Rock Reinforcement SDA SWX RFX

GDE Sales Conference 2007

Rock Reinforcement

Ing. Rudy Dante Aguilar Icho

Atlas Copco Geotechnical Drilling and Exploration

04/28/23

Contenido

SDA- Self Drilling Anchors

Swellex

Swellex Pumps

MAI Pump M400NT

Roofex (2008)

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Underground (Tunneling & Mining)

Surface (Slope Stabilization & Piling)

Rock Reinforcement

Increasing Stresses

Markets by application, domains and rock type

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Superficie (Estabilizacion de taludes y pilotes)

Productos MAI de sostenimiento de rocas

Subterráneo (Minería & Tunelería)

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Bars…produced from 12m long pipesAnd cut to size 1m,2m,3m,4mand 6m

Face plates, Nuts & Couplings

Drill bits

SDA – Product Line

Grout Pump

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A ) Elementos funcionales

Barra de anclaje

Extensiones

Platina

Tuerca

B) Elementos operacionales

Brocas y centralizadores

MAI SDA = Self Drilling Hollow Core Anchor System

SDA Pernos auto perforables

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• Perforación• Inyección de cemento• Instalación de la platina

SDA Métodos de Instalación

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MAI-SDA: Grouting method

Drilling Connecting grout hose

Grouting with MAI® Pump m400NT

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MAI-SDA: Grouting method

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A ) Functional elements

* Anchor rods

* Extension Couplings

* Nut and Plate

B) Operational elements

* Sacrificial Drill bits

200 / 150

280 /230

360 / 280

500 / 400

550 / 450

800 / 630

1600 / 1200

1900 / 1500

Ultimate Load / Yield LoadR32L

Replaced by

Self Drilling Hollow Core Anchor System

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- Corrosión de Sacrificio + So3, Cl ambiente C~ 0,15mm/ año + Ambiente de agua dulce

C~0,07mm/año Tiempo de vida se determina mediante

el grado anual de corrosión

- Galvanizado en caliente + Mínimo con capa de Zinc 80 micrones

(promedio actual 150-200 micrones Vida de servicio determinado

generalmente por standares existentes entre 5-10 años

Protección de Corrosión

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SDA – typical Sacrificial Drill bits

Type -X Type -EX, EXX Type -EC, ECC Type -ESF, ESSF

Type -EY,EYY Type -ESD,ESSD Type -XX

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Where are SDA anchors used ?

..... In very difficult and unstable ground conditions, such as unconsolidated sands, gravels or broken and fractured rock formations.

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Sistema Standard de Perforación: Roto – percusión …..(Perforación giratoria)

Tipos de Barrido: * Barrido de Agua... En arena densa, formación de grava o

de acuerdo a las condiciones de roca mejor barrido en cortes grandes y enfriamiento de las brocas * Barrido de Aire… En suelo suave, por ejemplo, caliza

suave, arcilla o similar donde se evite derrame excesivo de agua * Inyección de Cemento y Perforación Simultánea......

En todas las condiciones de suelo no consolidadas

- estabiliza el taladro de perforación durante la instalación, consiguiendo una mejor inyección que cubra la longitud de anclaje

- buena penetración alrededor del suelo, por lo tanto se obtiene mejores valores de fricción externos

- la instalación se realiza en una sola operación, por lo que se ahorra tiempo !

SDA Métodos de Instalación

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Surface crawler D7 with IRIA

D7 with COP 1838 – IRIA and Rod guiding/ clamping System

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IRIA – kit

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Alto grado de instalación ya que no requiere la operación básica de perforación. La perforación, posición e inyección se realiza en una sola operación

Comparisons: SDA and conventional rebars

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Herramientas de Instalación Atlas Copco

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Instalación Semi-Mecanizada y Post Inyección

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Instalación Semi Mecanizada e Inyección a través del IRIA

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Pull out test

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La bomba de Inyección m400NT y la m400EASY

22 04/28/23

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Function m400NT

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SDA - Applications

R 25 R 32

Soil & Rock Nailing'SRN '

R 38 R 51

Micro Injection Piling'M IP '

R 38 R 51

Temp. Prestress Anchor'TSA '

R 25 R 32

Tunnelling'SDA '

Applications

Ground Engineering (GE) Surface Applications

Tunnelling (TU) Underground Application

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Potential Problem Area - Slopes

Visit Guni Tunnel Portal 1 KatraIndia, 2004Site Report 05/2005 after 250m total Tunnelcollapse

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Fractured Rock / Unconsolidated soil

Visit Guni Tunnel Portal 2 ReasiIndia, 2004

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Introduction Soil Nailing

Lambagarh Slide Chamoli DistrictUttar Pradesh, India

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Potential Problem Area - Tunnelling

Hanbau Tunnel,Taiwan 2000

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Tunnelling Applications (TU)

Systematic Radial Bolting Fore-poling or Spiling

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Soil & Rock Nailing Applications (GE)

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Soil Nailing Construction Method

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Slope Stabilisation

Shortlands Junction, Bromley, 2002, UK

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Micro Injection Piles - Post settlement control on existing structures (e.g. MIP installation in cellars or similar).

