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BS 7861-1:2007 Strata reinforcement support system components used in coal mines - Specification for rockbolting, 2007
- Contents [Go to Page]
- 1 Scope 1
- 2 Normative references 1
- 3 Terms and definitions 2
- 4 Steel rockbolts and components 4
- 5 Glass fibre reinforced plastic (GRP) rockbolts and components for use in the sides 6
- 6 Resins and capsules 9
- 7 System type tests - Steel rockbolts 10
- 8 System type tests - GRP rockbolts 11
- Annexes
- Annex A (normative) Tensile test on steel bar 12
- Annex B (normative) Resistance to brittle fracture 12
- Annex C (normative) Breakout facility torque test 14
- Annex D (normative) Tensile test to establish flattening and pull through loads of steel domed washer plate assemblies 15
- Annex E (normative) Alignment test 17
- Annex F (normative) Fire resistance test on non-metallic components 18
- Annex G (normative) Torsional strength test on GRP bar 20
- Annex H (normative) Tensile strength test on GRP bar 21
- Annex I (normative) Minimum tensile strength of GRP rockbolt bar 23
- Annex J (normative) Flexural strength tests on GRP rockbolt bar 25
- Annex K (normative) Tensile test to establish GRP bolt assembly failure load 26
- Annex L (normative) Determination of uniaxial compressive strength (UCS) of resin 28
- Annex M (normative) Determination of elastic modulus of resin 29
- Annex N (normative) Determination of creep of resin 31
- Annex O (normative) Tensile test on rockbolt threaded end 33
- Annex P (normative) Shear test on rockbolt/resin system 34
- Annex Q (normative) Determination of bond strength and system stiffness 36
- Bibliography 44
- List of figures
- Figure 1 - Example of a steel rockbolt assembly in situ 3
- Figure B.1 - Charpy impact specimen - machining from bar details 13
- Figure C.1 - Arrangement for nut breakout torque test for GRP rockbolts 15
- Figure D.1 - Load test arrangement for tensile test flattening and pull through loads of steel domed washer plate 16
- Figure E.1 - Alignment capacity of conical seat and domed washer plate assembly 17
- Figure F.1 - Draught-free cabinet for flame test 19
- Figure G.1 - Arrangement for torsional strength test on GRP bar 20
- Figure H.1 - Arrangement for tensile test on GRP bar 22
- Figure I.1 - Double embedment tensile test - schematic diagram 24
- Figure J.1 - Arrangement for flexural strength test on GRP bar 25
- Figure K.1 - Load test arrangement for GRP components 27
- Figure M.1 - Arrangement for elastic modulus test and creep test: machine platen 31
- Figure O.1 - Arrangement for tensile test on rockbolt threaded end 33
- Figure P.1 - Sectional diagram of shear frame 34
- Figure Q.1 - General arrangement of lathe-based pull test apparatus 37
- Figure Q.2 - General arrangement of hydraulic pull test apparatus 38
- Figure Q.3 - Hydraulic biaxial pressure cell 39
- Figure Q.4 - Rock core performance envelope 43
- Table 1 - Colour coding of rockbolt length 5
- Table 2 - Resin setting times at 27 ËšC 10
- Table Q.1 - Standard consumables and criteria for rock core performance testing 42
- Foreword
- 1 Scope
- 2 Normative references
- 3 Terms and definitions [Go to Page]
- 3.1 bond strength
- 3.2 breakout facility
- 3.3 brittle fracture
- 3.4 conical seat
- 3.5 domed washer plate
- 3.6 equivalent diameter
- 3.7 flexural strength
- 3.8 gel time
- 3.9 hand held machine
- 3.10 resin
- 3.11 rockbolt
- 3.12 rockbolt assembly [Go to Page]
- Figure 1 Example of a steel rockbolt assembly in situ
- 3.13 rockbolting support system
- 3.14 setting time
- 3.15 system stiffness
- 4 Steel rockbolts and components [Go to Page]
- 4.1 Rockbolt [Go to Page]
- 4.1.1 Rockbolt bar [Go to Page]
- 4.1.1.1 Composition
- 4.1.1.2 Profile
- 4.1.1.3 Diameter
- 4.1.1.4 Straightness
- 4.1.1.5 Tensile properties [Go to Page]
- a) the minimum yield strength shall be 640 N/mm2;
- b) the tensile strength shall be at least 20% greater than the yield strength on each tensile test;
- c) the elongation after fracture (A) shall be a minimum of 18% and the elongation at maximum force (Agt) shall be a minimum of 8%.
