Rock Reinforcement SDA SWX RFX
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Transcript of 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
GDE Sales Conference 2007
Contenido
SDA- Self Drilling Anchors
Swellex
Swellex Pumps
MAI Pump M400NT
Roofex (2008)
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GDE Sales Conference 2007
Soi
l / w
eak
Roc
k
Underground (Tunneling & Mining)
Har
d R
ock
Surface (Slope Stabilization & Piling)
Rock Reinforcement
Increasing Stresses
U/G
Markets by application, domains and rock type
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GDE Sales Conference 2007
Sue
lo /
Roc
a dé
bil
Roc
a du
ra
Superficie (Estabilizacion de taludes y pilotes)
Productos MAI de sostenimiento de rocas
Subterráneo (Minería & Tunelería)
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GDE Sales Conference 2007
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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GDE Sales Conference 2007
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
1
2
3
4
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MAI-SDA: Grouting method
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GDE Sales Conference 2007
SDA
A ) Functional elements
* Anchor rods
* Extension Couplings
* Nut and Plate
B) Operational elements
* Sacrificial Drill bits
200 / 150
R25N
R25
280 /230
R32N
360 / 280
R32S
R32
500 / 400
R38N
R38
550 / 450
R51L
800 / 630
R51N
R51
1600 / 1200
T76N
1900 / 1500
T76S
T76
Ultimate Load / Yield LoadR32L
Replaced by
Self Drilling Hollow Core Anchor System
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GDE Sales Conference 2007
- 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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GDE Sales Conference 2007
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
1/3
Comparisons: SDA and conventional rebars
1/2
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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
R 38
Soil & Rock Nailing'SRN '
R 38 R 51
T 76
Micro Injection Piling'M IP '
R 38 R 51
T 76
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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Temporary support anchors
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
Slope Stabilisation and Protection
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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
Slope Stabilisation and Protection
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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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Micro Injection Piles
Unicorn Abrasives, UK, 1998R32N
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Micro Injection Piles
MIP Bank of Finnland, Helsinki, 2000
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Temporary support anchors
Secant pile retaining structure, Uk, 1999
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Temporary support anchors
Centerville, Vancouver, 2000R38N 9.000m
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GDE Sales Conference 2007
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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GDE Sales Conference 2007
Tunnelling – Pipe Roofing
Umbrella at Montegiglio Tunnel Project, Italy, April 2002 R51L L=9m/ 3m overlap
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GDE Sales Conference 2007
Sue
lo /
Roc
a dé
bil
Roc
a du
ra
Superficie (Estabilizacion de taludes y pilotes)
Productos MAI de sostenimiento de rocas
Subterráneo (Minería & Tunelería)
04/28/23
GDE Sales Conference 2007
Swellex Products Line
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GDE Sales Conference 2007
SWELLEX MANUFACTURING
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GDE Sales Conference 2007
Folded Steel Tube Expanded through high water pressure Radial pressure on surrounding rock Immediate roof support !!!
SWELLEX PRINCIPLE
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GDE Sales Conference 2007
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
B
EXPANSION PRINCIPLE
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GDE Sales Conference 2007
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
0,5
m
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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GDE Sales Conference 2007
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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GDE Sales Conference 2007
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
Swellex Mn24 & Pm24 43 mm 52 mm36 mm
Swellex Mn16 & Pm16 43 mm 52 mm36 mm
Initial Profile Min Hole diameter Max hole diameter
INSTALLATION HOLE DIAMETER
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GDE Sales Conference 2007
30 35 40 45 5038
300
200
100
StandardSwellex & Mn12
SuperSwellex & Mn24
kN/mFr
ictio
nal r
esis
tenc
e
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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GDE Sales Conference 2007
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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GDE Sales Conference 2007
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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GDE Sales Conference 2007
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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GDE Sales Conference 2007
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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GDE Sales Conference 2007
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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GDE Sales Conference 2007
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
Arm
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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INSTALLATION METHODS
SEMI MECHANIZED INSTALLATION
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INSTALLATION METHODS
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!
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GDE Sales Conference 2007
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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GDE Sales Conference 2007
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]
Forc
e [k
N]
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RoofexBolt after having reached the end of the defined sliding length(=stop element hits bale)
Forc
e [k
N]
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]
Forc
e [k
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
0 20 40 60 80 100 120 140 160 180 200
Plate displacement (mm)
Load
(kN)
Roofex 60 cm Set Displacement
0,00
2,00
4,00
6,00
8,00
10,00
12,00
0,00 200,00 400,00 600,00Plate Displacement (mm)
Load
(Ton
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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GDE Sales Conference 2007
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
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We are committed to your superior productivity throughinteraction and innovation.
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