Ground Control Solutions for Tunneling and Mining 2 Contents
DSI’s Business Activities in the Underground Construction Market ...... 4
DYWI® Drill...... 6
DYWI® Drill Hollow Bar System ...... 7 DYWI® Drill S-D Expansion Bolt Type T...... 15 DYWI® Drill System Accessories ...... 21
Anchors and Rock Bolts ...... 26
Mechanical Anchors, Resin and Rebar Rock Bolts ...... 27 CT-BoltTM Combination Rock Bolts ...... 39 Friction Stabilizers ...... 43 OMEGA-BOLT® Expandable Friction Bolts ...... 47 POWER SET Self-Drilling Friction Bolts ...... 51 DYWIDAG Cable Bolts ...... 59 DYWIDAG GRP Anchors and Rock Bolts ...... 63
Pre-Support ...... 68
AT - Pipe Umbrella Support System ...... 69 AT - TUBESPILETM ...... 81 Spiles and Forepoling Boards ...... 85
Drainage Drilling Systems ...... 94
AT - TUBESPILETM Vacuum Lances ...... 95 AT - Drainage System ...... 99
Passive Support ...... 104
PANTEX Lattice Girders ...... 105 Support Profiles and Rock Bolt Straps ...... 108 LSCTM Elements...... 113
Injection and Waterproofing Systems ...... 118
AT - GRP Injection Systems ...... 119 DYWI® Inject Systems - Underground ...... 123 DYWI® Seal Waterproofing System and Bentonite Mats ...... 145
Service, Accessories and Equipment ...... 154
3 DSI’s Business Activities in the Underground Construction Market
DYWIDAG-Systems International (DSI) is a global market leader in the development, Ground Control Solutions manufacturing, and distribution of systems and products for the construction industry.
ALWAG Tunnelausbau Gesellschaft m.b.H. was merged into DYWIDAG-Systems Ground Control Solutions International GmbH., Austria. The goal of this merger was to create a consistent presence on the Austrian market while simultaneously strengthening the international distribution of the innovative ALWAG Systems. DSI continues to use the well-known brand name ALWAG on the market.
DSI Austria’s main business is the development, manufacturing, and distribution of entire product lines and system solutions for Tunneling, Mining, and Special Foundations. In conformity with DSI’s mission statement “Local Presence - Global Competence”, Product Range DSI Austria is oriented towards its customers’ needs and offers the advantages of complete DSI Austria’s extensive product range includes: DSI product lines, which are adjusted to ■■ Anchors and Rock Bolts individual customer requirements. All Rebar Rock Bolt; Mechanical Anchor; GEWI® Anchor and Rock Bolt; GRP Rock underground construction activities in Europe, Bolt; DYWI® Drill Hollow Bar System; OMEGA-BOLT® Expandable Friction Bolt; Middle East, and Africa (EMEA) are coordinated POWER SET Self-Drilling Friction Bolt; Friction Stabilizer; CT-BoltTM; DSI Resin by DSI Austria. Cartridges DSI Austria’s product range includes a wide ■■ Spiles TM variety of anchors, rock bolts, and support Rebar Spile; Injection Spile; IBO - Self-Drilling Spile; AT - TUBESPILE systems, as well as the well-known series of ■■ Rock Support the field-approved AT-SYSTEM. The AT - Casing PANTEX Lattice Girder; LSCTM Element; Forepoling Board; Underground Beam System, as part of this series, is just one ■■ AT - Casing System example for DSI Austria’s high quality systems. AT - Pipe Umbrella Support System; AT - Drainage System, AT - GRP Injection It permits the cost-effective and practical System; AT - Automation Unit implementation of static support, injection, or ■■ Injection and Waterproofing Systems drainage drills. DYWI® Inject Systems; DSI Waterproofing System; RIA Rotary-Injection-Adapter; Flow-Pressure Meter; Mortar-Mixing Pump; Injection Packer, Injection Lance and The POWER SET Self-Drilling Friction Bolt and Gunite Pipe AT - TUBESPILETM as well as the LSCTM Element, which offers support for squeezing rock ground conditions, also form part of DSI Austria’s innovative system solutions.
4 Ground Control Solutions Ground Control Solutions
Research & Development Technical Support & Services All R&D activities of DSI Underground EMEA are coordinated by DSI provides technical support as well as on-site product the Regional Head Office based in Pasching, Austria. As a result management carried out by a team of experienced technicians of the consolidation of its activities, DSI provides a full range of and supervisors. Our service team is available for general and ground control products globally, backed by technical support product-specific questions related to: and innovative system solutions. This has already led to a more effective customer service, ■■ Design, testing, and evaluation of ground control systems benefiting from the transfer of technology made possible by this ■■ Self-Drilling ground control technology consolidation: ■■ Layout and optimization of lattice girder support ■ Pipe umbrella support and drainage drilling works ■■ Preparation of National and European Technical Approvals ■ ■ Accomplishment and monitoring of injection works ■■ Self-Drilling ground control solutions: ■ one-step anchors, rock bolts, and forepoling elements ■■ Testing of product usage properties featuring immediate load-bearing capacity ■■ Rock bolt automation: fully automated bolting attachment units for underground construction ■■ AT - Pipe Umbrella Support System: various innovative pipe connections tailored to customer demands ■■ LSCTM Element: improved yielding support element for advances dealing with squeezing or swelling ground conditions ■■ Numerical simulations, laboratory and field tests of DSI’s products: understanding of the in-situ behavior of ground control solutions
5 DYWI® Drill
DYWI® Drill Hollow Bar System ...... 7
DYWI® Drill S-B Expansion Bolt Type T...... 15
DYWI® Drill System Accessories ...... 21
6 DYWI® Drill Hollow Bar System
Introduction...... 7
Fields of Application...... 8
Main Advantages...... 9
System Description...... 9
System Components...... 10
Specifications...... 11
Drill Bits...... 12
Installation Procedures...... 13
Accessories...... 14
Further References...... 14
Introduction
The DYWI® Drill Hollow Bar System is a self-drilling ground control solution used in Civil Engineering and underground construction. It features a wide range of applications such as soil nails, micro- piles, rock bolts, or ground anchors.
Installations in weak ground and under unstable borehole conditions represent no difficulty and are ideal for the application of the DYWI® Drill Hollow Bar System.
Additionally, the DYWI® Drill Hollow Bar System may be used as a forepoling element for pre-support or as a lance for injection works.
DYWIDAG-Systems International has a long-term experience in the development, manufacturing, and distribution of the DYWI® Drill Hollow Bar System.
7 Fields of Application Civil Engineering
■■ Pile foundation ■■ Reinforcement of excavation pits and ■■ Anchorage of avalanche protection ■■ Buoyancy control retaining walls structures and noise barriers ■■ Slope and embankment stabilization ■■ Foundation of pylons and wind mills ■■ Injection works
Underground Mining and Tunneling
■■ Stabilization of tunnel portals, ■■ Face stabilization ■■ Roof and rib bolting trenches, and cut-and-cover areas ■■ Radial rock bolting ■■ Injection works ■■ Forepoling ■■ Foot piles
8 Main Advantages
■■ Fast and safe self-drilling installation ■■ Sound and efficient alternative ■■ Functional adjustment of required ■■ Easy and similar operating principle compared to time-consuming cased lengths using couplings using on-site personnel and standard drilling installation methods and ■■ Broad range of hollow bar load drilling machinery products capacity classes allows basic ■■ Drilling, installation, and optional ■■ Minimization of ground disturbance dimensioning and adaptation of grouting in a single operational step ■■ Adjustment of the drill bit design and design ■■ Proven installation process under diameter to different and varying ■■ Robust system and high-strength difficult ground conditions ground conditions possible thread designed for the demands of the construction industry ■■ Trouble-free application under ■■ Minor space requirements for unstable borehole conditions installation
System Description
■■ Self-Drilling ground control solution ■■ Installation with standard rotary ■■ Grouting may either be performed ■■ Used as anchor, rock bolt, soil nail, or rotary-percussive rock drilling while drilling with a rotary injection micropile, spile, or injection lance equipment adapter or after the drilling operation ■■ Preferably used under unstable ■■ Hollow bar with continuous left-hand ■■ Thread profile allows an ideal bond borehole conditions cold-rolled outside thread utilized as between the hollow bar and the drill rod during installation grouting medium ■■ Self-Drilling installation without casing using a lost drill bit ■■ Easy extension of hollow bars using ■■ Assembly and fixation of the head couplings construction: plate and nut
9 System Components
■■ Nut ■■ Coupling ■■ Drill Bit ■ Convex seat or domed version ■ Continuous inside thread with ■ One drill bit per installed unit ■ Different designs and dimensions middle stop ■ Different diameters and designs available ■ Controlled drilling energy ■ Hardened and carbide insert transmission versions ■ Full load bearing capacity
Example: assembly system components rock bolt
Nut Coupling Drill Bit
Plate Hollow Bar
■■ Plate ■■ Hollow Bar ■ Flat or domed ■ Used as drill rod during installation ■ Plate design adjusted to ■ Suitable for simultaneous or system demands subsequent grouting ■ Various angle compensation ■ Tension or compression member systems and special plate designs with continuous left-hand available outside thread
10 Specifications
■■ Special lengths and dimensions ■■ Galvanized or combi-coated system ■■ DSI product approvals also include available on request components available on request notes for temporary or permanent system applications
Technical Data Series R32
No. Characteristic Value / Type1) Symbol Unit R32-210 R32-250 R32-280 R32-320 R32-360 R32-400 1 Nominal external diameter Øe.nom [mm] 32 2 Actual external diameter Øe [mm] 31.1 2) 3 Average internal diameter Øi [mm] 21.0 20.0 18.5 16.5 15.0 12.5 3) 4 Nominal cross-sectional area S0 [mm²] 340 370 410 470 510 560 5 Nominal weight 4) m [kg/m] 2.65 2.90 3.20 3.70 4.00 4.40 5) 6 Yield load Fp0.2.nom [kN] 160 190 220 250 280 330 5) 7 Ultimate load Fm.nom [kN] 210 250 280 320 360 400 6) 8 Yield strength Rp0.2 [N/mm²] 470 510 540 530 550 590 6) 9 Ultimate strength Rm [N/mm²] 620 680 680 680 710 710 7) 10 Rm / Rp0.2 – [1] ≥ 1.15 7) 11 Ultimate load strain Agt [%] ≥ 5.0 12 Thread standard – [–] ISO 10208 13 Standard bar length 8) L [m] 2/3/4/6 14 Article No. 9) – [–] 30101YYY10X0
Technical Data Series R38 and R51
No. Characteristic Value / Type 1) Symbol Unit R38-420 R38-500 R38-550 R51-550 R51-660 R51-800 1 Nominal external diameter Øe.nom [mm] 38 51 2 Actual external diameter Øe [mm] 37.8 49.8 2) 3 Average internal diameter Øi [mm] 21.5 19.0 17.0 34.5 33.0 29.0 3) 4 Nominal cross-sectional area S0 [mm²] 660 750 800 890 970 1150 5 Nominal weight 4) m [kg/m] 5.15 5.85 6.25 6.95 7.65 9.00 5) 6 Yield load Fp0.2.nom [kN] 350 400 450 450 540 640 5) 7 Ultimate load Fm.nom [kN] 420 500 550 550 660 800 6) 8 Yield strength Rp0.2 [N/mm²] 530 530 560 510 560 560 6) 9 Ultimate strength Rm [N/mm²] 640 670 690 620 680 700 7) 10 Rm / Rp0.2 – [1] ≥ 1.15 7) 11 Ultimate load strain Agt [%] ≥ 5.0 12 Thread standard – [–] ISO 10208 ISO 1820 13 Standard bar length 8) L [m] 2/3/4/6 14 Article No. 9) – [–] 30201YYY10X0 30301YYY10X0
Technical Data Series T76
No. Characteristic Value / Type1) Symbol Unit T76-1200 T76-1600 T76-1900 1 Nominal external diameter Øe.nom [mm] 76 2 Actual external diameter Øe [mm] 74.6 3) 3 Nominal cross-sectional area S0 [mm²] 2000 2700 3200 4 Nominal weight 4) m [kg/m] 16 20 24 5) 5 Yield load Fp0.2.nom [kN] 1000 1200 1500 5) 6 Ultimate load Fm.nom [kN] 1200 1600 1900 6) 7 Yield strength Rp0.2 [N/mm²] 500 450 470 6) 8 Ultimate strength Rm [N/mm²] 600 600 600 7) 9 Rm / Rp0.2 – [1] > 1.15 7) 10 Ultimate load strain Agt [%] > 5.0 11 Thread standard – [–] DSI T76 12 Standard bar length 8) L [m] 2/3/4 13 Article No. 9) – [–] 30401YYY10X0
1) Status: 2012-06, note: all values are subject to change 2) Calculated from the actual external diameter, the average thread height, and the nominal cross-sectional area, rounded 6 3 3) Calculated from the nominal weight: S0 = 10 x m / 7,850 [kg/m ] ; 4) Deviation: -3 / +9 [%] ; 5) Characteristic 5%-fractile value 6) Calculated from the characteristic load value and nominal weight, rounded ; 7) Characteristic 10%-fractile value 8) Off-size bar lengths are available on request / modulus of elasticity: 205,000 [N/mm2] ; 9) “YYY“ ... Ultimate Load/10 [kN]; “X“ ... hollow bar length [m]
11 Drill Bits Characteristics
■■ Successful installation performance ■■ Optimized in regards to installation ■■ Further information regarding drill bit dependent on selection of the drill bit parameters such as cutting ability and design and selection are included in a ■■ Large drill bit portfolio for different drilling rates separate DSI leaflet on drill bits for the ® ground conditions ■■ Adjusted to the requirements of Civil DYWI Drill Hollow Bar System Engineering as well as underground Mining and Tunneling
Article No. Description Article Code Design Thread Diameter Ø [mm] 1)
(„XXX“ … Diameter Ø [mm]) 51 76 90 100 110 115 120 130 150 175 200 300
301080111XXX R32 X X 302080111XXX Cross drill bit, R38 X X X CB-Thread-D-HD 303080111XXX hardened R51 X X X X X X 304080111XXX T76 XXXX
301080121XXX R32 X X Cross drill bit, 302080121XXX R38 X X X with carbide CB-Thread-D-HM 303080121XXX R51 XXX inserts 304080121XXX T76 XX X
301080211XXX R32 X X 302080211XXX Button drill bit, R38 X X X X BB-Thread-D-HD 303080211XXX hardened R51 X X X 304080211XXX T76 XX
301080221XXX R32 X X Button drill bit, 302080221XXX R38 X X X X with carbide BB-Thread-D-HM 303080221XXX R51 X X X inserts 304080221XXX T76 XX
301080411XXX Arc-shaped R32 X X X X 302080411XXX drill bit, AR-Thread-D-HD R38 X X X 303080411XXX hardened R51 X X
301080511xxx R32 X X Arc-shaped drill bit, 302080421XXX AR-Thread-D-HM R38 with carbide inserts 303080421XXX R51
301080811XXX R32 X X 302080511XXX Arc-shaped button R38 X X X AB-Thread-D-HD 303080511XXX drill bit, hardened R51 X X X 304080511XXX T76 XX
301080521XXX R32 X X Arc-shaped button 302080521XXX R38 X X X drill bit, AB-Thread-D-HM 303080521XXX R51 X X X with carbide inserts 304080521XXX T76 XX
301080611XXX R32 Two-stage R-flush 302080611XXX R38 drill bit TSB-Thread-D-R 303080611XXX R51 (retro-flush), hardened 304080611XXX T76 XXXXXX
301080613XXX R32 X X X X Two-stage RS-flush 302080613XXX R38 X X X XX drill bit (retro-flush and TSB-Thread-D-RS 303080613XXX R51 X XX side flush), hardened 304080613XXX T76
1) X-marked fields indicate standard drill bit types, other dimensions available on request
12 Installation Procedures
Self-drilling installation may be accomplished either manually or semi-automated, depending on the available drilling machinery.
