they are safeguarded against mechanical damage.

E. Safeguardallsteelpartsandpackedmaterialsagainstcorrosion.Storethemclearoftheground,covered and protected against weather and soiling.

F. StoreProductssuchthatthedeliverysequenceisobservedinordertoreducetheriskofcorrosion(Firstin–Firstout).

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CertificationISO certificationProductioniscertifiedaccordingto:• ISO9001QualityManagementSystems• ISO14001EnvironmentalManagementSystems• ISO45001OccupationalHealthandSafetyMan-

agement Systems

European technical assessments, CE certificationETA-08/0277SelfDrillingSoilandRockNailsETA-11/0134SelfDrillingMicropiles

TheEuropeanTechnicalAssessmentsconfirmthetechnical performance in the assessment documents andpermitthecomponentstobeartheCEmarking.

IfCEcertifiedmaterialisrequiredthishastobere-questedintheorder.TheCEcertificationisonlyvalidincombinationwiththeCEcertificateandtheDecla-rationofPerformanceforthespecificorder.TheCEcertificationincludesfrequentexternalqualitycontroland audits, both of Minova MAI and its suppliers.

German technical approvalDIBtZ-34.713-080277NationalTechnicalApprovalfortemporarySoilandRockNails


Legal disclaimer:This installation manual replaces and supersedes all prior manuals. It provides basic information only. Technical data and information provided herein may be changed without prior notice. Minova MAI does not assume any liability for damage or losses attributed to the use of this technical data or any improper use of the products. For further information on our products please contact Minova MAI directly.

Issue2018-02

Austrian technical approvalsBMVIT-327.120/0014-IV/IVVS2/2016SelfDrillingSoilandRockNailBMVIT-327.120/0015-IV/IVVS2/2016Self Drilling Micropile

Polish technical approvalAT/2016-02-3278SelfDrillingSoilandRockNailandMicropile

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26THE EARTH. UNDER CONTROL.

Minova MAI GmbHWerkstrasse17

9710Feistritz/Drau,AustriaT.+434245651660

[email protected]

www.minovaglobal.com

minova mai self drilling systems

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