- 4.1.1.6 Resistance to brittle fracture [Go to Page]
- a) no more than two of the individual values shall be lower than 27 J;
- b) no more than one individual value shall be lower than 19 J;
- c) the average value of all tests shall be no lower than 27 J.
- 4.1.2 Manufacture [Go to Page]
- 4.1.2.1 Proximal end
- 4.1.2.2 Distal end
- 4.1.2.3 Length [Go to Page]
- Table 1 Colour coding of rockbolt length
- 4.1.2.4 Corrosion protection
- 4.1.3 Supplier identification
- 4.2 Nut [Go to Page]
- 4.2.1 General
- 4.2.2 Nut breakout type test [Go to Page]
- a) high torque range 100 Nm to 185 Nm;
- b) low torque range 35 Nm to 80 Nm.
- 4.3 Domed washer plate/conical seat [Go to Page]
- 4.3.1 Material
- 4.3.2 Form
- 4.3.3 Supplier identification
- 4.3.4 Performance requirements [Go to Page]
- 4.3.4.1 Assembly load [Go to Page]
- a) flatten under a load of 50% to 70% of the nominal breaking load of the bar, based on the equivalent diameter and a stress of 770 N/mm2;
- b) allow pull-through of the rockbolt, nut and conical seat assembly under a load (the maximum tensile load or pull-through load) of 70% to 95% of the breaking load of the bar, based on the equivalent diameter and a stress of 770 N/mm2.
- 4.3.4.2 Alignment
- 5 Glass fibre reinforced plastic (GRP) rockbolts and components for use in the sides [Go to Page]
- 5.1 Rockbolt [Go to Page]
- 5.1.1 Rockbolt bar [Go to Page]
- 5.1.1.1 Composition
- 5.1.1.2 Profile
- 5.1.1.3 Diameter
- 5.1.1.4 Straightness
- 5.1.1.5 Electrical resistance
- 5.1.1.6 Fire resistance
- 5.1.1.7 Torsional strength
- 5.1.2 Manufacture [Go to Page]
- 5.1.2.1 Proximal end
- 5.1.2.2 Distal end
- 5.1.2.3 Length
- 5.1.3 Type tests [Go to Page]
- 5.1.3.1 Tensile strength
- 5.1.3.2 Flexural strength
- 5.2 Nut, conical seat and domed washer plate [Go to Page]
- 5.2.1 Material properties [Go to Page]
- 5.2.1.1 Electrical resistance of the nut, conical seat and domed washer plate
- 5.2.1.2 Fire resistance of domed washer plate
- 5.2.2 Form of the nut, conical seat and domed washer plate
- 5.2.3 Supplier identification
- 5.2.4 Breakout facility for the nut
- 5.2.5 Type tests [Go to Page]
- 5.2.5.1 Nut breakout test
- 5.2.5.2 Assembly load test
- 5.2.5.3 Alignment test
- 6 Resins and capsules [Go to Page]
- 6.1 General
- 6.2 Capsule material
- 6.3 Capsule size
- 6.4 Shelf life of resins
- 6.5 Packaging of capsules [Go to Page]
- a) manufacturer’s name;
- b) type of resin;
- c) size of capsule;
- d) quantity of capsules;
- e) colour code, as specified in Table 2;
- f) gel and setting time at 27 ËšC (see 6.6);
- g) shelf life and storage conditions;
- h) date of manufacture;
- i) weight;
- j) batch or time reference;
- k) manufacturer’s identification;
- l) the symbols, risk and safety phrases as required under the current legislation [2];
- m) installation procedure, taking into account the Control of Substances Hazardous to Health Regulations 2002 [3].