Simultaneous drilling Self-drilling installation and grouting and subsequent grouting
■■ Assembly of the DYWI® Drill Hollow Bar System and ■■ Assembly of the DYWI® Drill Hollow Bar System and connection to the rotary injection adapter connection to the rock drill
■■ Rotary self-drilling installation and simultaneous grouting ■■ Rotary percussive self-drilling installation without casing: single-use drill bit and hollow bar drill steel, water or air- water mixture flushing
■■ Optional extension using couplings ■■ Optional extension using couplings
■■ De-coupling from the rotary injection adapter ■■ De-coupling from the drilling machinery, subsequent grouting using a post-grouting adapter
■■ Assembly of anchorage or head construction (plate and nut), depending on the application
Technical Features
■■ Immediate grouting ensures ideal mixing with loose gravel or soil ■■ Permeation of the grout into the surrounding ground ■■ Improved and uniform distribution of the grouting medium over the entire installation length
13 Accessories
■■ Centralizers ■■ Drill bit adapters ■■ Flow-Pressure meters ■■ Sleeves for free length systems ■■ Rotary injection adapters ■■ Stressing, pre-loading, or pull testing ■■ Rock drilling equipment: shank ■■ Grouting adapters equipment adapters, couplings, and coupling ■■ DSI cement grout ■■ Further information on accessories adapters can be found in DSI’s system ■■ Mortar-Mixing pumps brochures and technical approvals
Corrosion Protection
■■ Design principle sacrificial corrosion protection: consideration of loss in cross-section over the design life, depending on the corrosion potential ■■ Improved corrosion protection of the DYWI® Drill Hollow Bar System: galvanized or duplex coated versions available on request ■■ Hollow bar galvanizing according to EN 1461 ■■ Hollow bar duplex coating according to EN 15773 and EN 13438 ■■ Further information on permanent system applications and corrosion rate classifications are included in DSI’s product approvals
Further References
■■ DSI leaflet on drill bits for the application by the Austrian Federal permanent application, currently in DYWI® Drill Hollow Bar System Ministry of Transport, Innovation preparation (ETA application: GZ OIB- ■■ EN 14490: Execution of special and Technology, Vienna, GZ: BMVIT- 240-007/09) geotechnical works - Soil nailing 327.120/0010-IV/ST2/2012 ■■ Designs and dimensions of system ■■ EN 14199: Execution of special ■■ European Technical Approval (ETA) as components and primary material geotechnical works - Micropiles rock and soil nail for temporary and specifications are included in DSI’s system brochures and approvals ■■ EN 1461: Hot dip galvanized coatings on fabricated iron and steel articles - Specifications and test methods ■■ EN 15773: Industrial application of powder organic coatings to hot dip galvanized or sherardized steel articles [duplex systems] - Specifications, recommendations and guidelines ■■ EN 13438 Paints and varnishes - Powder organic coatings for galvanized or sherardised steel products for construction purposes ■■ Approval for application as soil nail for temporary and semi-permanent
14 DYWI® Drill S-D Expansion Bolt Type T
Introduction ...... 15
Fields of Application ...... 16
Main Advantages ...... 16
System Description...... 16
System Components ...... 17
Technical Data ...... 18
Technical Features ...... 18
Installation Procedure ...... 19
Accessories ...... 19
Further References ...... 19
Order Information...... 19
Introduction
Within the last few years, various so-called Immediately after the self-drilling ”one-step” rock bolt systems have been installation, an activation of the developed. This is a result of steadily expansion element leads to immediate increasing demands on rock bolting load-bearing capacity. procedures in underground Mining The DYWI® Drill Expansion Bolt can and Tunneling and the ensuing higher be optionally tensioned following the demand for self-drilling rock bolts. fixation of plate and nut. Subsequent The self-drilling rock bolt product family grouting, de-coupled from the actual has now been extended by providing an installation procedure, permits further expansion element for the optimization of installation cycle times. DYWI® Drill Hollow Bar System. The DYWI® Drill Expansion Bolt is The key factor for the success of this available in two different versions. rock bolt is the combination of the long- Type M is mainly used for systematic term proven DYWI® Drill Hollow Bar rock bolting in underground Mining (see with a robust and innovative expansion separate brochure). Type T is used for element. The DYWI® Drill Expansion Bolt rock bolting in hanging wall areas and in is installed self-drilling; borehole drilling applications that require an extension of and bolt installation are accomplished bolts using couplings. in one operational step. The system’s adaptability to changing rock and ground conditions is an important feature of the DYWI® Drill Expansion Bolt.
15 Fields of Application Main Advantages
■■ Mining ■■ Simultaneous drilling and installation ■■ Safe, easy, and reproducible ■ Systematic rock reinforcement ■■ Installation using standard drilling installation procedure ■ Rock bolting in remote areas or areas machinery ■■ Improved drilling accuracy thanks to of difficult access ■■ Immediate load-bearing capacity the directional guidance of the ■ Supplementary bolting after installation and activation of the self-drilling expansion element ■ Utility and hanger bolts expansion element ■■ Trouble-free application in unstable ■■ Tunneling ■■ Reduction of cycle time due to the borehole conditions ■ Rock bolting in underground caverns de-coupling of the grouting procedure ■■ Easy extension using couplings ■ Face bolts from installation ■ Driving in critical ground conditions ■■ Design and diameter of the ■ Squeezing ground ■■ Ability to maintain load-bearing expansion element can be adjusted capacity even when undergoing large to suit different and varying ground ■■ Civil Engineering deformations conditions ■ Rock fall and rock slide protection ■ Anchorage of avalanche barriers ■■ Tough system components ■ Reinforcement of excavation pits and retaining walls
System Description DYWI® S-D Expansion Bolt Type T, R32-051
■■ Expansion bolt: mechanically anchored and fully grouted ■■ Self-drilling installation based on the principle of the DYWI® Drill Hollow Bar System ■■ Hollow bar with continuous cold-rolled left-hand outside thread utilized as drill rod during installation ■■ Rotary-percussive installation using standard underground drilling machines ■■ Conventional or automated installation ■■ Immediate load-bearing capacity via DYWI® S-D Expansion Bolt Type T, R38-076 the mechanical end anchorage ■■ Subsequent optional grouting feature ■■ Flexible application range from 210 to 800 [kN]: R32-210 to R51-800 ■■ Type T: version for rock bolting in hanging wall areas or for larger bolt lengths, permits coupled installation ■■ Type T: utilization of several subsequently aligned expansion elements allows a higher load-bearing capacity even in weak ground DYWI® S-D Expansion Bolt Type T, R38-076, with two coupled expansion elements
16 System Components Type T
■■ DYWI® Drill Bit ■■ DYWI® Drill Hollow Bar R32, R38 or R51 ■■ Domed plate ■ Single-use drill bits in different ■ Used as drill rod during installation ■ Different designs and dimensions diameters and designs ■ Type R32-210 to R51-800 available on request ■ Hardened or carbide inserts ■■ DYWI® Drill Coupling ■■ DYWI® Drill Nut ® ■■ DYWI Drill S-D Expansion Element ■ Optional extension ■■ Drive adapter Type T ■ Continuous inside thread with ■ Couplings in different versions ■ Standard hollow bar diameters: middle stop R32, R38 and R51 ■ Controlled drilling energy transmission ■ R38 and R51: several coupled ■ Full load bearing capacity expansion elements can be used
Ready-for-use DYWI® S-D Expansion Bolt Type T, R32-051
Ready-for-use DYWI® S-D Expansion Bolt Type T, R38-076
17 Technical Data Series R32
No. Characteristic Value / Type 1) Symbol Unit R32-210 R32-250 R32-280 R32-320 R32-360 R32-400
1 Nominal external diameter Øe.nom [mm] 32 2 Actual external diameter Øe [mm] 31.1 2) 3 Average internal diameter Øi [mm] 21.0 20.0 18.5 16.5 15.0 12.5 3) 4 Nominal cross-sectional area S0 [mm²] 340 370 410 470 510 560 5 Nominal weight 4) m [kg/m] 2.65 2.90 3.20 3.70 4.00 4.40 5) 6 Yield load Fp0.2.nom [kN] 160 190 220 250 280 330 5) 7 Ultimate load Fm.nom [kN] 210 250 280 320 360 400 6) 8 Yield strength Rp0.2 [N/mm²] 470 510 540 530 550 590 6) 9 Ultimate strength Rm [N/mm²] 620 680 680 680 710 710 7) 10 Rm/Rp0.2 – [1] ≥ 1.15 7) 11 Ultimate load strain Agt [%] ≥ 5.0 12 Thread standard – [–] ISO 10208 13 Standard bar length 8) – [m] 2/3/4/6 14 Article No. 9) – [–] 30101YYY10X0
Technical Data Series R38 and R51
No. Characteristic Value / Type 1) Symbol Unit R38-420 R38-500 R38-550 R51-550 R51-660 R51-800
1 Nominal external diameter Øe.nom [mm] 38 51 2 Actual external diameter Øe [mm] 37.8 49.8 2) 3 Average internal diameter Øi [mm] 21.5 19.0 17.0 34.5 33.0 29.0 3) 4 Nominal cross-sectional area S0 [mm²] 660 750 800 890 970 1150 5 Nominal weight 4) m [kg/m] 5.15 5.85 6.25 6.95 7.65 9.00 5) 6 Yield load Fp0.2.nom [kN] 350 400 450 450 540 640 5) 7 Ultimate load Fm.nom [kN] 420 500 550 550 660 800 6) 8 Yield strength Rp0.2 [N/mm²] 530 530 560 510 560 560 6) 9 Ultimate strength Rm [N/mm²] 640 670 690 620 680 700 7) 10 Rm/Rp0.2 – [1] ≥ 1.15 7) 11 Ultimate load strain Agt [%] ≥ 5.0 12 Thread standard – [–] ISO 10208 ISO 1820 13 Standard bar length 8) – [m] 2/3/4/6 14 Article No. 9) – [–] 30201YYY10X0 30301YYY10X0
1) Status: 2012-06, note: all values are subject to change 2) Calculated from the actual external diameter, the average thread height, and the nominal cross-sectional area, rounded 3 3) Calculated from the nominal weight: S0 = 106 x m/7,850 [kg/m ] 4) Deviation: -3 /+9 [%] 5) Characteristic 5%-fractile value 6) Calculated from the characteristic load value and nominal weight, rounded 7) Characteristic 10%-fractile value 8) Off-size bar lengths are available on request / modulus of elasticity: 205,000 [N/mm2] 9) “YYY“ ... Ultimate Load/10 [kN]; “X“ ... hollow bar length [m]
Technical Features
■■ Adjustment of the single-use DYWI® Drill bits to different rock conditions and applications ■■ Reliable anchorage in the toe area due to a widening of the expansion element ■■ Free length systems available on request ■■ Compression tube anchor version available on request
18 Installation Procedure Type T
■■ Assembly of the DYWI® Drill Expansion Bolt Type T and connection of the drive adapter to the rock drill ■■ Rotary percussive self-drilling installation (counterclockwise rotation) without casing: single-use drill bit and hollow bar drill steel, water or air-water mixture flushing ■■ Optional extension using couplings ■■ Activation of the expansion element after the final drilling depth has been reached: withdrawal of the rock drill with hammer strokes ■■ De-coupling of the drive adapter ■■ Fixation and assembly of anchorage (plate and nut) ■■ Optional de-coupled post injection
Accessories Further References Order Information
® ■■ Centralizers ■■ Leaflet DYWI Drill Hollow Bar System Description Article No. ■■ Sleeves for free length systems ■■ DSI leaflet on drill bits for the S-D Expansion Bolt Type T, R32-051 301050043051 ® ■■ Rock drilling equipment: DYWI Drill Hollow Bar System S-D Expansion Bolt Type T, R32-076 301050044076 shank adapters, couplings, and ■■ Approval for application as soil nail S-D Expansion Bolt Type T, R38-095 301050044095 S-D Expansion Bolt Type T, R51-125 301050044125 coupling adapters for temporary and semi-permanent ■■ Grouting adapters application by the Austrian Federal Ministry of Transport, Innovation and ■■ DSI cement grout Technology, Vienna, ■■ Mortar-Mixing pumps GZ: BMVIT-327.120/0010-IV/ST2/2012 ■■ Flow-Pressure meters ■■ European Technical Approval (ETA) as ■■ Stressing, pre-loading, or pull testing rock and soil nail for temporary and equipment permanent application, currently in preparation (ETA application: GZ OIB-240-007/09)
19 DYWI® Drill System Accessories
20 DYWI® Drill System Accessories
Introduction...... 21 DYWI® Drill Sealing Coupling...... 22 Fields of Application ...... 22 Main Advantages ...... 22 Specifications ...... 22 Technical Features ...... 22 Accessories ...... 22 DYWI® Drill Lock Coupling ...... 23 Fields of Application ...... 23 Main Advantages ...... 23 System Description ...... 23 Specifications...... 23 Technical Features ...... 23 Accessories ...... 23 DYWI® Drill Post-Injection Coupling ...... 24 Fields of Application ...... 24 Main Advantages ...... 24 System Description ...... 24 Specifications...... 24 Technical Features ...... 24 Accessories ...... 24 DYWI® Drill Expansion Shell ...... 25 Fields of Application ...... 25 Main Advantages ...... 25 System Description ...... 25 Specifications...... 25 Technical Features ...... 25 Accessories ...... 25 Angle Compensation Plates...... 25 Spacers...... 25 Drill Bit Adapters...... 25
Introduction
The DYWI® Drill Hollow Bar System is a DYWI® Drill Sealing Couplings, Lock self-drilling reinforcement element used Couplings and Post-Injection Couplings in Civil Engineering and underground complete the range of premium quality construction. The broad field of system accessories and supplement the application ranges from soil nails and DYWI® Drill standard coupling. anchors to micropiles and rock bolts. The DYWI® Drill Expansion Shell permits Neither difficult ground conditions nor an immediate and secure anchorage unstable boreholes are limiting factors of hollow bar tension members in for the application of the DYWI® Drill pre-drilled boreholes. For challenging Hollow Bar System. In addition to the and demanding rock bolt procedures, applications mentioned above, the DSI also offers the DYWI® Drill S-D DYWI® Drill Hollow Bar System is also Expansion Bolt (see separate brochure). used as a forepoling element (spile) or as an injection lance for ground Angle compensation plates allow a improvement or cavity filling. safe anchorage even in large angular deviation. Spacers and drill bit adapters are additional accessories for installation.
21 DYWI® Drill Sealing Coupling
Due to the design of conventional The DYWI® Drill Sealing Coupling allows This advantage is especially significant couplings for standard applications, the an optimized installation procedure with for simultaneous drilling and injection absolute leak tightness of the couplings regards to the leak tightness of the drill operations. cannot be warranted when applying string. standard flushing pressures.
Fields of Application
■■ Suitable for all standard DYWI® Drill system applications ■■ Simultaneous drilling and grouting using rotary injection adapters (flushing heads) ■■ Drilling operations with increased demands in terms of occupational safety and cleanliness
Main Advantages
■■ Targeted and safe injection of the flushing and/or injection medium ■■ DYWI® Drill Sealing Couplings ensure leak tightness when applying standard flushing pressures ■■ Easy application; same operating principle as for standard couplings
Specifications Technical Features Accessories
■■ Available for series R32, R38 and R51 ■■ Handling during installation is the ■■ See DYWI® Drill Hollow Bar System ■■ Designed for the highest load-bearing same as for standard couplings leaflet capacities ■■ A sealing ring inside the coupling and ■■ Mortar-Mixing and injection pumps ■ R32-400 chamfered hollow bar ends ensure ■■ Flow-Pressure meters ■ R38-550 optimum leak tightness ■■ Flushing heads ■ R51-800
22 DYWI® Drill Lock Coupling
When using standard couplings for Faulty installation may be caused by The DYWI® Drill Lock Coupling prevents installation, couplings inside the worn out coupling adapters, damaged a loosening of couplings inside the borehole may loosen due to hammer or missing clamping jaws, or loose borehole – the hollow bar is installed strokes applied in the course of drill couplings if non system-conform continuously in one piece. string extension. There may be no components have been used. external signs for this failure.