- Increasing the foundation capacity for existing structures.

- New deep foundation for structures in congested city areas with narrow access routes.

- The use of simultaneous drilling and grouting method.

Application and advantages

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Temporary support anchors

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Retaining Structure for railway embankment at Bijlmer Station; Amsterdam Ca. 700 no TSA T76N L=25m , BL=12m, Working Load 600kN

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Birmingham Northern Relief Rd.( M6-Toll), UK

Battered wall

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Birmingham Northern Relief Rd.( M6-Toll), UK

Design

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Slope Stabilisation and Protection

Koudiat Acerdoune Dam project Algeria, 2004

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Tunnel Project Eichelberg,Germany: R51L

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Jerusalem 200340.000m R32N galvanized, Production with D7 24no SRN, 12m lg per WD

Battered wall

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Taipei , Taiwan, 1999R32N 1.000m

Battered wall

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Preparation Tunnel Portal Greece, 2000

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Sir Herbert Miles Road, Gibraltar, 1999R32N 8.500m

Battered wall

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Flexible Facing

Shortlands Junction, Bromley, 2002, UK

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Pensnett Industrial Estate Project, UK, 1999

Soft Facing

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Soft Facing with wire meshes

Tintern Nr. Chepstow, 2000, UK

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Dublin M50, Ireland, 2000

Drainage System

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........somewhere in the UK, 2000

Drainage System

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SRN Application

Limestone Quarry Carriere D’Arvel Switzerland 2004

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SRN Solution

Limestone Quarry Carriere D’ArvelSwitzerland 2004

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Rock Fall & Avalanche Barriers

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Micro Injection Piles

MIP for Nokia, Jyväskviä, Finland 2000

Settlement Control at City hall in Tallinn Estonia, 1999

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Unicorn Abrasives, UK, 1998R32N

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MIP Bank of Finnland, Helsinki, 2000

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Secant pile retaining structure, Uk, 1999

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Centerville, Vancouver, 2000R38N 9.000m

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Permanent support anchors

Restructuring of channel support, Holland, 1996

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Tunnelling (TU)

Hanbau Tunnel, Taiwan, 1999R 32N 80.000m

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Dual Railway Tunnel Bologna, Italy 2003R38N L=15m

Tunnelling (TU)

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Tunnelling – Pipe Roofing

Umbrella at Montegiglio Tunnel Project, Italy, April 2002 R51L L=9m/ 3m overlap

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Superficie (Estabilizacion de taludes y pilotes)

Productos MAI de sostenimiento de rocas

Subterráneo (Minería & Tunelería)

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Swellex Products Line

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SWELLEX MANUFACTURING

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Folded Steel Tube Expanded through high water pressure Radial pressure on surrounding rock Immediate roof support !!!

SWELLEX PRINCIPLE

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High water

Pressure

Expanded SWELLEX in the hole

After expansion air pressure force water out of the inlet hole

300bar

SWELLEXafter expansion

Face Plate

SWELLEXInstalled In the hole

Inlet Hole

SWELLEXbefore

expansion

A >> B

EXPANSION PRINCIPLE

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INSTALLATION SEQUENCE

Drilling1 Expansion 3

Atlas Copco

Pumpsautomatically stops 4

Atlas Copco

Insertion2

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Immediate full column support

IMMEDIATE FULL COLUMN SUPPORT

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SwellexNet washer for screening

Swellex bridges gaps in

the rock

Allows major shear movements

In hard rock, 50 cm inflated profile develop 100KN friction

Swellex followsall the

irregularituis in the hole

SWELLEX FEATURES IN THE HOLE

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SafetyImmediate rock support

Productivity

ProductivityFast installation

Easy and trouble-free installation

VersatilityInsensitive to irregularities in the hole

Reliability , SafetyAtlas Copco Quality control

Enviromentally friendlyNo Resin, No cement

Controllable rock reinforcementPressure control after the installation

SafetyFull column action

SWELLEX ADVANTAGES

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Mn12 / Pm12 Pm16 Bitumen-Coated Mn24 / Pm24