- 6.6 Gel and setting times of mixed resin [Go to Page]
- Table 2 Resin setting times at 27 ËšC
- 6.7 Mechanical performance criteria for resins [Go to Page]
- 6.7.1 Uniaxial compressive strength (UCS)
- 6.7.2 Elastic modulus
- 6.7.3 Resistance to creep
- 6.7.4 Re-testing of resin
- 7 System type tests - Steel rockbolts [Go to Page]
- 7.1 Tensile test of threads
- 7.2 Shear test
- 7.3 Bond strength and system stiffness
- 8 System type tests - GRP rockbolts [Go to Page]
- 8.1 Tensile test of threads
- 8.2 Shear test
- 8.3 Bond strength and system stiffness
- Annex A (normative) Tensile test on steel bar [Go to Page]
- A.1 Principle
- A.2 Apparatus
- A.3 Procedure [Go to Page]
- A.3.1 Sample size
- A.3.2 Method
- A.4 Results
- Annex B (normative) Resistance to brittle fracture [Go to Page]
- B.1 Principle
- B.2 Apparatus
- B.3 Procedure [Go to Page]
- B.3.1 Sampling [Go to Page]
- Figure B.1 Charpy impact specimen - machining from bar details
- B.3.2 Method
- B.3.3 Results
- Annex C (normative) Breakout facility torque test [Go to Page]
- C.1 Procedure for steel rockbolts [Go to Page]
- C.1.1 Sample size
- C.1.2 Method
- C.1.3 Results
- C.2 Procedure for GRP rockbolts [Go to Page]
- C.2.1 Sample size
- C.2.2 Method
- C.2.3 Results [Go to Page]
- Figure C.1 Arrangement for nut breakout torque test for GRP rockbolts
- Annex D (normative) Tensile test to establish flattening and pull through loads of steel domed washer plate assemblies [Go to Page]
- D.1 Apparatus [Go to Page]
- Figure D.1 Load test arrangement for tensile test flattening and pull through loads of steel domed washer plate
- D.2 Procedure [Go to Page]
- D.2.1 Sample size
- D.2.2 Method
- D.3 Results
- Annex E (normative) Alignment test [Go to Page]
- E.1 Principle
- E.2 Apparatus [Go to Page]
- Figure E.1 Alignment capacity of conical seat and domed washer plate assembly
- E.3 Procedure [Go to Page]
- E.3.1 Sample size
- E.3.2 Measurement
- E.4 Results
- Annex F (normative) Fire resistance test on non-metallic components [Go to Page]
- F.1 Principle
- F.2 Apparatus
- F.3 Procedure [Go to Page]
- F.3.1 Sample size
- F.3.2 Method
- F.4 Results [Go to Page]
- Figure F.1 Draught-free cabinet for flame test
- Annex G (normative) Torsional strength test on GRP bar [Go to Page]
- G.1 Principle
- G.2 Apparatus [Go to Page]
- Figure G.1 Arrangement for torsional strength test on GRP bar
- G.3 Sample size
- G.4 Procedure
- G.5 Results
- Annex H (normative) Tensile strength test on GRP bar [Go to Page]
- H.1 Principle
- H.2 Apparatus
- H.3 Test specimens
- H.4 Procedure
- H.5 Results [Go to Page]
- Figure H.1 Arrangement for tensile test on GRP bar
- Annex I (normative) Minimum tensile strength of GRP rockbolt bar [Go to Page]
- I.1 Principle
- I.2 Apparatus [Go to Page]
- a) a tensile testing machine calibrated in accordance with BS EN ISO 7500-1, having a suitable recording facility;
- b) a suitably calibrated test rig which permits application of load at a steady rate and in an axial direction relative to the tube assembly.