Fields of Application Main Advantages System Description
■■ Suitable for all standard DYWI® Drill ■■ The DYWI® Drill Lock Coupling does The standard coupling is replaced by a system applications not detach itself during a clockwise DYWI® Drill Lock Coupling. ■■ Rotary-percussive installation (drilling rotation of the drill string direction: counter-clockwise) ■■ Trouble-free extension or de-coupling During the counter-clockwise rotation of the drill string, the inside locking ■■ Longer hollow bar members with more of the drill string mechanism (toothed gear with radial and than one coupling ■■ Especially suitable for free length longitudinal teeth) cuts transverse ribs sections ■■ Structures with increased demands in onto the hollow bar. Thus, the hollow terms of occupational and structural ■■ Controlled removal of defined hollow bar coupling is locked against clockwise safety bar sections by the selective use of rotation and loosening. ■■ Installation of the DYWI® Drill Hollow standard couplings and lock couplings Bar System using drill booms without The DYWI® Drill Lock Coupling is clamping devices optionally available with a one-sided or ■■ Rehabilitation and re-working of old double locking mechanism. drifts and tunnels
Specifications Technical Features Accessories
■■ Available for series R32, R38 and R51 ■■ Handling during installation is the ■■ See DYWI® Drill Hollow Bar System ■■ Designed for highest load-bearing same as for standard couplings leaflet capacities ■■ The DYWI® Drill Lock Coupling ■■ Mortar-Mixing and injection pumps ■ R32-400 permits rotary-percussive installation ■■ Flow-Pressure meters ■ R38-550 (counter-clockwise) and locks the ■ R51-800 coupling during clockwise rotation of the drill string
23 DYWI® Drill Post-Injection Coupling
By default, the annular gap between The DYWI® Drill Post-Injection Coupling These injections can be carried out hollow bar and ground is grouted via allows the targeted post-injection for ground improvement, sealing, or the outlet port at the drill bit to achieve through the cleaned inner hole of the compensating grouting. improved load transmission. hollow bar using different injection media.
Fields of Application
■■ The load-bearing capacity of the DYWI® Drill Hollow Bar System can be improved by multiple injections ■■ Ground improvement ■■ Sealing measures ■■ Compensation grouting ■■ Re-working of caved areas or driving through fault zones
Main Advantages
■■ Application in all ground types ■■ No partial loss of drilling and cooling medium during installation ■■ Controlled and targeted post-injection of the ground
System Description
The standard coupling is replaced by a DYWI® Drill Post-Injection Coupling.
This special coupling type allows targeted multiple injections through circumferentially aligned injection holes with valves.
Valve opening pressures can be adapted on customer request.
Specifications Technical Features Accessories
■■ Available for series R32, R38 and R51 ■■ Handling during installation is the ■■ See DYWI® Drill Hollow Bar System ■■ Designed for highest load-bearing same as for standard couplings leaflet capacities ■■ The load-bearing capacity of the ■■ Mortar-Mixing and injection pumps ■ R32-400 system (hollow bar – coupling) remains ■■ Flow-Pressure meters ■ R38-550 completely intact ■■ DYWI® Inject Systems ■ R51-800 ■■ Multiple injections can be accomplished through valves with injection holes
24 DYWI® Drill Expansion Shell
Rock Bolts with a variable free anchor The DYWI® Drill Expansion Shell Anchor The injection of the annular gap between length ensure a pre-tensioning of is installed into pre-drilled boreholes. the DYWI® Drill Hollow Bar tension the anchor and thus an active force Immediate load-bearing capacity member and the borehole using cement transmission. is achieved by an activation of the grout or DYWI® Inject Systems is expansion shell. accomplished in a second working step.
Fields of Application Installation Procedure Accessories
■■ Systematic anchoring in underground ■■ Drilling of an anchor borehole in ■■ See DYWI® Drill Hollow Bar System Mining and Tunneling accordance with the specifications, leaflet ■■ Doweling of rock layers in the hanging approx. 150 [mm] longer than the ■■ Mortar-Mixing and injection pumps expansion shell anchor when installed wall ■■ Flow-Pressure meters ■■ Introduction of the assembled ■■ Utility hangers ■■ DYWI® Inject Systems expansion shell anchor into the ■■ Injection anchors borehole - the expansion shell shall fit tight into the borehole ■■ Pre-tensioning via impact screw driver or adequate driver tool Main Advantages ■■ Optional post grouting after installation
■■ Simple handling and optimized installation time ■■ Immediate loading-bearing capacity ■■ Unproblematic installation in aquiferous boreholes Specifications ■■ The choice of the appropriate DYWI® Drill Hollow Bar ensures optimum anchor force No. Characteristic Value / Type Unit Symbol SK-R32-048 SK-R38-068 SK-R38-078 ® 1 Nominal external diameter Øe.nom [mm] 48 68 78 ■■ Continuous DYWI Drill Hollow Bar 2 Length L [mm] 170 186 230 thread allows flexible length 3 Nominal weight m [kg] 1.8 4.0 7.8 adjustments and posterior extension 4 Required borehole diameter Ød.nom [mm] 52 - 58 72 - 78 90 - 95 on site Maximum ulitmate 5 Fm.nom [kN] 230 400 630 ■■ Available for series R32, R38 and R51 load-bearing capacity
Drill Bit Adapters Angle Compensation Disks
■■ Connection of hollow bar and drill bit ■■ Secure anchorage even when threads of different diameters undergoing large inclinations ■■ Large drill bit portfolio for diameter ■■ Standard application in combination ranges outside standard versions with domed nuts ■■ Controlled transmission of the drilling ■■ Standard version for hollow bar series energy from the hollow bar onto the R32 and R38 drill bit
Centralizers
■■ Centralization of DYWI® Drill Hollow Bars inside the borehole ■■ Increased directional installation accuracy ■■ Optimum grout cover ■■ Available for series R32, R38, R51 and T76
25 Anchors and Rock Bolts
Mechanical Anchors, Resin and Rebar Rock Bolts ...... 27
CT-BoltTM Combination Rock Bolts ...... 39
Friction Stabilizers ...... 43
OMEGA-BOLT® Expandable Friction Bolts ...... 47
POWER SET Self-Drilling Friction Bolts ...... 51
DYWIDAG Cable Bolts...... 59
DYWIDAG GRP Anchors and Rock Bolts ...... 63
26 Mechanical Anchors, Resin and Rebar Rock Bolts
Introduction ...... 27
Mechanical Anchors ...... 28
Resin Rock Bolts ...... 30
SN-Anchors ...... 32
DYWIDAG THREADBAR®...... 35
Accessories ...... 36
Further Information ...... 37
Order Information SN-Anchors ...... 38
Introduction
Anchors and rock bolts, which are GEWI® Mining Anchors and Mechanical Generally, this does not apply to resin commonly assigned the general Anchors Type ALWAG are well- rock bolts, which can be actively pre- term ”rock bolts”, are used for rock established systems with variable anchor tensioned using resin cartridges with reinforcement in Mining and Tunneling. lengths. The maximum load-bearing different curing times. Rock bolts limit the loosening of capacity of these mechanical anchors is blocks out of the rock mass and shear mainly determined by the stability of the Which rock bolt system is the best one displacements. Furthermore, the borehole (ground characteristics), the to use depends on a variety of factors, frictional force between individual rock amount of the pre-tensioning, and the which have to be considered in each layers is increased. design of the expansion shell. individual case. DYWIDAG-Systems International has longtime experience in Anchors with a variable anchor length Rock bolts such as SN-Anchors or the development, production and supply enable pre-tensioning and thus an active the DYWIDAG THREADBAR® are fully of mechanical anchors and rock bolts. force transmission. grouted over the whole length and are usually installed untensioned.
27 Mechanical Anchors Fields of Application
■■ Systematic anchoring in underground Mining and Tunneling ■■ Doweling of rock layers in the hanging wall ■■ Utility hangers
Main Advantages
■■ Simple handling and optimized ■■ Continuous threaded GEWI® anchor installation time bars allow flexible length adjustments ■■ Immediate loading-bearing capacity and posterior extension on site ■■ Field-proven and reliable anchors ■■ Expansion sleeves are available for different borehole diameters ■■ Unproblematic installation in ® aquiferous boreholes ■■ The GEWI Mining Anchor is approved for underground application by the ■■ Optimized ratio of anchor force Regional Government Arnsberg, vs. borehole diameter Dep. 6 Mining and Energy in NRW, Germany
System Components GEWI® Mining Anchors
■■ Steel expansion shell ■■ Anchor plate ■ Different versions available on request ■ Flat plate with conical through-hole ■■ Anchor shaft ■■ Anchor nut ■ Highly ductile GEWI® anchor steel ■ Constructed as one-sided convex with continuous clock-wise coarse hexagonal nut, self-locking nut, or thread domed nut ■ Individual delivery lengths on agreement
Steel expansion shell Anchor shaft
Anchor plate Anchor nut
28 Mechanical Anchors Specifications GEWI® Mining Anchors
Characeristics / Type Unit KS-145 KS-190 KS-220 Nominal diameter [mm] 16.2 18 20 Nominal weight [kg/m] 1.62 2.00 2.46 Nominal cross-section [mm2] 207 254 314 Yield stress 1) [N/mm2] 450 670 500 Tensile stress 1) [N/mm2] 700 800 700 Ultimate load 2) [kN] 145 190 220 1) Ultimate elongation A5 [%] 15 15 15 Nut version 3) [–] S, H K K Borehole diameter 4) [mm] 34 - 36 44 - 47 44 - 47 Approval file No. 5) [–] 83.18.24.6-2004-9 62.18.24.6-2008-1 83.18.24-6-2001-9
1) Steel tendon 2) Anchor system: anchor bar, plate, and nut 3) H = hex nut, one-sided convex seat, S = stop nut, K = domed nut 4) Standard version expansion shell 5) Regional Government Arnsberg, Dep. 6 Mining and Energy in NRW, Germany
System Components Mechanical Anchors Type ALWAG
■■ Expansion shell ■■ Plate ■■ Other dimensions, steel grades, and ■ Expansion shells in versions B38 ■ Standard version: domed plate with galvanized versions are available on and B43 available, appropriate for round hole request borehole diameters of 38 and 43 [mm] ■■ Nut and washer ■■ Anchor bar ■ Spherical washers and driver tools ■ Solid anchor bar, threaded on both available on request ends ■ Steel grade E360 according to EN 10025-2
Specifications Mechanical Anchors Type ALWAG 1) Installation Procedure
Characteristics Unit Type ■■ Drilling of an anchor borehole in Diameter [mm] 16 accordance with the specifications, Thread designation [–] M18 approx. 150 [mm] longer than the Cross-sectional area [mm2] 200 expansion shell anchor when installed Yield strength 2) [N/mm2] 360 ■■ Introduction of the readily assembled 2) 2 Ultimate strength [N/mm ] 690 expansion shell anchor into the 2) Ultimate elongation A5 [%] 11 borehole - the expansion shell shall fit Ultimate load 3) [kN] 140 tight into the borehole Delivery lengths [mm] 500 - 6,000 ■■ Pre-tensioning via impact screw driver 1) Mechanical Anchors and expansion shells in other dimensions are available on request, all indicated or adequate driver tool values are nominal 2) Round bar tendon ■■ Optional post grouting using a 3) Mechanical Anchors with cold-rolled thread, plate, washer, and nut factory-fitted injection hose
29 Resin Rock Bolts Fields of Application Main Advantages System Components
■■ Systematic rock bolting in ■■ All-purpose rock bolt system - ■■ Rock bolt shaft underground Mining installation in jointed or soft rock ■ Mining steel ■■ Increase of the load-bearing capacity ■■ Standardized and field-proven rock ■ Optimized thread profile for combined of the rock mass, especially in coal bolts use with resin cartridges ■ Pointed, with one-sided cold-rolled Mining ■■ Resistant against blasting vibrations thread ■■ Standard application for use in ■■ High bolting forces at short bond ■■ Plate combination with DYWIDAG resin lengths cartridges ■ Domed plate, alternative compatible versions available on request ■■ Nut ■ Standard version with DYWIDAG drive nut (shear pin nut) ■ DYWIDAG OZ-Nut available on request ■ Installation spanners available on request
Specifications
No. Characteristics / Type 1) Symbol Unit MN16-130 MN18-210 MN20-230 MN25-360
1 Nominal diameter Da.nom [mm] 16 18 20 25 2 Thread – [mm] M18 M20 M22 M27 2) 2 3 Nominal cross-section anchor bar S0 [mm ] 210 316 329 468 4 Nominal weight anchor bar 3) m [kg/m] 1.67 2.14 2.58 3.67 4) 5 Yield load anchor bar Fe.nom [kN] 105 158 164 234 4) 6 Ultimate tensile load anchor bar Fe.nom [kN] 134 202 240 341 5) 2 7 Yield stress anchor bar Re.nom [N/mm ] 500 500 500 500 5) 2 8 Tensile stress anchor bar Rm.nom [N/mm ] 640 640 730 730 5) 9 Ultimate elongation anchor bar Agt [%] 10 10 10 10 6) 10 Ultimate load anchor system Fm.A.nom [kN] 130 210 230 360 11 Wrench size nut SW [mm] 27 30 32 41 12 Delivery lengths 7) L [mm] 600 - 1,600 600 - 1,600 600 - 2,400 600 - 2,400
1) Status: 2012-08, note: all values are subject to change; other dimensions and steel grades available on request 6 3 2) Calculated from the nominal weight: S0 = 10 x m / 7,850 [kg/m ] 3) Characteristic fractile value 4) Calculated from the characteristic load value and nominal weight, rounded 5) Mining steel type DD-BAR, modulus of elasticity: 210,000 [N/mm2] 6) Nominal value ultimate system load: anchor head with cold-rolled thread, plate, and nut 7) Off-size lengths are available on request
30 Resin Rock Bolts Torque Indicators
■■ Reliable indication for a correctly installed resin rock bolt ■■ Assembly between nut and bolt plate ■■ Available for all resin rock bolt types
Corrosion Protection
■■ Corrosion protection of system components may be provided by hot dip galvanizing or alternative coatings
Installation Procedure
■■ Borehole drilling ■ Manual or automated insertion of the resin cartridges ■ Rotary installation of the resin anchor until the installation depth has been reached ■■ Activation of the resin cartridge by mixing the components ■ Holding time is to be adjusted to the applied synthetic resin cartridges or valid installation instructions ■ Tensioning of the bolt’s head by tightening the nut
31 SN-Anchors Fields of Application
SN-Anchors, also known as mortar For special requirements in Tunneling, The DYWIDAG THREADBAR® is mainly embedded concrete reinforcement especially rock reinforcement in squeezing used for special underground bolting steel anchors or Store-Norfors-Anchors ground and large displacements directly works as well as for underpinnings or (named after the first place of installation), after bolt installation, DSI also offers as utility hanger. are used for rock reinforcement in SN-Anchors with ALWAGRIP special rib underground Mining and Tunneling. geometry for an increased load-bearing capacity.