Plastic-Coated

SWELLEX BOLTS PORTFOLIO

Pm24Connectable Pm24Hanger

Pm24Connectable

Retainer Section

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Swellex Mn12 & Pm12 32 mm 39 mm27 mm

Initial Profile Min Hole diameter Max hole diameter

INSTALLATION HOLE DIAMETER

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30 35 40 45 5038

StandardSwellex & Mn12

SuperSwellex & Mn24

kN/mFr

Hole diameter (mm)

MidiSwellex & Mn16

Traction Test in Granite

Resistencia a la Fricción vs. Diámetro del Taladro

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Diámetro de la broca

Bit Gauge

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SWELLEX PREMIUM LINE

Swellex ® Premium

Pm12 Pm16 Pm24

Yield Load kN 100 130 200

Min. Breaking Load kN 120 160 240

Min. Elongation % 15 10 10

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Swellex ® Manganese

Heat Treated Mn12 Mn16 Mn24

Yield Load kN* 75 N/A 150

Min. Breaking Load kN 100 N/A 200

Min. Elongation % 20 - 25 N/A 20 - 25

SWELLEX MANGANESE LINE

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RESULTADO: un perno superior

Un perno que produce mas trabajo!

Alta capacidad de carga yal mismo tiempo

Alta capacidad de absorción de energía

Swellex Mn

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TYPES OF STEEL BASICS

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SwellexSwellex

Cohesive Material Frictional Material Clay Shale Limestone Granit Sansdstone Breccia Sand

HARD & COHESIVE ROCK

In hard rock Swellex profile will deform regularly accordingly with small irregularities in the hole. Anchorage in a combination of small (differential) mechanical interlocking and friction. As hard rock do not deform plastically, better anchorage will be reached when hole diameter in the upper recommended range (larger hole) to maximize the area of contact.

ROCK MECHANICS ANCHORAGE

SWELLEX ANCHORAGE MECHANISM

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SwellexSwellex

Cohesive Material Frictional Material Clay Shale Limestone Granit Sansdstone Breccia Sand

ROCK MECHANICS ANCHORAGE

SWELLEX ANCHORAGE MECHANISMSOFT & NON-COHESIVE ROCK

In soft rock, Swellex profile will deform irregularly, compressing the rock, accordingly with variation of plastic property of the rock in the hole (non-homogeneity). Anchorage in a combination of large mechanical interlocking and friction. As soft rock will deform plastically, better anchorage will be reached with hole diameters in the lower recommended range (small hole) to maximize the fluctuation of profile diameter in the hole.

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Active, radial forces

increase the friction

on the surfaces of the joints

Radial expansion

increases

the friction coefficient in

granular material

SWELLEX en roca fracturada

- In soft rock, macro deformation variations along the profile provide strong interlock.

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Confinamiento radial

Alojamiento en el taladro

Presión de la placa sobre la roca

Soporte de carga libre

Acción dominante del bloque

Desarrollo del arco

Confinamiento de la roca

Comportamiento Del Perno Swellex

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SWELLEX PLATES AND WASHER PORTFOLIO

Adjustable face plate for optimal load distribution, even in case of angled hole direction

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1 Swellex Bolt and Plate

2 Chuck 3Installation

we ell xS ®

4Swellex Pump

Principal components SWELLEX System

INSTALLATION COMPONENTS

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Pneumatic

Electric

Hydraulic

SWELLEX PUMPS PORTFOLIO

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ARMS & CHUCKS PORTFOLIO

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INSTALLATION METHODS

MANUAL INSTALLATION

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SEMI MECHANIZED INSTALLATION

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MECHANISED INSTALLATION

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1. SLIP PULL TEST2. DESTRUCTIVE PULL TEST3. NON-DESTRUCTIVE PULL TEST

PULL TESTS

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QUALITY ASSURANCE on the Field

PULL TEST EQUIPMENT

The Pull Test Equipment is used to control the anchorage capacity and the integrity of Swellex bolts.Note: Sleeves are required to perform slip test (anchorage capacity test)

Pull Test Equipment Complete for Mn12/Pm12, Mn16/Pm16 & Mn24/Pm24

8613 1108 00

Sleeve for Mn12/Pm12: 150mm length 3128 3139 75

Sleeve for Mn16/Pm & Mn24/Pm24: 150mm length 3196 2302 00

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PULL TESTS SLIP

SLIP PULL TEST

The slip pull test is done to determine the anchorage capacity of Swellex. Sleeves are slid on the profile in order to limit the length of the profile inflated (in contact) in the hole and authorize sliding of the bolt when pull tested.