- I.3 Procedure [Go to Page]
- I.3.1 Sample preparation
- I.3.2 Testing
- I.3.3 Results [Go to Page]
- Figure I.1 Double embedment tensile test - schematic diagram
- Annex J (normative) Flexural strength tests on GRP rockbolt bar [Go to Page]
- J.1 Principle
- J.2 Apparatus [Go to Page]
- Figure J.1 Arrangement for flexural strength test on GRP bar
- J.3 Sample size
- J.4 Procedure
- J.5 Results
- Annex K (normative) Tensile test to establish GRP bolt assembly failure load [Go to Page]
- K.1 Principle
- K.2 Apparatus [Go to Page]
- Figure K.1 Load test arrangement for GRP components
- K.3 Procedure [Go to Page]
- K.3.1 Sample size
- K.3.2 Method
- K.4 Results
- Annex L (normative) Determination of uniaxial compressive strength (UCS) of resin [Go to Page]
- L.1 Principle
- L.2 Apparatus
- L.3 Procedure [Go to Page]
- L.3.1 Preparation of test specimens
- L.3.2 Method
- L.4 Results
- Annex M (normative) Determination of elastic modulus of resin [Go to Page]
- M.1 Principle
- M.2 Apparatus
- M.3 Procedure [Go to Page]
- M.3.1 Preparation of test specimens
- M.3.2 Method
- M.4 Results [Go to Page]
- Figure M.1 Arrangement for elastic modulus test and creep test: machine platen
- Annex N (normative) Determination of creep of resin [Go to Page]
- N.1 Principle
- N.2 Apparatus
- N.3 Procedure [Go to Page]
- N.3.1 Preparation of test specimens
- N.3.2 Method
- N.4 Results
- Annex O (normative) Tensile test on rockbolt threaded end [Go to Page]
- O.1 Principle
- O.2 Apparatus [Go to Page]
- Figure O.1 Arrangement for tensile test on rockbolt threaded end
- O.3 Procedure [Go to Page]
- O.3.1 Sample size
- O.3.2 Loading
- O.4 Results
- Annex P (normative) Shear test on rockbolt/resin system [Go to Page]
- P.1 Principle
- P.2 Apparatus [Go to Page]
- Figure P.1 Sectional diagram of shear frame
- P.3 Procedure [Go to Page]
- P.3.1 Sample size
- P.3.2 Preparation of test assemblies
- P.3.3 Curing
- P.3.4 Method
- P.4 Results
- Annex Q (normative) Determination of bond strength and system stiffness [Go to Page]
- Q.1 Principle
- Q.2 Apparatus [Go to Page]
- Figure Q.1 General arrangement of lathe-based pull test apparatus
- Figure Q.2 General arrangement of hydraulic pull test apparatus
- Figure Q.3 Hydraulic biaxial pressure cell
- Q.3 Procedure [Go to Page]
- Q.3.1 Rock core preparation
- Q.3.2 Installing rock core in biaxial cell
- Q.3.3 Drilling
- Q.3.4 Bolt installation
- Q.3.5 Pull testing
- Q.3.6 Core examination
- Q.4 Results
- Q.5 Rock core performance criteria [Go to Page]
- Table Q.1 Standard consumables and criteria for rock core performance testing
- Figure Q.4 Rock core performance envelope
- Bibliography [Go to Page]
- [1] The Health and Safety at Work etc. Act 1974. London: TSO
- [2] The Chemicals (Hazard Information and packaging for Supply) Regulations 2002. London: TSO
- [3] The Control of Substances Hazardous to Health Regulations 1995. London: TSO
- [4] Shuter, DM. Enhanced standards for rockbolts HSL report MM/00/09 September 2001
- [5] Shuter, DM, Geary W and Heyes PF. Engineering performance of Mining Rockbolts. In the proceedings of the 29th International Conference on Safety in Mines Research Institute. Szczyrk, Poland 8-11 October 2001. ISBN 83-87610-32-1
- [6] International Society for Rock Mechanics Commission on Standardization of Laboratory and Field Tests, “Suggested Methods for... [Go to Page]