Main Advantages
■■ Field-proven rock bolt system ■■ Effective and standardized installation ■■ Embedding of the tension member in grout ensures optimal bond strength ■■ Low sensitivity concerning the actual diameter of the anchor borehole ■■ ALWAGRIP special rib geometry for optimized bond strength available on request
System Components
Rock bolt shaft Standard rock bolt head with plain washer and nut
Washer Plate and nut
■■ Rock bolt shaft ■■ Plate ■ Reinforcement steel B 500 B ■ Default bolt plate: domed, with long according to DIN 488, B 550 B hole according to ÖNORM B 4707 or ■ Other bolt plates in different rock bolt steel FA 650/820 dimensions available on request ■ Pointed, with cold-rolled thread at ■■ Waher and nut the far end, including nut and washer ■ Rock bolt head version with ■ Standard thread length approximately hemispherical washer available 120 [mm], maximum thread length on request 200 [mm] available on request ■ Optional free bolt length using a ■ Special ALWAGRIP rib geometry shrink tube for increased bond available on Rock bolt head with hemispherical recommendation washer, plain washer, and nut
32 SN-Anchors Specifications
No. Characteristics / Type 1) Symbol Unit SN20-180 SN25-250 SN25-330 SN28-330
1 Nominal diameter Da.nom [mm] 20 25 25 28 2 Thread – [mm] M21 M26 M26 M30 2) 2 3 Nominal cross-section anchor bar S0 [mm ] 315 490 490 615 4 Nominal weight anchor bar 3) m [kg/m] 2.47 3.85 3.85 4.83 4) 5 Yield load anchor bar Fe.nom [kN] 173 245 319 308 4) 6 Ultimate tensile load anchor bar Fm.s.nom [kN] 190 260 340 330 5) 2 7 Yield stress anchor bar Re.nom [N/mm ] 550 500 650 500 6) 2 8 Tensile stress anchor bar Rm.s.nom [N/mm ] 594 540 820 540 5) 9 Ultimate elongation anchor bar Agt [%] 5.0 5.0 5.0 5.0 7) 10 Ultimate load anchor system Fm.A.nom [kN] 180 250 330 330 11 Wrench size nut SW [mm] 36 41 41 46 12 Delivery lengths 8) L [mm] 1,000 - 12,000 1,000 - 12,000 1,000 - 12,000 1,000 - 12,000
1) Status: 2012-06, note: all values are subject to change; other dimensions and steel grades available on request 6 3 2) Calculated from the nominal weight: S0 = 10 x m / 7,850 [kg/m ] 3) Characteristic fractile value 4) Calculated from the characteristic load value and nominal weight, rounded 5) Reinforcement steel B 500 B according to DIN 488, B 550 B according to ÖNORM B 4707 or rock bolt steel FA 650/820, modulus of elasticity: 210,000 [N/mm2]
6) Calculated from the ratio Rm/Re or according to manufacturer specifications 7) Nominal value ultimate system load: anchor head with cold-rolled thread, plate, washer, and nut 8) Off-size lengths are available on request
Compatible domed plates
Characteristics / Type Symbol Unit SN20-180 SN25-250 SN25-330 SN28-330 Length L [mm] 150 200 200 200 Wall thickness s [mm] 8 10 12 12 Height H [mm] 32.5 32.5 32.5 32.5 Width center boring D1 [mm] 23 28 28 32 Length center boring D2 [mm] 28 38 38 42
Installation procedure
■■ Borehole drilling ■■ Filling of the boreholes with mortar ■■ Manual insertion of SN-Anchors into the pre-filled boreholes, fixation in the borehole using a wedge or similar device ■■ Curing time is to be adjusted to the applied grout or valid installation instructions ■■ Tensioning of the bolt’s head by tightening the nut
33 SN-Anchors ALWAGRIP Special Rib Geometry
■■ According to the guideline RVS 8T, ■■ Obtained rib area between 0.02 and 0.04 Federal Minstry for Transport, (cf. RVS 8T, Federal Ministry for Transport, Innovation and Technology, Austria Innovation and Technology, Austria) ■■ The rib geometry of conventional ■■ Material characteristics of SN-Anchors SN-Anchors is in accordance with with ALWAGRIP special rib geometry the regulations of concrete steel are considerably better than for similar reinforcement anchors and rock bolts with concrete reinforcement ribbing ■■ Ground deformations in Tunneling usually occur immediately after the ■■ The advantages of using a steel grade installation of SN-Anchors, which is with higher yield strength are observable why the requirements for bond strength after a curing time of 12 hours development differs from reinforced concrete construction ■■ Development of ALWAGRIP special rib geometry in accordance with the requirements for SN-Anchors in Tunneling, especially in squeezing ground conditions
■■ Examination of the inner bond for two ■■ Results of pull-out tests after different anchor steel types depending 12 hours curing time, bond length on curing time 500 [mm]
250
200
150
100 Tension force [kN] force Tension
50
0 0 25 50 75 100
Displacement [mm]
Rock bolt steel Ø 25 [mm] FA 650/820 with ALWAGRIP special rib geometry concrete rib steel Ø 25 [mm] B 500 B
34 DYWIDAG THREADBAR®
Nut Plate Main Advantages
■■ Optimized ratio of anchor force to borehole diameter ■■ Continuous threaded bar allows length adjustment and subsequent extension on-site ■■ Wear-resistant coarse thread according to the requirements in underground construction
GEWI® bar
System Components
■■ GEWI® bar ■■ Plate ■■ Double corrosion-protected version ■ With right or left hand coarse thread ■ Domed or flat and free length systems with jacket ■ Optional extension using couplings ■■ Nut tube available on request ■ Domed or hexagonal version ■ Eye bolts available on request
Specifications
Nominal diameter Cross-sectional Yield strength Tensile strength Yield load Ultimate load Type [mm] area [mm2] [N/mm2] [N/mm2] [kN] [kN] 16 201 500 550 101 111 20 314 500 550 157 173 25 491 500 550 246 270 GEWI® - left- 28 616 500 550 308 339 hand thread 32 804 500 550 402 442 40 1,257 500 550 628 691 50 1,963 500 550 982 1,080 18 254 670 800 170 204 22 380 670 800 255 304 25 491 670 800 329 393 GEWI® Plus - 28 616 670 800 413 493 right-hand 30 707 670 800 474 565 thread 35 962 670 800 645 770 43 1,452 670 800 973 1,162 57.5 2,597 670 800 1,740 2,077
35 Accessories Plates
■■ Standard version: domed or flat plate ■■ Steel grade S235 according to EN 10025-2 ■■ Custom-specific lugs for domed plates ■■ Special plates are available on request
Length Width Wall thickness Version 1) [mm] [mm] [mm] 150 150 8 C / W 150 150 10 C / W 180 180 8 C / W 200 200 10 C / W 200 200 12 C / W 250 250 12 W
1) C ... cold formed calotte with oval breakout (long hole); W ... warm formed calotte with round breakout (round hole)
36 Accessories Custom-specific accessories available on request
■■ Cable and bar truss systems ■■ Sliding nuts for anchors and rock bolts ■■ Angle compensation discs and plates ■■ Load indicators ■■ Spacers ■■ Dollies and spanners ■■ System components in galvanized or duplex-coated versions ■■ Mortar-Mixing pump and injection adaptors ■■ Pull testing equipment for all types of anchors and rock bolts
Further References
■■ DIN 21521-1,2: Rock bolts for mining ■■ Payer, M., Maydl, P.: ■■ Blümel, M.: and tunnel support Inspection report – Pull-out tests of Bearing load of rock bolts in squeezing ■■ DSI’s installation guidelines for SN-Anchors. Order-No.: 77.645/08, rock mass, Proceedings ISRM anchors and rock bolts Test date: 2008-04-22 - 2008-06-13. International Symposium EUROCK ’96 Technical Examination and Research Turin, Italy, Balkema Rotterdam, 1996 ■■ DIN 21521-1,2: Rock bolts for mining Center for stability and material tests, and tunnelling ■■ Blümel, M.; Schweiger, H.F.; Golser, H.: Graz Technical University. Graz, Austria, Effect of Rib Geometry on the ■■ EN 14490: Implementation of works in 2008 Mechanical Behaviour of Grouted foundation engineering – soil nailing ■■ Schubert, W. (Ed.): Rock Bolts, Proc. of World Tunnel ■■ Federal Ministry of Transportation, Recommendation – Fully mortared Congress ’97, 23rd General Assembly Innovation and Technology (Ed.): rock bolts (SN-Anchors) – Special Rib of the International Tunnelling Ass., Guidelines and regulations for road Geometry and requirements for the Vienna, Austria, 1997 building: RVS 8T – Technical contract mortar; Institute of Rock Mechanics conditions tunneling. 2004-08 and Tunnelling; Graz, Austria, 1997-07
37 Order Information SN-Anchors
Article Description Article No. SN-Anchor SN20-180, L = 2,000 [mm] 201310181020 SN-Anchor SN20-180, L = 3,000 [mm] 201310181030 SN-Anchor SN20-180, L = 4,000 [mm] 201310181040 SN-Anchor SN20-180, L = 6,000 [mm] 201310181060 SN-Anchor SN20-180, L = 8,000 [mm] 201310181080 SN-Anchor Domed plate SN20, 150x150x08-023 [mm] 201340012008 SN-Anchor Domed plate SN20, 200x200x10-023 [mm] 201340013010 SN-Anchor Nut M21, SW 36 [mm] 201320011036 SN-Anchor Coupling M21-M21 201330011000 SN-Anchor Hemispherical washer M21, d. 23 [mm] 201350010000 SN-Anchor SN25-250, L = 2,000 [mm] 201910251020 SN-Anchor SN25-250, L = 3,000 [mm] 201910251030 SN-Anchor SN25-250, L = 4,000 [mm] 201910251040 SN-Anchor SN25-250, L = 6,000 [mm] 201910251060 SN-Anchor SN25-250, L = 8,000 [mm] 201910251080 SN-Anchor SN25-330, L = 2,000 [mm], ALWAGRIP 201910332020 SN-Anchor SN25-330, L = 3,000 [mm], ALWAGRIP 201910332030 SN-Anchor SN25-330, L = 4,000 [mm], ALWAGRIP 201910332040 SN-Anchor SN25-330, L = 6,000 [mm], ALWAGRIP 201910332060 SN-Anchor SN25-330, L = 8,000 [mm], ALWAGRIP 201910332080 SN-Anchor Nut M26, SW 41 [mm] 201920011041 SN-Anchor Coupling M26-M26, L = 90 [mm] 201930011000 SN-Anchor Hemispherical washer M26, d. 26 [mm] 201950010000 SN-Anchor Domed plate SN25, 150x150x08-028 [mm] 201940012008 SN-Anchor Domed plate SN25, 150x150x10-028 [mm] 201940012010 SN-Anchor Domed plate SN25, 200x200x10-028 [mm] 201940013010 SN-Anchor Domed plate SN25, 200x200x12-028 [mm] 201940013012 SN-Anchor SN28-330, L = 2,000 [mm] 202110331020 SN-Anchor SN28-330, L = 3,000 [mm] 202110331030 SN-Anchor SN28-330, L = 4,000 [mm] 202110331040 SN-Anchor SN28-330, L = 6,000 [mm] 202110331060 SN-Anchor SN28-330, L = 8,000 [mm] 202110331080 SN-Anchor Nut M30, SW 46 [mm] 202120011046 SN-Anchor Coupling M30-M30 202130011000 SN-Anchor Hemispherical washer M30, d. 30 [mm] 202150010000 SN-Anchor Domed plate SN28, 200x200x10-032 [mm] 202140013010 SN-Anchor Domed plate SN28, 200x200x12-032 [mm] 202140013012
38 CT-BoltTM Combination Rock Bolts
Introduction...... 39
Fields of Application ...... 40
Main Advantages ...... 40
System Description...... 40
System Components ...... 41
Specifications...... 41
Installation Procedure ...... 42
Accessories ...... 42
Technical Features ...... 42
Introduction
The CT-BoltTM is an unique combination rock bolt system. It offers the combined advantages of an immediate mechanical point anchorage and subsequently a fully grouted rock bolt. A two-step installation procedure allows fast installation and immediate anchorage, separate and independent grouting provides flexibility in regard to working cycles.
Due to the controlled grouting procedure and different bar coatings available, the CT-BoltTM is a reliable ground control system for underground applications. The working ability of the CT-BoltTM has been proven throughout various underground construction projects; the system has become a standard in today’s state-of-the-art ground control procedures.
39 Fields of Application
■■ Systematic permanent reinforcement ■■ Permanent roadways and excavations ■■ Sub-sea and sewer tunnels of underground excavations ■■ Hydropower and underground oil or ■■ Rock fall protection and permanent ■■ Ground support for areas with limited gas storage caverns rock bolting or no access during operational lifetime
Main Advantages
■■ Efficient, practically proven, and reliable rock reinforcement system ■■ Combination of an immediate mechanical point anchorage and a fully grouted rock bolt ■■ Immediate load-bearing capacity after installation by the mechanical anchor ■■ Fast installation and flexible post- grouting behind the working face ■■ Double corrosion protection due to a polyethylene sleeve and grout coverage ■■ Easy adjustment of the corrosion protection level to customer demands ■■ Semi-automated or manual installation procedure
System Description
■■ Combination rock bolt ■■ Immediate mechanical point anchorage by activation of an expansion shell anchor ■■ Post-grouting assembly features double corrosion protection
40 System Components
Polyethylene sleeve Corrugated, with inner centralizers
Dome-shaped grouting adapter With grouting hole and welded-on sleeve
Nut Expansion shell
Rebar rock bolt Cold rolled threads on both sides for mounting expansion shell and nut Plate Incl. bore for grout discharge
Specifications
Characteristic Value / Type Unit CT-M20 CT-M22 Outer rebar diameter [mm] 20 21.7 Thread designation [mm] M20 M22 Characteristic yield load 1) [kN] 140 230 Characteristic ultimate load 1) [kN] 170 290 Borehole diameter range 2) [mm] 44 - 51 Delivery lengths 3) [m] 1.5 - 6.0
1) After grouting 2) Expansion shells for larger borehole diameters available on request 3) Delivery lengths up to 8.0 [m] are available on request
41 Installation Procedure
Borehole drilling Bolt installation Flexible bolt grouting ■■ Drilling of a borehole: Ø 44-51 [mm] ■■ Insertion of the assembled CT-Bolt™ ■■ Preparation of cement grout according ■■ Recommended borehole length: about into the pre-drilled borehole to given specifications 100 [mm] longer than the bolt length ■■ Pressing the bolt plate firmly against ■■ Connection of an injection adapter to the excavation surface the grouting adapter of the CT-Bolt™ ■■ Activation of the expansion anchor ■■ Primary grout flow inside the sleeve by pre-stressing of the anchor nut towards the bolt’s toe (expansion provides immediate mechanical point shell) - complete grout coverage of the anchorage rebar ■■ Typical required torque: 200-300 [Nm] ■■ Secondary grout flow outside the sleeve until the grouting medium flows out at the bore for grout discharge at the hemispherical bolt plate
Accessories
■■ Load indicators ■■ Rock bolt testing equipment
Technical Features
Combination rock bolt ■■ Active reinforcement by pre-stressing ■■ Flexible grouting behind the working ■■ Optimum alignment and assurance of of the expansion shell anchor face allows an optimum adaptation complete grout coverage of the rock ■■ Allowance of a certain amount of of the CT-Bolt™ to given ground and bolt by the polyethylene sleeve elastic deformation of the rebar operating conditions induced by displacements of the rock mass
Unique choice of the corrosion protection level ■■ Protection of the CT-Bolt™ components according to given levels of corrosive environments ■■ Bolts are available black, hot dip galvanised, or with a special Combi Coat® (combination of hot- dip galvanizing, zinc phosphate, and powder coating) ■■ Indicated lifetimes for load-bearing components of the fully-grouted CT-Bolt™ by accelerated corrosion tests performed by Vik Ørsta AS from 50 years (black type) to 150 years (Combi Coat® type)
42 Friction Stabilizers
Introduction ...... 43
Fields of Application ...... 44
Main Advantages ...... 44
System Components ...... 44
Specifications ...... 45
Technical Features ...... 45
Installation Procedure ...... 46
Accessories ...... 46
Order Information ...... 46
Introduction
Friction Stabilizers are mainly used for rock reinforcement in underground Mining. The shaft of the Friction Stabilizer consists of a metal strip which is folded to form a slotted tube. The bolt is installed into a borehole by applying impact energy. The borehole features a slightly smaller diameter than the outer diameter of the bolt tube.
The principle of this anchor system is based on the bond between the borehole and the tubular bolt shaft, caused by applying a force onto the borehole wall, which generates a frictional resistance in axial direction.
The main field of application of this rock bolt is underground metal ore or hard rock Mining. Recently, a self-drilling friction bolt system, the POWER-SET Self-Drilling Friction Bolt, has been developed in addition to conventional Friction Stabilizers.