Ex. A Mn12 having a “free” length (not covered by sleeve) of 0,3m is inflated in a 38mm holes in granite. Performing a pull test, sliding occurs at 60kN. The anchorage capacity can them be calculated; 60kN / 0,3m = 200kN/m for 38mm hole diameter in granite.

Slip pull-test are requested to:– Give engineers information for rock support

design.– Anchorage capacity in the different types of

rocks– Effect of hole diameter on the anchorage

capacity

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DESTRUCTIVE PULL TEST

A destructive pull tests gives information on the ultimate capacity of the Swellex bolt. Important information can be collected on the behavior of Swellex in the rock matrix. It is the best way to assess bolts condition, evaluate corrosion effect on old bolts and to compare results to original specification.

Destructive pull-tests are giving information on:

– Behavior of Swellex in the rock Mode of failure Total deformation prior to failure Progressive debonding

– Steel performances Max strength Deformation

PULL TESTS DESTRUCTIVE

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NON DESTRUCTIVE PULL TEST

Non destructive pull tests are performed to assess bolts performance up to a set value usually located in the elastic behavior of the bolt. This test offer the advantage of testing the Swellex bolts without damaging the bolt or affecting the surface support. It is the best test to monitor bolts performance in time.

Non destructive pull tests are useful:– To control Swellex quality without affecting

the bolt To assess that minimum performance

requested are met if corrosion is suspected

To evaluate that minimum performance are reached in time

– Steel performances Minimum strength

PULL TESTS NON-DESTRUCTIVE

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Aplicaciones SWELLEX

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Rock Pre-ReinforcementTunnel Front

Tunnel front stabilization in soft formations and fault zones

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Rock Pre-Reinforcement Tunnel Enlargement

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Rock Pre-ReinforcementTunnels

No damages to the cutting tools

TBM Road Headers

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COMING SOON….

The Roofex - A New Rock Bolt!

04/28/23

The new Roofex

Stop Element

Sleeve

Sliding Element

Sleeve Bar Plate Nut

Description of details

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The new Roofex Rx 10

Adapts itself to ground movements

Has a patented sliding element over a high strength steel bar

Provides constant load capacity at 75 kN in static loading conditions

Can absorb 20 kJoules of energy on a single event

Can still provide a 100 kN maximum load capacity after sliding is complete

The future of deep mine rock bolting

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Can be installed with resin or cement grout

Can be manufactured in most standard length

Can have the pre-set sliding distance choosen during manufacturing ( 60 cm is the maximum recommended)

The new Roofex Rx 10

The future of deep mine rock bolting

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RoofexSection after installation

Protection tubeStop Element

Steel BarSliding Element

ResinProtection tube

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Roofex in yielding ground

We want to control this!

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RoofexBolt sliding under design load

Distance [mm]

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RoofexBolt after having reached the end of the defined sliding length(=stop element hits bale)

Distance [mm]

Results of multiple tests

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RoofexThe bolt takes load up to the UL of the rebar before failing

Distance [mm]

N] Results of

Multiple tests

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Roofex Targeted Applications: Dynamic Failure Events

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Roofex in dynamic events

Impact Tests on Rx10Bolt can still hold more than 95 kN

ultimate load after the impact

Load vs displacement

0 20 40 60 80 100 120 140 160 180 200

Plate displacement (mm)

Roofex 60 cm Set Displacement

0,00 200,00 400,00 600,00Plate Displacement (mm)

s) Test B - 5kJTest C - 5 kJTest D - 5 kJTest E - 15 kJTest F - 20 kJTest G - 27 kJ

Bolt Failure

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New rock bolt with a patented sliding system that delivers consistent load displacement properties

Installation as simple as another conventional rock bolt

Can handle large deformations

Can handle large impact loads

Displacement length can be defined during manufacturing

The new Roofex Rx 10The future of deep mine rock bolting

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FUTURE PRODUCTS

Roofex: Introduction in 2008

R32L Galvanized: documentation to be completed

E1 Swellex pump available now

EC1 Swellex pump planned for early 2008

T100 under development: for 2008

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QUALITY CONTROL DURING MANUFACTURE

Swellex– IST System– Profile Inflation Test– Profile and Bushing Strength Tests

SDA Bars testing – raw material and end product– Coupling testing with external certification

04/28/23

We are committed to your superior productivity throughinteraction and innovation.

04/28/23

Rock Reinforcement SDA SWX RFX

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