Cable Bolts
DYWIDAG-SYSTEMS INTERNATIONAL
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
Minicage™ Cable Bolts (Plain & Bulb) 0.5", 0.6" and 0.7" Plain Cable Bolt
Bulbed Cable Bolt
Dimensions
Physical Properties
Construction Details
Installation Accessories Cable Bolts End Holding Device - conventional style • to hold cable bolt prior to grouting 3 4" x 2 / 3 4" (19 mm x 70 mm) • 2 straps / • 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 1 4" (32 mm) for 0.5" cable bolts • Ø 1 / 1 2" (38 mm) for 0.6" cable bolts • Ø 1 / • 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 • rated for full load of cable bolt • 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
Installation Accessories continued
Passive Spinnable Cable Bolt - for resin installation • 0.6" & 0.7" cable available • resin anchored • bulbs provide resin mixing and anchoring 1 8" square or hex male spinner • accepts 1 / • 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 • rated for full load of cable bolt • used to join cables for slings or trusses • used to wrap failing pillars • requires 2 sets of wedges (included)
Grout and Breather Tubing 7 8" OD black poly tubing (400' roll) • ¾" ID x / 7 8" OD high density grout tubing (400' roll) • ¾" ID x / 5 8" OD regular poly tubing (400' roll) • ½" ID x / 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
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 1 8" hex or head. Wedge barrel shaped to accept 1 / 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 3 8" hole: plunge bulb 1 / 1" 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 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.
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
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
35,000 30,000 25,000
20,000 15,000 10,000 5,000 0
0
250
500
750
1000
Note • cylinder area = 5.01 in² • 2000 psi is the maximum pressure allowed for use with 0.6" cable
1250
1500
1750
2000
Operating Procedure For intensified cable truss tensioner
• 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
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
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.
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.
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 foll ow 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 HITEN 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.
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 to oth shaped threads which are forced into the surface of the cable wires.
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.
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 dirtaccumulation), 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)
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.
USA DSI Underground Systems, Inc. 9786 S Prosperity Road West Jordan, UT 84081, USA Phone: +1-801 973-7169 Fax: +1-801 973-7172 DSI Underground Systems, Inc. 447 DuPont Rd. Martinsburg, WV 25404, USA Phone: +1-800 332-3308 Fax: +1-304 274-4194 DSI Underground Systems, Inc. 700 Technology Dri ve South Charleston, WV 25309, USA Phone: +1-800 547-4751 Fax: +1-304 553-0924 DSI Underground Systems, Inc. 1959 Old White Plains Road Morton’s Gap, KY 42440, USA Phone: +1-800 547-4751 Fax: +1-270 258-9204 DSI Underground Systems, Inc. 9344 Sunrise Road Cambridge, Ohio 43725, USA Phone: +1-800 457-7633 Fax: +1-740 432-2827 DSI Underground Systems, Inc. 26161 Old Trail Road Abi ngd on VA 2 421 0- 763 1, U SA Phone: +1-276 623-2784 Fax: +1-276 623-8273 DSI Underground Systems, Inc. 1774 Mellwood Ave Louisville KY 40206-1756, USA Phone: +1-502 473-1010 Fax: +1-502 473-0707 DSI Underground Systems, Inc. 1032 East Chestnut Street Louisville KY 40204-1019, USA Phone: +1-502 583-1001 Fax: +1-502 583-7865 Canada DSI Canada Ltd. 3919 Millar Avenue Saskatoon SK S7P 0C1, Canada Phone: +1-306 244-6244 Fax: +1-306 931-3481
A R G E N T I N A DSI Canada Ltd. 199 Mumford Road Unit C&D Lively ON P3Y 1L2, Canada Phone: +1-705 692-6100 Fax: +1-705 692-0441
A U S T R A L I A A U S T R I A BELGIUM BOSNIA AND HERZEGOVINA BRAZIL
DSI Canada Ltd. 853 Boulevard Rideau Rouyn-Noranda, QC J9Y 0G3, Canada Phone: +1-819 762-0901 Fax: +1-819 797-1367 Mexico DS Internat ional S.A. de C.V. Carretera a Base Aérea Militar No. 1002 Bodegas 13, 14 & 15 Parque Industrial FERRAN San Juan de Ocotán, Zapopan, Jalisco México CP 45010 Phone: +52-33-3366-57-94 Fax: +52-33-3366-58-03 Brazil DSI Fosminas Rua Um, 276 Distrito Industrial da bela Fama Nova Lima/MG, Brazil Phone: +55-31-35 42 02 00 Fax: +55-31-35 42 08 10 Chile DSI Chile Industrial Ltda. Las Encinas #1387 Vall e Gr and e Lampa, Santiago de Chile, Chile Phone: +56-2-596 96 20 Fax: +56-2-596 96 69 Colombia DSI Colombia S.A.S Carrera 43A No. 8 sur – 15 Oficina 403 Edificio Torre Oviedo Medellín, Colombia Phone: +57-4-403 12 00 Fax: +57-4-403 12 01 Peru DSI Peru S.A.C. Calle Rodolfo Beltran No. 947 Lima 1, Perú Phone: +51-1-431 3157 Fax: +51-1-638 3201
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Please Note: This brochure serves basic information purposes only. Technical data and infor mation provided herein shall be considered non-binding and may be subject to change without notice. We do not assume any liability for losses or damages attributed to the use of this technical data and any improper use of our products. Should you require further information on particular products, please do not hesitate to contact us.
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