43 Fields of Application
■■ Systematic reinforcement of underground excavations ■■ Rock bolting in hard rock Mining ■■ Additional reinforcement ■■ Utility bolting
Main Advantages
■■ Easy and fast installation procedure ■■ Both hand-held and fully automated installation are possible ■■ Immediate load-bearing capacity after installation ■■ Low sensitivity to rock mass displacements
System Components
■■ Friction stabilizer tube ■■ Plate ■■ Galvanized or coated system ■ Slotted steel tube ■ Default domed version components available on request ■ Tapered on the far end ■ Different designs and dimensions ■ Welded-on collar ring available on request
44 Specifications
Friction Stabilizer Type FS
No. Characteristics / Type 1) Symbol Unit FS33-105 FS39-110 FS46-150
1 Outer diameter Da.nom [mm] 33 39 46 2 Wall thickness t [mm] 2.5 2.5 3.0
3 Inner diameter Di.nom [mm] 28 34 40 4 Slot opening width w [mm] 13 16 22 5 Nominal weight 2) m [kg/m] 1.50 1.75 2.85 2) 6 Ultimate load Fm.s.nom [kN] 105 110 150 3) 2 7 Yield strength Re.s.nom [N/mm ] 410 410 410 3) 2 8 Ultimate strength Rm.s.nom [N/mm ] 520 520 520 3) 9 Elongation Agt [%] 10 10 10 Recommended 10 B [mm] 30 - 32 36 - 38 43 - 45 drill bit diameter 11 Delivery lengths 4) L [mm] 900 - 2,400 900 - 3,000 900 - 3,700
1) Status: 2012-08, note: all values are subject to change; other dimensions, steel grades and compliant bolt plates available on request 2) Nominal value 3) According to primary material supplier information; modulus of elasticity: 210,000 [N/mm²] 4) Off-size lengths are available on request
Technical Features
■■ The reference values indicated apply to correctly drilled boreholes and FS33-105 80 properly installed Friction Stabilizers 70 Type FS 60 ■■ Deviations in actual borehole 50 Recommended initial diameters affect the load-bearing 40 anchorage: 30 - 60 [kN] capacity of Friction Stabilizers Type FS 30 ■■ The actual load-bearing capacity is 20 Holding force [kN] Holding force determined by the existing rock mass 10 strength 0 33 32 31 30 ■■ Required borehole diameters must Borehole diameter [mm] be adapted when installing in soft or highly jointed rock mass FS39-110 80 70 60 50 Recommended initial 40 anchorage: 30 - 60 [kN] 30 20 Holding force [kN] Holding force 10 0 38 37 36 35 Borehole diameter [mm]
FS46-150 140
120
100 Recommended initial 80 anchorage: 60 - 100 [kN] 60
40 Holding force [kN] Holding force 20
0 45 44 43 42 41 Borehole diameter [mm]
45 Installation Procedure
■■ Drilling of a borehole according to ■■ Installation into the borehole using specifications; borehole lengths should percussion from the rock drill via exceed the Friction Stabilizer length a driving tool onto the collar of the by approx. 150 [mm] Friction Stabilizer until the plate is ■■ Insertion of the Friction Stabilizer plus firmly pressed against the excavation bolt plate onto the driver tool surface ■■ Launch of the Friction Stabilizer into ■■ Note: Friction Stabilizers should the borehole, either manually be installed as perpendicularly as or mechanized possible to the excavation surface
Accessories
■■ Straps or mesh ■■ Driver tools for hand-held and mechanized bolters ■■ Rock bolt testing equipment
Order Information
Article Description Article No. Friction Stabilizer Type FS33-105, L = 1,200 [mm] 204011001120 Friction Stabilizer Type FS33-105, L = 1,200 [mm], galvanized 204011011120 Friction Stabilizer Type FS33-105, L = 1,800 [mm] 204011001180 Friction Stabilizer Type FS33-105, L = 1,800 [mm], galvanized 204011011180 Friction Stabilizer Type FS39-110, L = 2,100 [mm] 204011001210 Friction Stabilizer Type FS39-110, L = 2,100 [mm], galvanized 204011111210 Friction Stabilizer Type FS39-120, L = 2,400 [mm] 204011201240 Friction Stabilizer Type FS39-110, L = 2,400 [mm], galvanized 204011111240 Friction Stabilizer Type FS39-110, L = 3,600 [mm] 204011101360 Friction Stabilizer Type FS46-150, L = 2,100 [mm] 204011501210 Domed Plate for Friction Stabilizer FS-33, 150x150x5-33 [mm], with notch 204041032500 Domed Plate for Friction Stabilizer FS-33, 150x150x5-33 [mm], with notch, galvanized 204041032501 Domed Plate for Friction Stabilizer FS-39, 150x150x4-40 [mm] 204041212400 Domed Plate for Friction Stabilizer FS-39, 150x150x4-40 [mm], with notch 204041232400 Domed Plate for Friction Stabilizer FS-39, 150x150x4-40 [mm], with notch, galvanized 204041232401 Domed Plate for Friction Stabilizer FS-46, 150x150x5-47 [mm], with notch 204041732500 Domed Plate for Friction Stabilizer FS-46, 150x150x5-47 [mm], with notch, galvanized 204041732501 Butterfly Plate for Friction Stabilizer FS-33, 300x300x2.2-33 [mm] 204041045220 Butterfly Plate for Friction Stabilizer FS-33, 400x300x2.2-33 [mm] 204041046220 Combination Plate for Friction Stabilizer FS-33, 300x300x2.2-33 [mm] 204011055220 Combination Plate for Friction Stabilizer FS-33, 400x300x2.2-33 [mm] 204011056220 Driver Tool for Friction Stabilizer FS-33 204051010001 Driver Tool for Friction Stabilizer FS-39 204051210001 Driver Tool for Friction Stabilizer FS-46 204051710001
46 OMEGA-BOLT® Expandable Friction Bolts
Introduction...... 47
Fields of Application...... 48
Main Advantages...... 48
System Description...... 48
System Components...... 49
Specifications...... 49
Installation Procedure...... 50
Accessories...... 50
Order Information...... 50
Introduction
The main application of the OMEGA-BOLT® Expandable Friction Bolt is temporary rock reinforcement in Mining and Tunneling.
Bonding forces between the friction bolt and the rock mass are caused by form closure and friction transfer between the borehole wall and the rock bolt which is expanded by hydraulic pressure.
47 Fields of Application
■■ Systematic reinforcement of underground excavations ■■ Temporary ground control
Main Advantages
■■ Immediate full load bearing capacity over the entire installed bolt length ■■ Low sensitivity against vibrations caused by blasting works ■■ Ability to maintain load-bearing capacity even when undergoing deformations ■■ Safe and easy installation ■■ No additional building materials required for installation ■■ Flexibility in case of differing or varying borehole diameters ■■ Quality check during every single installation ■■ Different customized high-pressure pumps available
System Description
■■ Manual or automated installation ■■ Adjustment of the expanded profile to ■■ Zinc or duplex coated versions by expansion of the omega-shaped irregularities of the borehole wall and available on request profile with high-pressure water variations in borehole diameter ■■ Frictional load transfer between bolt ■■ OMEGA-BOLT® Version “Plus“ and borehole provides improved elongation properties
48 System Components
■■ Bushing Head ■■ Domed Plate ■■ OMEGA-BOLT® friction bolt ■ Flared, with inflation hole ■ Different designs and dimensions ■■ Upper bushing available on request
Domed Plate Upper bushing
Bushing Head OMEGA-BOLT® friction bolt
Specifications
No. Characteristic Value / Type 1) Unit EFB-120 EFB-160 EFB-240 EFB-120+ EFB-160+ EFB-240+ 1 Yield load 2) [kN] 100 130 200 90 120 170 2 Characteristic ultimate load 2) [kN] 130 170 250 120 160 240 3 Nominal ultimate load 2) [kN] 120 160 240 120 160 230 4 Characteristic ultimate strain 2) [%] 15 15 15 30 30 30 5 Nominal ultimate strain 2) [%] 10 10 10 20 20 20 1) Status: 2012-05 ; 2) Expanded profile
EFB-120 EFB-160 EFB-240 No. Characteristic Value / Type 1) Unit EFB-120+ EFB-160+ EFB-240+ 1 External diameter Ω-profile [mm] 27.5 36 36 2 External diameter original tube [mm] 41 54 54 3 Wall thickness [mm] 2 2 3 4 Diameter bushing head [mm] 30 / 36 41 / 48 41 / 48 5 Diameter upper bushing [mm] 28 38 38 6 Required borehole diameter [mm] 32 - 39 43 - 52 43 - 52 7 Optimum borehole diameter [mm] 35 - 38 45 - 51 45 - 51 8 Inflation pressure [bar] 300 250 300 9 Delivery lengths 2) [m] 1.0 - 8.0 1) Status: 2012-05 ; 2) Off-size lengths are available on request
49 Installation Procedure Accessories 1. Borehole drilling OMEGA-BOLT® High-Pressure Pump Type 300E
Characteristics Unit Value Dimensions (L x B x H) [mm] 800 x 400 x 455 Weight [kg] 90 Max. flow rate [l/min] 21 Operating pressure 1) [bar] 300 Max. operating pressure [bar] 320 Power supply [V] 3 ~ 400 Nominal power [kW] 11 Electrical connection [A] 25 Pumping rotation speed [rpm] 1,400 1) Required tube connection 3/4", water connection pressure: 2 [bar]
2. Connection to the installation chuck and insertion of the OMEGA-BOLT® into the borehole
■■ Tough design and easy handling ■■ Alternative high-pressure pumps ■■ Fast installation due to high pump available on request performance ■■ OMEGA-BOLT® pull test kit available ■■ Warranty of optimum expansion of on request the OMEGA-BOLT® 3. Expansion of the OMEGA-BOLT® with high-pressure water Order Information
Article Description Article No. OMEGA-BOLT® EFB-120, L = X,X00 [mm]; ”XX” ... Length 2072101210XX OMEGA-BOLT® EFB-160, L = X,X00 [mm]; ”XX” ... Length 2074101610XX OMEGA-BOLT® EFB-240, L = X,X00 [mm]; ”XX” ... Length 2074102410XX OMEGA-BOLT® Sleeve pipe, d = 48 [mm], L = 300 [mm] 207050002030 OMEGA-BOLT® Sleeve pipe, d = 38 [mm], L = 300 [mm] 207050001030 OMEGA-BOLT® Sleeve pipe, d = 51 [mm], L = 300 [mm] 207050003030 OMEGA-BOLT® Domed Plate 150x150x8-030 [mm] 207240013008 4. De-coupling from OMEGA-BOLT® Domed Plate 180x180x8-030 [mm] 207240014008 the chuck after the OMEGA-BOLT® Domed Plate 125x125x6-030 [mm] 207240012006 OMEGA-BOLT® is OMEGA-BOLT® Domed Plate 200x200x10-040 [mm] 207440015010 ® fully widened OMEGA-BOLT Domed Plate 150x150x8-40 [mm] 207440013008 OMEGA-BOLT® Flate Plate 150x150x8-030 [mm] 207240023008 OMEGA-BOLT® Flate Plate 150x150x8-040 [mm] 207440023008 OMEGA-BOLT® Flate Plate 180x180x8-040 [mm] 207440024008 OMEGA-BOLT® Flate Plate 180x180x8-030 [mm] 207240024008 OMEGA-BOLT® Flate Plate 200x200x10-040 [mm] 207440025010 OMEGA-BOLT® Flate Plate 200x200x12-040 [mm] 207440025012
50 POWER SET Self-Drilling Friction Bolts
Introduction...... 51
Fields of Application...... 52
Main Advantages...... 52
System Description...... 52
System Components...... 53
Specifications...... 53
POWER SET Drill Bits...... 54
Installation Procedure...... 54
POWER SET Automation Unit...... 56
Introduction
The POWER SET Friction Bolt is a self- drilling reinforcement element used for ground control in Mining and Tunneling. In addition, the POWER SET rock bolt system is deployed for rock fall and rock slide protection.
This patented one-step POWER SET rock bolt system stands for a safe and easy installation as well as immediate load-bearing capacity after installation. Another feature is the flexibility of the POWER SET Self-Drilling in regard to changing rock conditions.
Optional installation of an expansion element features additional mechanical anchorage up to the ultimate load of the friction bolt tube. A specially developed automation unit for six bolts per installation sequence allows safe and state-of-the-art rock bolt installation.
51 Fields of Application
Tunneling and Mining Civil Engineering ■■ Systematic reinforcement of ■■ Additional rock reinforcement ■■ Rock fall and rock slide protection underground excavations ■■ Face anchoring ■■ Anchorage of avalanche barriers ■■ Rock bolting in remote or areas that are difficult to access
Main Advantages
■■ Simultaneous drilling and installation ■■ Ability to maintain load-bearing ■■ Trouble-free application under ■■ Installation using standard drilling capacity even when undergoing large unstable borehole conditions machinery deformations ■■ No injection or grouting necessary ■■ Immediate load-bearing capacity after ■■ High shear strength ■■ Ergonomic and safety-related installation ■■ Safe, easy, and fast installation advantages for the workforce ■■ Direct load transfer over the entire bolt procedure length
System Description
■■ Improved self-drilling friction bolt ■■ Installation with standard rotary- ■■ Temporary corrosion protection by ■■ Frictional load transfer between bolt percussive rock drilling equipment: increased friction bolt wall thickness and borehole controlled transfer of impact energy ■■ Non-sensitive to nearby blasting onto the friction bolt ■■ Application for rock bolting in remote works areas or in case of unstable roof ■■ Optional installation of an expansion conditions element: increase of the load bearing capacity up to the ultimate load of the friction bolt tube
52 System Components
■■ POWER SET Drill Bit ■■ POWER SET Drill Rod ■■ POWER SET Adapter Single-use drill bit in different designs Special drill steel for optimum Controlled transfer of the impact and dimensions available service life energy onto the friction bolt
POWER SET Drill Bit POWER SET Drill Rod POWER SET Adapter
Domed Plate POWER SET Friction Bolt
■■ Domed Plate ■■ POWER SET Friction Bolt Different designs and dimensions Slotted tube with bolt head and available on request tapered end
Ready-for-use POWER SET Self-Drilling Friction Bolt
Specifications
Characteristic Value / Type 1) Unit Type 1 Type 2 External diameter [mm] 50 50 Wall thickness [mm] 3.75 5.0 Nominal cross-section 2) [mm2] 470 600 Ultimate load [kN] 330 300 Ultimate strength 3) [N/mm2] 700 500 Guiding value shear force 4) [kN] 370 - 470 360 - 420 Delivery length 5) [m] 1 - 4 Article No. 6) [–] 204515031XXX 204515051XXX 1) Status: 2012-06, note: all values are subject to change ; 2) Rounded 3) Calculated from the characteristic load value and nominal cross-section, rounded 4) In-situ value for installed rock bolts ; 5) Customized lengths are available on request 6) ”XXX” ... Friction bolt length [m] /10
53 POWER SET Drill Bits
■■ Tuned to rock mass conditions and ■■ Hardened or carbide insert version ground control applications available ■■ Different drill bit diameters allow an ■■ Diameter colour code optimum on-site adaption ■ 47.5 RED ■■ Cross or button drill bit design ■ 48.5 YELLOW ■ 49.5 BLUE
Article No. Description Article Code Design (”XX” ... Diameter Ø [mm]) 48.5 49.5 2045801110XX Cross drill bit, hardened PSB-HEX28-0XX-HD
2045801210XX Cross drill bit, with carbide inserts PSC-HEX28-0XX-HM XX
2045802110XX Button drill bit, hardened PSB-HEX28-0XX-HD
2045802210XX Button drill bit, with carbide inserts PSB-HEX28-0XX-HM XX
2045802410XX Arc-shaped drill bit, hardened PSA-HEX28-0XX-HD
2045804210XX Arc-shaped drill bit, with carbide inserts PSA-HEX28-0XX-HM
1) X-marked fields indicate standard drill bit types, other dimensions available on request
Installation Procedure
1. Assembly POWER SET Self-Drilling Friction Bolt and connection of the adapter to the rock drill
2. Rotary-percussive self-drilling installation with a single-use drill bit; back-flushing of the cuttings through the annulus between drill steel and friction bolt
3. Completion of installation after the final drilling depth has been eachedr
4. Retraction of the POWER SET drill rod from the installed friction bolt – the single-use drill bit remains inside
5. Optional installation of an expansion element
6. Mechanical anchorage of the POWER SET friction bolt by enlargement of the expansion element using hammer strokes of the rock drill
7. Retraction of the POWER SET drill steel
54 Accessories
■■ POWER SET pull test kit
■■ POWER SET Hanger Bolt for both types
Order Information
Article Description Article No. POWER SET SD Friction Bolt Type 1: PS50-330, L= X,X00 [mm]; ”XX” ... Length 204515035XX0 POWER SET SD Friction Bolt Type 2: PS50-300, L= X,X00 [mm]; ”XX” ... Length 204515055XX0 POWER SET SD Friction Bolt Type 2: Expansion element, PS50-300 204520011001 POWER SET SD Hanger Bolt Type 2: PS50-300-HB, L= 4,000 [mm] 204515052400 POWER SET SD Hanger Bolt PS-HB Shackle 204530053001 POWER SET SD Hanger Bolt PS-HB Head Bolt 204530054001 POWER SET SD Friction Bolt Drill Rod, HEX28-T38 x Y,Y00 [mm]; ”YY” ... Length 204550011YY0 POWER SET SD Friction Bolt PS-Adapter T38F-T38Fx200 [mm] 204550021020 POWER SET SD Friction Bolt PS-Adapter R38F-T38Fx200 [mm] 204550022020 POWER SET SD Friction Bolt PS-Adapter T38F-T38Fx400 [mm] 204550021040 POWER SET SD Friction Bolt PS-Adapter R38F-T38Fx400 [mm] 204550022040 POWER SET SD Friction Bolt PS-Adapter R51M-T38Fx800 [mm] 204550023089 POWER SET SD Friction Bolt PS-Adapter T38F-T38Fx600 [mm] 204550021060 POWER SET SD Friction Bolt PS-Adapter R38F-T38Fx600 [mm] 204550022060
55 POWER SET Automation Unit
The POWER SET Automation Unit is used for the fully automated installation of the POWER SET Self-Drilling Friction Bolt. This independent boom unit can be attached to underground drilling or continuous Mining machines; alternatively, it can be mounted onto support frames.
Featuring a bolt magazine, fully automated installation of six POWER SET Self-Drilling Friction Bolts per bolt operation cycle can be achieved. The combination of a friction bolt with optional additional point end anchorage and remote-controlled installation is ideal for bolting under difficult and unstable ground conditions.
Main Advantages
■■ Fast and safe installation of the POWER SET Self-Drilling Friction Bolt ■■ Fully remote-controlled and automated installation ■■ Tough design for underground Mining applications ■■ No personnel has to be present in unsupported areas ■■ Easy and similar operating principle using standard personnel and on-site drilling machinery ■■ Proven installation procedure under difficult ground conditions
56 System Description
■■ Rock bolt automation for the installation of the POWER SET Self-Drilling Friction Bolt ■■ Independent boom unit for underground drilling or continuous Mining machines ■■ Rock bolt drum magazine with space for up to six fully preassembled POWER SET Self-Drilling Friction Bolt units plus drill steel ■■ Self-Drilling bolt installation and additional fixation of an expansion element - (see installation procedure) ■■ For all standard bolt lengths up to 2.5 [m]; special lengths available on request ■■ Customer-specific hydraulic rock drills ■■ ATEX conform version available on request
Assembly
1. Hydraulic hammer and carriage 2. Main frame boom 3. POWER SET drum magazine and gripper 4. Expansion element magazine 5. Swiveling front centralizer and support pin 1. 6. Remote control
3.
6.
4. 2.
5.
57 Specifications
Characteristics Unit Value Notes Dimensions [m] app. 1 x 1 x 5 W x H x L Weight [kg] app. 1,500 without bolts Hydraulic supply requirements [L/min] 20 at app. 170 [bar] Electric supply requirements [V] 24 DC
Further References
■■ Assembly instructions ■■ Spare parts list ■■ Operation and service manual, ■■ POWER SET Self-Drilling Friction bolt hydraulic and electric plans user manual
58 DYWIDAG Cable Bolts
Introduction ...... 59
Fields of Application ...... 60
Main Advantages ...... 60
System Description ...... 60
System Components ...... 61
Specifications ...... 61
Installation Procedure ...... 62
Accessories ...... 62
Introduction
DYWIDAG Cable Bolts for Mining are used for temporary and semi-permanent rock reinforcement in underground Mining. Rock bolting with prestressing steel cable bolts combines low bolt weight with high load-bearing capacity. The system remains flexible even with larger cable bolt lengths.
Special DYWIDAG Mining Cable Bolts featuring a free length or a threaded anchorage instead of the default barrel and wedge system were developed for challenging ground control works. These bolts allow a tensioning of the system without tensioners.
59 Fields of Application Main Advantages
■■ Ground control for different fields of ■■ Long cable bolts are easily displaceable in limited space application - from coal Mining to hard ■■ High load-bearing capacity at a low weight per meter rock Mining ■■ Flexible bolt lengths ■■ Bolting in limited space conditions ■■ Installation using cement cartridges, resin cartridges, cement grout or injection resin ■■ Reinforcement of roadways and gateways ■■ Bolting in the hanging wall of longwall T-junctions
System Description
■■ DYWIDAG Cable Bolts for Mining are available in three different versions
■■ Cable bolt, plain version
■■ Cable bolt, with bulbs
■■ DYWIDAG Strand Thread Anchors
60 System Components
■■ End holding devices ■ Single strand fish hook
■■ 7 wire prestressing strand ■ Uncoated, low relaxation strand ■ 1 center wire and 6 outer wires ■ Plain or bulbed version ■ Different customer-specific lengths ■ Greased strands with free lengths available on request
■■ Plate ■ Different designs and dimensions available on request
■■ Domed cable grip ■ Domed barrel ■ 3 pcs. wedge ■ Optional plastic cap
■■ Press sleeve ■ Anchorage for DYWIDAG Strand Thread Anchors ■ Yielding element for large ground deformation or areas prone to rockbursts ■ Thread M30 or DYWI® Drill left-handed R32 or R38 thread plus hex nut
■■ Injection and breather tubes ■ Standard versions 13 x 2 [mm] and 16 x 2 [mm] ■ Alternative designs and dimensions available on request
Specifications
Characteristics / Type Unit CB15.3 CB15.7 LG18.3 Nominal diameter [mm] 15.2 15.7 18.3 Nominal diameter [inch] 0.60 0.62 0.70 Cross-section [mm2] 140 150 200 Weight [kg/m] 1.09 1.17 1.56 2 Yield strength Rp0.1 [N/mm ] 1,560 1,640 1,570 Tensile strength [N/mm2] 1,770 1,860 1,770
Yield load Fp0.1 [kN] 220 251 312 Ultimate load [kN] 248 279 354
61 Installation Procedure
■■ Borehole drilling ■■ The choice of the borehole diameter depends on the drilling machinery, the cable bolt length, and the bond medium ■■ Version A: Filling of the borehole with cement grout or synthetic resin cartridges, then insertion of the cable bolt ■■ Version B: Insertion of the cable bolt with factory-installed injection hose, subsequent injection with cement grout or injection resin ■■ Anchorage of the anchor head: Plate and wedge or press sleeve ■■ Prestressing of anchor and wedge sleeve using a cable bolt tensioner
Accessories
■■ Cable bolt tensioning jack ■■ Cable bolt expansion shell ■■ Dog bone coupling for slings or trusses ■■ Galvanized system components available on request ■■ Packers and borehole seals available on request
62 DYWIDAG GRP Anchors and Rock Bolts
Introduction ...... 63
Fields of Application ...... 64
Main Advantages ...... 64
System Description ...... 64
System Components ...... 64
Specifications ...... 65
Technical Features ...... 66
Accessories ...... 66
Order Information ...... 67
Introduction
GRP Anchors and Rock Bolts are used as an alternative to conventional ground control elements made of steel. Thanks to the rapid development of production technologies and a higher amount of mechanical excavation, GRP systems have gained importance in underground construction around the world.
Fields of application of GRP Anchors and Rock Bolts range from cuttable rock bolts for underground coal Mining or ground control for mechanical excavations to injection lances or forepoling.
DYWIDAG-Systems International provides a diversified portfolio of GRP systems for various applications in Mining, Tunneling, and Civil Engineering which is completed by longtime experience in the production and application of GRP Anchors and Rock Bolts.
63 Fields of Application Main Advantages System Description
■■ Rock reinforcement and rock support ■■ Lightweight system ensures an easy ■■Composite system consisting of in underground excavation application in challenging conditions high-strength glass fibers and ■■ Mechanical excavations – TBM, ■■ High tensile load-bearing capacity high performance resin roadheaders, and continuous miners ■■ Tough and durable, yet easy to cut ■■ Bars manufactured according to the ■■ Cuttable ground control system for using mechanical excavators or requirements of the construction underground coal Mining shearers industry ■■ Injection lance for DYWI® Inject ■■ Enhanced corrosion resistance ■■ Available in different versions ■ Type CS: fully threaded solid bars Systems ■■ Anti-static components – EX-proof ■ Type CH: fully threaded hollow bars ■■ Forepoling element system ■ Type CR: fully threaded self-drilling ■■ Tunnel portals and temporary ■■ Tough and resistant threadform hollow bars with advanced, resistant rock reinforcement to be removed adjusted to the demands in surface composite structure by excavators and underground construction ■ Flat and round bars type MN ■■ Ground stabilization in special ■ Reinforcing bars and composite mesh foundations ■■ Application in combination with concrete, cement grout, anchor mortar, or resin, depending on the application
System Components
■■ Type CS ■ Fully threaded solid GRP bar ■ GRP plate ■ GRP nut
■■ Type CH ■ Fully threaded hollow bar ■ GRP plate ■ GRP nut
■■ Type CR ■ Single-use drill bit – different designs and dimensions available ■ Fully threaded self-drilling hollow bar ■ GRP plate ■ GRP nut
■■ Flat and round bars type MN ■ Flat or round GRP bar, optionally available with an angle cut on the far end and a driver tool adapter ■ GRP plate, domed or square version ■ Barrel and wedge anchorage
64 Specifications
GRP Bars Type CS, CH, and CR
No. Characteristic value / type1) Symbol Unit CS20-190 CS25-350 CS32-560 CH25-250 CH32-350 CR32-340
1 Nominal diameter Da,nom [mm] 20 25 32 25 32 32 2) 2 2 Nominal cross-section S0 [mm ] 186 346 580 230 340 340 3 Nominal weight 2) m [kg/m] 0.56 0.90 1.30 0.64 0.95 0.95 3) 4 Ultimate load bar Fm.s.nom [kN] 190 350 560 250 350 350 4) 2 5 Ultimate strength bar Rm.s.nom [N/mm ] 1,000 1,000 960 1,000 1,000 1,000 5) 6 Elongation bar Agt [%] 2.5 2.5 2.5 2.5 2.5 2.5 5) 7 Shear force bar FS.nom [kN] 90 160 230 110 140 140 6) 8 Ultimate load bar-nut Fm.n.nom [kN] – – 130 – 130 130 6) 9 Ultimate load bar-coupling Fm.c.nom [kN] – – 160 – 160 160 10 Delivery lengths 7) L [m] 1.0 - 6.0 1.0 - 6.0 1.0 - 6.0 1.0 - 6.0 1.0 - 6.0 1.0 - 6.0 11 Color code bar – –Black Black Black Green Green Red
1) Status: 2012-08, note: all values are subject to change; other designs and dimensions available on request; corresponding plates according to manufacturer specifications 2) Characteristic fractile value 3) Calculated from the characteristic ultimate strength value and nominal weight, rounded 4) Modulus of elasticity: 40,000 [N/mm²] 5) According to manufacturer specifications 6) Nominal value ultimate system load: bar or hollow bar and steel nut or DYWI® Drill steel coupling R32 (standard versions) 7) Standard lengths max. 6 [m], customized length up to 11 [m] available on request
GRP Accessories Type CS, CH, and CR
Nr. Characteristic value / type1) Symbol Unit CS20-190 CS25-350 CS32-560 CH25-250 CH32-350 CR32-340 1 Wrench size nut SW [mm] 36 41 46 41 46 46
2 Length nut LM [mm] 70 80 100 80 100 100 3 Weight nut GM [kg] 0.08 0.11 0.15 0.11 0.15 0.15 4 Article No. nut – [–] 206020051036 206120051041 206220051046 206420051041 206520051046 206720051046
5 Diameter plate DP [mm] 140 170 170 170 170 170 6 Height plate HP [mm] 34 46 46 46 46 46 7 Weight plate GP [kg] 0.36 0.54 0.54 0.54 0.54 0.54 8 Article No. plate – [–] 206040021014 206140021017 206240021017 206440021017 206540021017 206740021017
1) Status: 2012-08, note: all values are subject to change; other designs and dimensions available on request; corresponding plates according to manufacturer specifications
GRP Round and Flat Bars Type MN
Characteristic value / type1) Symbol Unit MNR-200 MNR-250 MNR-280 MNR-440 MNF-280 MNF-320 MNF-360
Nominal diameter/dimensions Da.nom [mm] 16 19 20 25 40 x 7 40 x 8 40 x 9 Nominal weight 2) m [kg/m] 0.39 0.55 0.64 0.98 0.55 0.63 0.70 2) Ultimate load bar Fm.s.nom [kN] 200 250 280 440 280 320 360 3) Ultimate strength bar Rm.s.nom [N/mm²] 1,000 900 900 900 1,000 1,000 1,000 4) Elongation bar Agt [%] > 4 > 2 4) Ultimate load anchorage Fm.a.nom [kN] 90 100 110 120 100 110 120 1) Status: 2012-08, note: all values are subject to change; other designs and dimensions available on request; corresponding plates according to manufacturer specifications 2) Characteristic fractile value 3) Modulus of elasticity: 40,000 [N/mm²] 4) According to manufacturer specifications
65 Technical Features
Drill Bits
■■ The success of the installation depends ■■ Optimized in terms of cuttability and ■■ Further information on the on the selection of the proper drill bit drilling characteristics and selection of ■■ Extensive drill bit portfolio for various ■■ Adapted to the requirements of drill bits is available in a separate ® ground conditions Civil Engineering and underground DSI data leaflet for DYWI Drill Bits Mining
Diameter Article No. Description Article Code Design Thread Accessories Ø [mm] 1) ■■ Steel accessories available on request (”XXX” … diameter Ø [mm]) 51 76 ■■ GRP rebars ■ Fully threaded solid GRP bar ■ Cross drill bit, Threading according to the demands 301080111XXX CB-Thread-D-HD R32 X X hardened for concrete reinforcing elements ■ Connectors depending on the application Cross drill bit, 301080121XXX CB-Thread-D-HM R32 X X ■ Reinforcing cages available on request with carbide inserts
Button drill bit, 301080211XXX BB-Thread-D-HD R32 X X hardened
Button drill bit, 301080221XXX BB-Thread-D-HM R32 X X with carbide inserts
Arc-shaped drill bit, 301080411XXX AR-Thread-D-HD R32 X X hardened
Arc-shaped drill bit, 301080511XXX AR-Thread-D-HM R32 X X with carbide inserts
Arc-shaped button 301080811XXX drill bit, AB-Thread-D-HD R32 X hardened
Arc-shaped button 301080521XXX drill bit, AB-Thread-D-HM R32 X with carbide inserts
1) X-marked fields indicate standard drill bit types; other dimensions available on request
■■ GRP composite mesh ■ Rock bolt mesh and rockfall nets available on request GRP Mesh
Characteristic value / type 1) Symbol Unit CS15-130 CR20-250
Nominal diameter Da.nom [mm] 15 20 2) 2 Nominal cross-section S0 [mm ] 180 320 Nominal weight 2) m [kg/m] 0.36 0.65 3) Ultimate load bar Fm.s.nom [kN] 130 250 4) 2 Ultimate strength bar Rm.s.nom [N/mm ] 1,000 1,000 5) Elongation bar Agt [%] 2.5 2.5 5) Shear force bar FS.nom [%] 60 120 1) Status: 2012-08, note: all values are subject to change; other designs and dimensions available on request 2) Characteristic fractile value 3) Calculated from the characteristic ultimate strength value and nominal weight, rounded 4) Modulus of elasticity: 40,000 [N/mm²] 5) According to manufacturer specifications
66 Order Information 1)
Article Description 2) Article No. DYWIDAG GRP Solid Bar CS20-190, L = X,X00 [mm] 2060101910XX DYWIDAG GRP Solid Bar Nut CS20 206020051036 DYWIDAG GRP Solid Bar Plate CS20, d. 140 [mm] 206040021014 DYWIDAG GRP Solid Bar CS25-350, L = X,X00 [mm] 2061103510XX DYWIDAG GRP Solid Bar Nut CS25 206120051041 DYWIDAG GRP Solid Bar Plate CS25, d. 170 [mm] 206140021017 DYWIDAG GRP Solid Bar CS32-560, L = X,X00 [mm] 2062105610XX DYWIDAG GRP Solid Bar Nut CS32 206220051046 DYWIDAG GRP Solid Bar Plate CS32, d. 170 [mm] 206240021017 DYWIDAG GRP Hollow Bar CH25-250, L = X,X00 [mm] 2064102510XX DYWIDAG GRP Hollow Bar Nut CH25 206420051041 DYWIDAG GRP Hollow Bar Plate CH25, d. 170 [mm] 206440021017 DYWIDAG GRP Hollow Bar CH32-350, L = X,X00 [mm] 2065103510XX DYWIDAG GRP Hollow Bar Nut CH32 206520051046 DYWIDAG GRP Hollow Bar Plate CH32, d. 170 [mm] 206540021017 DYWIDAG GRP S-D Hollow Bar CR32-340, L = X,X00 [mm] 2067103410XX DYWIDAG GRP S-D Hollow Bar Nut CR32 206720051046 DYWIDAG GRP S-D Hollow Bar Steel Nut CR32-S 206720022046 DYWIDAG GRP S-D Hollow Bar Plate CR32, d. 170 [mm] 206740021017
1) Threadform according to ISO 10208 2) ”X,X” ... variable length; couplings available on request
67 Pre-Support
AT - Pipe Umbrella Support System ...... 69
AT - TUBESPILETM ...... 81
Spiles and Forepoling Boards ...... 85
68 AT - Pipe Umbrella Support System
Introduction ...... 69
Fields of Application ...... 70
Main Advantages ...... 70
System Description...... 71
System Components...... 71
Specifications...... 72
Technical Features ...... 73
AT - Drilling System...... 73
AT - Pipe Couplings ...... 74
Installation Procedure ...... 10
AT - Pipe Umbrella Automation Unit...... 77
Accessories...... 80
Further References ...... 80
Introduction
The AT - Pipe Umbrella System is a pre-support measure used in weak ground conditions in conventional as well as mechanized Tunneling. Pipe umbrella pipes increase the stability in the working area by transferring loads in the longitudinal direction and decrease excavation induced deformations. The system increases safety in the working area.
Beside this standard usage, the system is often applied to increase stability in portal sections and for the re-excavation of collapsed sections in underground construction. Another application area is ground improvement and waterproofing in combination with all tunnel construction methods.
69 Fields of Application
■■ Advances in weak ground and ground ■■ Advances in sediments or talus ■■ Re-excavation of collapsed drifts conditions prone to subsidence ■■ Portal sections or tunnels ■■ Advances in alpine fault zones ■■ Advances in frequently changing ground ■■ Urban Tunneling conditions
Cross section when excavating under an AT - Pipe Umbrella Single AT - Pipe Umbrella
Single AT - Pipe Umbrella with double overlap Double AT - Pipe Umbrella
Main Advantages
■■ Installation with conventional drill jumbos ■■ Execution of pipe umbrella drilling with on-site personnel ■■ Simple and robust system components ■■ Fast self-drilling installation ■■ Smallest possible stress relaxation due to an immediate support of the borehole wall during installation ■■ Accurate installation due to a minimized annular gap ■■ Length of pipe umbrella pipes can be adapted to constricted space ■■ Different pipe coupling types available to suit different project requirements
70 System Description
The AT - Pipe Umbrella System is installed
■■ Using the overburden drilling method ■■ Piecewise ■■ With conventional drill booms ■■ By hydraulic, rotary-percussive drilling
Cooling, flushing, and back-flow of the cutting takes place inside the casing pipes using water.
System Components
■■ AT - Starter Unit with Drill Bit ■■ AT - Extension Tube ■■ Valves in injection holes ■■ Various AT - Adapters ■■ Drill Rods ■■ AT - Grouting Plug (End Plug)
71 Specifications 1)
Maximum Steel Modulus of Yield Outer Wall Standard Moment of Section System Weight moment grade elasticity strength diameter thickness tube length inertia modulus (elastic) Type 2) [N/mm2] [N/mm2] [mm] [mm] [kg/m] [m] [cm4] [cm3] [kNm] AT - 76 76.1 6.3 10.8 3.0 85 22 7.9 AT - 89 88.9 6.3 12.8 3.0 140 31 11.2 AT - 114 S355 210,000 355 114.3 6.3 16.8 3.0 312 54 19.4 AT - 139 139.7 8.0 26.0 3.0 720 103 36.6 AT - 168 168.0 12.5 48.0 2.0 1,860 221 78.5
1) Deviating structural properties are available on request 2) According to EN 10025-2
72 Technical Features
■■ Quick length adjustment of the ■■ Special pipe coupling types for ■■ Application of preventers possible AT - Pipe Umbrella System facilitated different static requirements ■■ Recording and control of the grouting by piecewise installation ■■ The use of the AT - Pipe Umbrella process using a flow-pressure meter ■■ Simple connection of extension tubes Automation Unit increases the drilling even in restricted space progress, minimizes over-excavation ■■ High drilling accuracy of pipe (saw tooth profile), and increases umbrella drills personnel safety
AT - Drilling System
The drilling energy is transferred via drill rods and an inside adapter onto the single-use drill bit of the AT - Starter Unit. The cooling and flushing medium is immediately transported from the drill bit front backward inside the umbrella pipes. After completion of the installation, the single-use drill bit remains at the toe of the borehole; adapter and drill rods are removed and re-used for consecutive pipe installations.
■■ Loss or blocking of a drill bit is impossible because it is fixed within the starter unit ■■ A single-use drill bit ensures the same high quality for each drilling process ■■ Application of a single-use drill bit provides optimum pre-conditions to achieve the total drilling depth every time ■■ The drill bit type can be adapted to given geological conditions ■■ Stable drilling direction due to stable drill bit orientation ■■ Disconnecting and reconnecting of drill rods is possible at any time ■■ Small overcutting ensures the lowest possible stress relaxation
73 AT - Pipe Couplings
The AT - Pipe Umbrella System is installed Type and quality of the pipe coupling For this reason, three different types of with conventional drilling machines. are decisive factors for the maximum couplings are available for the AT - Pipe Single pipes are installed piecewise at a achievable load-bearing capacity of the Umbrella System. length that fits the drill boom length. support system.
Standard Thread Connection
When using a standard thread connection, an outside and inside This connection type can be recommended for the installation thread is cut into the ends of the pipe umbrella pipes. This type of of measurement instrumentations and for ground-improving coupling reduces the cross-section of the pipe at the area of the injection works. thread connection. Thereby, the section modulus is decreased as well. Besides the geometrical conditions of the thread, the overall quality of the pipes is a major concern for the maximum load-bearing capacity. In general, calibrated tubes reach a higher resistance against bending than non-calibrated ones.
■■ Simplest connection type ■■ Installed tubes show a constant inner diameter ■■ The stiffness of the connection is considerably lower than the stiffness of the standard pipes ■■ The rupture load of the connections is comparable to the design load of standard pipes; it is clearly lower for non-calibrated tubes ■■ Further decrease of the load-bearing capacity if mistakes occur during screwing or grouting of the pipes ■■ A lower load-bearing capacity can only be compensated by a higher number of pipes ■■ Dislocation of the coupling positions in the longitudinal direction does not increase the load-bearing capacity ■■ Installation can be accomplished with or without an AT - Pipe Umbrella Automation Unit
Squeezed Connection
A squeezed connection consists of a reduced pipe end which is Usage of this connection type can be recommended for all force-fitted with its counter piece. In the coupling area, the cross advances where a pipe umbrella is installed because of its section stays constant and the section modulus is decreased. static load-bearing capacity.
■■ The ultimate load of this connection is higher than the elastic design load of a normal pipe (> 1.5) ■■ Transition from elastic to plastic material behavior begins at approximately ¾ of the elastic design load (standard pipe) ■■ Reduction of the inner diameter in the connection area ■■ Reduction of the stiffness against bending in the connection area ■■ Installation can only be accomplished with an AT - Pipe Umbrella Automation Unit incorporating a squeezing unit
74 AT - Pipe Couplings Nipple Coupling
Nipple couplings are an additional steel nipple where a thread Usage of this connection type can be recommended for advances connection is pressed and welded into both ends of the extension where the static load-bearing capacity is required to achieve stable tubes. This ensures that the section modulus at the coupling is conditions and settlement limitations are part of the design. never lower than the section modulus of the standard pipe.
■■The elastic design load is equal to the one of a standard pipe ■■Stiffness in the elastic range is comparable to the one of a standard pipe ■■Reduction of the inner cross-section ■■Installation can be accomplished with or without an AT - Pipe Umbrella Automation Unit
200
180
160
140
120 Elastic Design Load 100 Load [kN] 80
60
40
20
0 0 1 2 3 4 5 6 7 8 9 10 Deflection [mm] Standard Pipe Standard Thread Connection Squeezed Connection Nipple Coupling Elastic Material Behavior (analytic) Plastic Material Behavior (analytic, bi-linear material characteristics)
75 Installation Procedure
1. For drilling, the AT - Starter Unit with drill bit is assembled 2. Installation of the first TA - Extension Tube together with the first AT - Extension Tube, the AT - Adapter, and the drill rod onto the drill boom
3. The next drill rod with AT - Extension Tube is connected to 4. The last step shall be repeated until the designed length of the AT the previously installed pipe and the drilling process is - Pipe Umbrella has been installed continued afterwards
76 AT - Pipe Umbrella Automation Unit
The AT - Pipe Umbrella Automation Unit allows automated feeding, screwing, and installation of extension tubes plus drill rods.
Main Advantages
■■ Shorter manipulation times due to ■■ No handling besides moving parts of ■■ Less manpower required exact and automated feeding the drilling machine ■■ Optimum utilization of the working ■■ Faster construction of a pipe umbrella ■■ Simple re-charging of extension tubes space support system via a loading basket ■■ Smaller saw-tooth shaped profile and ■■ Higher occupational safety ■■ Remote-controlled feeding of tubes thereby less excavation volume
77 Assembly groups
Screwing unit and centering/clamping device Central guiding device
Loading device and pipe feeding system
Electric switch case
Remote control
Hydraulic control box Pipe deposition
Specifications
Dimensions Characteristics / Assembly group Weight [kg] (L x B x H) [mm] Pipe deposition 1,040 x 230 x 350 28 Screwing unit and centering / clamping device 1,165 x 360 x 745 160 Loading device and pipe feeding system 3,485 x 350 x 565 160 Central guiding device 155 x 190 x 220 12 Hydraulic control box 550 x 275 x 345 60 Electric switch case 380 x 600 x 350 35 Remote control 250 x 140 x 180 2.3
Characteristics Unit Value Remark Deviations possible, Total weight (gross) [kg] 460 - 490 depending on the type Electric supply [V] 24 DC Hydraulic supply [L/min] 20 At approx. 170 [bar]
78 Assembly groups
Central guiding Screwing unit and centering/clamping device device Hydraulic rock drill
AT - Starter Unit with drill bit
Drill boom
Foundation ground
Pipe deposition with AT - Extension Tube and drill rod
Loading device and pipe feeding system with AT - Extension Tube and Hydraulic control box drill rod
79 Accessories
■■ Flow-Pressure meter ■■ Mortar-Mixing pump ■■ Drill rod wrench ■■ Injection packer ■■ DYWI® Inject Systems ■■ Chain pipe wrench ■■ Fishing tab ■■ Rock drilling equipment: shank adapter, coupling, and coupling adapter
Further References
■■ Volkmann, G.M. & W. Schubert 2007. “Geotechnical Model for Pipe Roof Supports in Tunneling.” In Proc. of the 33rd ITA-AITES World Tunneling Congress, Underground Space - the 4th Dimension of Metropolises, Volume 1. eds. J. Bartak, I.Hrdina, G.Romancov, J. Zlamal, Prague, Czech Republic, 5-10 May 2007, Taylor & Francis Group, ISDN: 978-0- 415-40802. app. 755-760 ■■ Volkmann G.M. & Schubert W. 2008. Tender Document Specifications for Pipe Umbrella Installation Methods. In proceedings of the 34th ITA-AITES World Tunneling Congress, Agra, India, 22-24 September 2008, pp. 285-293 ■■ AT - Pipe Umbrella Geometry Calculator ■■ Installation Manual for the AT - Pipe Umbrella System
80 AT - TUBESPILETM
Introduction...... 81
Fields of Application...... 82
Main Advantages...... 82
System Description...... 82
System Components...... 83
Specifications...... 83
Technical Features...... 83
Installation Procedure...... 84
Accessories...... 84
Further References...... 84
Order Information...... 84
Introduction
The AT - TUBESPILETM forms part of the POWER SET product family. It qualifies perfectly as a pre-support system in conventional Tunneling and is classified as a spile.
The application of the AT - TUBESPILETM permits the stabilization of local instabilities in the excavation area and the prevention of ground loosening induced by installation. In poor ground conditions, this system is a sound alternative to conventional ram spiles, rebar spiles, or IBO - Self-Drilling Spiles.
81 Fields of Application
■■ Tunneling in soft homogenous or ■■ Advances through alpine fault zones ■■ Advances through blocky rock mass inhomogeneous ground ■■ Advances through sedimentary foundation soil or debris
Main Advantages System Description
■■ Installation using conventional drill The AT - TUBESPILETM is installed in one jumbos step through rotary percussive drilling ■■ Secure and easy installation procedure with conventional drill booms. The drill rod inside the spile tube transfers the ■■ Spile drilling and installation in one step drilling energy onto the drill bit, which is ■■ Ground preserving, self-drilling available as a button drill bit with carbide installation inserts and as a hardened arc-shaped drill ■■ Higher section modulus than bit. The AT - TUBESPILETM is pushed into comparable ram spiles, rebar spiles, the borehole by an adapter and follows or IBO - Self-Drilling Spiles directly behind the drill bit. Cooling, flushing, and transport of cuttings take place inside the spile tube with water.
82 System Components
■■ AT - TUBESPILETM drill bit ■■ POWER SET drill rod ■ Single-use drill bit Ø 52 [mm], arc- ■ Special drill steel for optimum service shaped or button bit version available life ■■ AT - TUBESPILETM ■■ POWER SET Adapter ■ Spile tube Ø 51 x 3.2 [mm] ■ Controlled transfer of the impact energy onto the AT - TUBESPILETM
AT - TUBESPILETM Drill Bit POWER SET Drill Rod POWER SET Adapter
AT - TUBESPILETM
Ready-for-use AT - TUBESPILETM
Specifications 1)
Steel Modulus of Yield Outer Wall Weight Standard Moment of Section Maximum grade 2) elasticity strength diameter thickness tube length inertia modulus moment System (elastic) [N/mm2] [N/mm2] [mm] [mm] [kg/m] [m] [cm4] [cm3] [kNm] 3.0 / 3.5 / AT - TUBESPILETM ≥ S235 210,000 235 51 3.2 3.8 13.8 5.4 1.9 4.0 / 4.5
1) Deviating structural properties are available on request 2) According to EN 10025-2
Technical Features
■■ Self-Drilling installation permits ■■ Self-Drilling installation ensures proper ■■ Back-flushing inside the spile tube installation in all ground types installation even in changing ground ensures minimized influence the ■■ Different drill bits for all geological conditions flushing water on ground properties conditions ■■ High heading accuracy of the spile ■■ Optionally available with injection holes ■■ Cased installation enables proper drills thanks to the guidance of the for drainage or injection purposes installation in poor foundation soil spile tube ■■ Recording and control of the injection even with unstable borehole walls ■■ No annular gap and therefore no through a flow-pressure meter settlements or ground loosening during installation
83 Installation Procedure
1. Attachment of the AT - TUBESPILETM spile tube and the AT - TUBESPILETM single-use drill bit onto the POWER SET drill rod, connection of the POWER SET adapter and the rock drill 2. Rotary-percussive self-drilling installation with a single-use drill bit; back-flushing of the cuttings through the annulus between drill rod and spile tube 3. Completion of installation after the final drilling depth has been eachedr 4. Retraction of the POWER SET drill rod from the installed AT - TUBESPILETM, the single-use drill bit remains inside the borehole
Accessories Further References
■■ POWER SET Automation Unit ■■ Brochure POWER SET Self-Drilling ■■ Mortar-Mixing pump Friction Bolt TM ■■ DYWI® Inject Systems ■■ Technical Data Sheet AT - TUBESPILE ■■ Flow-Pressure meter ■■ Injection packer
Order Information
Article description 1) Article code Article No. 1) AT - TUBESPILE™ SD TUBESPILE™ TS51, L = X,X00 [mm] TS51-3-XX00 5005151300XX AT - TUBESPILE™ arc-shaped drill bit, HEX28-052, hardened PSA-HEX28-052-HD 500580411052 AT - TUBESPILE™ button drill bit, HEX28-053, carbide inserts PSB-HEX28-053-HM 500580221053 AT - TUBESPILE™ drill rod, HEX28-T38 x Y,Y00 [mm] PS-GST-YY00 204550011YY0 PS-Adapter T38F-T38Fx200 [mm] PS-AD-T38-T38-200 204550021020 PS-Adapter R38F-T38Fx200 [mm] PS-AD-R38-T38-200 204550022020 PS-Adapter T38F-T38Fx400 [mm] PS-AD-T38-T38-400 204550021040 PS-Adapter R38F-T38Fx400 [mm] PS-AD-R38-T38-400 204550022040 PS-Adapter R51M-T38Fx800 [mm] PS-AD-R51-T38-890 204550023089 PS-Adapter T38F-T38Fx600 [mm] PS-AD-T38-T38-600 204550021060 PS-Adapter R38F-T38Fx600 [mm] PS-AD-R38-T38-600 204550022060
1) ”XX” and ”YY” … length
84 Spiles and Forepoling Boards
Introduction...... 85
Rebar Spiles...... 86
Tubular Spiles...... 88
IBO - Self-Drilling Spiles ...... 90
Forepoling Boards...... 92
Introduction
Spiles and forepoling boards are used as temporary pre-support system for the working area. They ensure the stability of the perimeter of the open span until the primary lining is installed.
Depending on the foundation soil characteristics, different spile types are used in order to achieve the best technical solution for each project. The products range from rebar spiles, IBO - Self-Drilling Spiles or the AT - TUBESPILETM to forepoling boards, which permit driving in non-cohesive ground.
85 Rebar Spiles
Rebar spiles and tube spiles are universally applicable as pre-support. They can be installed into pre-drilled, stable boreholes in blocky foundation soil as well as rammed into soft, homogenous foundation soil.
Fields of Application
■■ Tunnel driving in blocky and jointed rock mass ■■ Tunnel driving in soft, homogenous foundation soil conditions
Main Advantages
■■ Practice-proven spile system ■■ Secure and simple installation ■■ Universally applicable ■■ Installation using conventional drilling machines
System Description
Rebar spiles consist of smooth or ribbed steel bars that are pointed on one side. They are installed in pre-drilled grouted or ungrouted spile holes or are rammed into the foundation soil. Pre-drilled rebar spiles are installed in jointed and blocky rock mass as pre-support against falling blocks; ram spiles are installed in homogenous, soft foundation soil.
By ramming, a loosening of the foundation soil is prevented, and an optimum initial condition for arching between the spiles is achieved. Following driving, the load of the foundation soil is transferred on the bearings by the resisting torque of the spiles. These are the ground ahead of the face and the support arch in the already supported excavation area.
86 Rebar Spiles Specifications
Bar diameter 1) [mm] 20 25 28 30 36 Delivery lengths 2) [m] 3 / 4 / 6
1) Spiles from smooth or ribbed concrete steel with a minimum steel grade of B 500 B (DIN 488-1 and ÖNORM B 4707) 2) Pointed on one side; diverse lengths and unpointed concrete steel spiles are available on request
Technical Features
■■ Simple and uncomplicated installation into pre-drilled spile holes ■■ Mortared annular gaps improve contact with the rock mass ■■ Ramming is an installation method which retains the original stress condition ■■ The foundation soil is displaced by ramming. This permits optimum conditions for subsequent load carrying ■■ Installation is possible above as well as through support arches
Installation Procedure
■■ Installation into pre-drilled spile holes ■ Pre-drilling of the spile holes through or over the support arch ■ Filling of the spile holes with mortar (only for mortared installation) ■ Installation of the Rebar spile ■■ Installation as ram spile ■ Ramming of the rebar spiles through or over the support arch
87 Tubular Spiles
Tubular spiles and rebar spiles are universally applicable for pre-support measures. They can be installed into predrilled, stable boreholes in blocky or jointed rock mass as well as rammed into soft, homogenous foundation soil.
Fields of Application
■■ Tunnel driving in blocky and jointed rock mass ■■ Tunnel driving in soft, homogenous foundation soil conditions
Main Advantages
■■ Practice-proven spile system ■■ Secure and simple installation ■■ Universally applicable ■■ Installation using conventional drilling machines ■■ Optionally also available as injection spile ■■ Higher section modulus than ram spiles or self-drilling spiles at comparable weight
System Description
Tube spiles consist of a steel tube, which is optionally provided with a welded ram top. The installation is carried out with conventional drilling machines. The tube spiles are either installed into pre-drilled spile holes or rammed directly into the foundation soil. Pre-drilled tube spiles are used for jointed and blocky rock mass as pre-support against falling rock mass, whereas ram spiles are applied in homogenous, soft foundation soil.
By ramming, a loosening of the foundation soil is prevented, and an optimum initial condition for arching between the spiles is achieved. Following driving, the load of the foundation soil is transferred to the bearings by the spiles. These are the ground ahead of the face and the primary lining.
88 Tubular Spiles Specifications
Outer diameter 1) [mm] 38 51 51 Wall tickness [mm] 4 3.2 4.5 Delivery lengths 2) [m] 3 / 4 / 6
1) Minimum steel grade S 235 (EN 10025-2) 2) Differing shipping lengths and injection boreholes according to customer demands are available on request
Technical Features
■■ Simple and uncomplicated installation into pre-drilled boreholes ■■ Tube-ram spiles with steel point are available on request ■■ Foundation soil preserving installation by ramming – the original stress condition remains ■■ Ramming displaces the foundation soil and allows for optimum load carrying characteristics at a later stage ■■ Installation is possible over as well as through the support arch ■■ High section modulus in relation to the weight ■■ Also available as injection spile with injection holes for ground improvement
Installation Procedure
■■ Installation into pre-drilled spile holes ■ Pre-drilling of spile holes through or over the support arch ■ Insertion of tube spiles ■■ Installation as ram spile ■ Ramming of the tube spile through or over the support arch
89 IBO - Self-Drilling Spiles
IBO - Self-Drilling Spiles form part of the DYWI® Drill Hollow Bar System product range. They are ideal for pre-support measures in all foundation soil types. Especially in unstable boreholes, the fast and self-drilling installation offers distinct advantages compared to conventional spile types.
IBO - Self-Drilling Spiles support local instabilities in the working area. In poor foundation soil, this system is an excellent alternative to conventional ram spiles or steel tube spiles.
Fields of Application
■■ Pre-support in any kind of foundation soil ■■ Especially suitable for foundation soils with unstable boreholes
Main Advantages
■■ Installation using conventional drilling machines ■■ Secure, simple, and fast installation ■■ Unproblematic application in case of unstable boreholes ■■ Spile drilling and spile installation in one step ■■ Greater spile lengths can be achieved with couplings
System Description
IBO - Self-Drilling spiles are installed with conventional drill booms using rotary percussive drilling. The installed hollow bar simultaneously serves as drilling rod and reinforcement. The drilling energy is transferred onto the drill bit, which has a higher outer diameter than the hollow bar. Cooling, flushing, and backflush of cuttings is accomplished with water between the foundation soil and the IBO - Self-Drilling Spiles.
90 IBO - Self-Drilling Spiles System Components Specifications
■■ IBO - Self-Drilling Spile Outer diameter 1) [mm] R32 R38 R51 ■■ Optionally available with injection Delivery lengths 2) [m] 3.0 / 4.0 holes ® ■■ Spile drill bits or welded drill bit 1) Technical Data is enclosed in the DYWI Drill Hollow Bar System brochure 2) Differing shipping lengths and injection holes according to customer demands are available on request
Installation Procedure
■■ Assembly of the IBO - Self-Drilling Spile and connection onto the drill boom
■■ Rotary-percussive self-drilling installation without casing: Single- use drill bit and hollow bar serving as drilling rod; flushing with water or an air-water-mixture
■■ Optional extension with couplings
■■ Decoupling from the drifter, optional subsequent injection using an injection adapter
Technical Features Accessories Further Information
■■ Extensive drill bit portfolio for different ■■ Mortar-mixing pumps ■■ DYWI® Drill Hollow Bar System foundation soil conditions ■■ Injection adapter brochure ■■ Mortaring of the annular gap increases ■■ DYWI® Inject System ■■ Further information about accessories the load transmission and load bearing can be found in DSI system brochures ■■ Sleeve pipe packers capacity and technical approvals ■■ Rock drilling equipment: shank adapters, ■■ Optionally with injection holes for couplings, and coupling adapters ground improvement
91 Forepoling Boards
Forepoling boards are used for laminar- active pre-support, which is particularly suitable for unstable, non-cohesive foundation soil. This support is rammed into the foundation soil using hydraulic drifters.
Fields of Application
■■ Pre-support in non-cohesive foundation soil ■■ Pre-support in nearly non-cohesive foundation soil
Main Advantages
■■ Installation using conventional drilling machines ■■ Secure and simple installation ■■ Closed support at the open span ■■ Ramming minimizes drive-induced rock mass stress relaxation
System Description
Forepoling boards are rammed over the support arch in a single step with conventional drill booms via a ram shoe. They are either installed overlapping or with a gap when the foundation soil shows little cohesion.
■■ Steel plate with one or two longitudinal seams ■ Plate thickness: 3 - 6 [mm] ■ Length: 1,250 - 3,000 [mm] ■ Width: ca. 220 [mm] ■■ Forepoling board template ■ Different versions available on request
92 Forepoling Boards Specifications
120 t 35 30
175
B
Forepoling boards Type A
Characteristics Symbol Unit Type A3 Type A4 Type A5 Type A6 Thickness t [mm] 3 4 5 6 Length 1) L [m] 1.25 1.50 2.00 2.50 3.00 1.25 1.50 2.00 2.50 3.00 1.25 1.50 2.00 2.50 3.00 1.25 1.50 2.00 2.50 3.00 Width 2) B [mm] 220 220 220 220 Weight m [kg/m] 6 8 10 12
Weight mPcs [kg/pcs] 7.5 9.0 12.0 15.0 18.0 10.0 12.0 16.0 20.0 24.0 12.5 15.0 20.0 25.0 30.0 15.0 18.0 24.0 30.0 36.0 Resisting torque Wx [cm³] 8.9 10.6 12.2 13.8 1) Special lengths available on request 2) Guidance value installation width with overlapping: 5.7 pieces per meter
140 t 35 30
185
B
Forepoling boards Type B 1)
Characteristics Symbol Unit Type B3 Type B4 Type B5 Type B6 Thickness t [mm] 3 4 5 6 Length 2) L [m] 1.25 1.50 2.00 2.50 3.00 1.25 1.50 2.00 2.50 3.00 1.25 1.50 2.00 2.50 3.00 1.25 1.50 2.00 2.50 3.00 Width 3) B [mm] 220 220 220 220 Weight m [kg/m] 6 8 10 12
Weight mPcs [kg/pcs] 7.5 9.0 12.0 15.0 18.0 10.0 12.0 16.0 20.0 24.0 12.5 15.0 20.0 25.0 30.0 15.0 18.0 24.0 30.0 36.0 Resisting torque Wx [cm³] 8.9 10.6 12.2 13.8 1) Dimension sheets and weight tables are available on request 2) Special lengths available on request 3) Guidance value installation width with overlapping: 5.4 pieces per meter
Technical Features
■■ Ramming with drill-driving jumbo ■■ Secure and simple installation ■■ Closed and open support of the tunnel perimeter ■■ Ramming prevents settlement and stress release ahead of the construction
93 Drainage Drilling Systems
AT - TUBESPILETM Vacuum Lances...... 95
AT - Drainage System...... 99
94 AT - TUBESPILETM Vacuum Lances and AT - Drainage System
Introduction ...... 95
AT - TUBESPILE™ Vacuum Lances ...... 96
Introduction...... 96
Fields of Application ...... 96
Main Advantages ...... 96
System Description...... 96
System Components ...... 97
Specifications ...... 97
Technical Features ...... 97
Installation Manual...... 98
Accessories ...... 98
Further Information ...... 98
AT - Drainage System ...... 99
Introduction...... 99
Fields of Application ...... 99
Main Advantages ...... 99
System Description...... 99
System Components ...... 100
Specifications ...... 100
Technical Features ...... 100
Installation Manual...... 101
Accessories ...... 102
Further Information ...... 102
Introduction
Drainage Systems are used in Tunneling and in Civil Engineering for draining the surrounding foundation soil.
The aim of drainage is the stabilization of the particular ground section. In accordance with project requirements, DSI offers two different systems for drainage works. Applications range from jointed rock to soft foundation soil.
95 AT - TUBESPILE™ Vacuum Lances Introduction Fields of Application Main Advantages
The AT - TUBESPILE™ Vacuum Lance ■■ Drainage works around the excavation ■■ Installation using standard drilling forms part of the POWER SET product ■■ Drainage with and without vacuum machinery family. The system consists of an application ■■ Simple and robust system components exterior steel tube with a PVC-drainage ■■ Drainage works in all geological ■■ Secure and simple installation tube inserted after drilling. The main field conditions of application is the temporary or semi- ■■ Drainage drilling and casing temporary drainage of ground around installation in one operational step the excavation geometry in Tunneling ■■ Foundation soil preserving, self-drilling and special foundation engineering. installation
System Description
AT - TUBESPILE™ Vacuum Lances are installed rotary-percussive in one step using a conventional drill boom. Drill rods inside the casing tubes transfer the drilling energy onto the drill bits, which are available either as button drill bits with carbide inserts or hardened arc-shaped drill bits.
The AT - TUBESPILE™ with drainage openings is pushed through an adapter directly behind the drill bit. Cooling, flushing and back-flushing of the borehole cuttings are carried out using water inside the casing tube. To finish the installation, a PVC filter pipe is inserted into the casing. In case of vacuum drainage, a drainage hose can be fastened to the vacuum lance following the installation.
96 AT - TUBESPILE™ Vacuum Lances System Components
■■ AT - TUBESPILETM Drill Bit ■■ POWER SET Drill Rod ■ Single-use drill bits Ø 52 [mm] ■ Special drill rod for high service life available as arch-shaped or ■■ POWER SET Coupling Adapter pin-shaped drill bits ■ Controlled transfer of the impact ■■ AT - TUBESPILETM Vacuum Lance energy onto the AT - TUBESPILETM ■ Ø 51 x 3.2 [mm] with drainage ■■ AT - TUBESPILETM Filter Pipe openings and 2" connecting thread
AT - TUBESPILETM Drill Bit POWER SET Drill Rod POWER SET Coupling Adapter
AT - TUBESPILETM Filter Pipe AT - TUBESPILETM Vacuum Lance
Ready-for-use AT - TUBESPILETM Vacuum Lance
Specifications 1)
Outer Wall Drainage slot Standard Material Weight System diameter thickness width tube length [mm] [mm] [mm] [kg/m] [m] AT - TUBESPILE™ with Drainage Openings Steel ≥ S235 2) 51 3.2 – 3.8 3.0 / 3.5 / 4.0 / 4.5 AT - TUBESPILE™ Filter Pipe PVC 44 3.5 0.6 / 1.0 / 1.5 1.55 3
1) Differing dimensions are available on request 2) Minimum values in accordance with EN 10025-2
Technical Features AT - TUBESPILETM Filter Pipe
■■ Self-drilling installation permits ■■ Cased installation allows proper application in all foundation soils installation even with frequently ■■ Numbers of drainage holes and filter changing or poor ground conditions slots are adaptable to foundation soil ■■ No annular gap and therefore no conditions settlement or loosening during ■■ Different drill bit types are available for installation all geological conditions
97 AT - TUBESPILE™ Vacuum Lances Installation Manual
1. Attachment of the AT - TUBESPILETM Vacuum Lance and the AT - TUBESPILETM single-use Drill Bit onto the POWER SET Drill Rod, coupling of the POWER SET Coupling Adapter to the hydraulic rock drill 2. Rotary-percussive self-drilling installation via single-use drill bit; flushing of the cuttings through the annular gap between the drill rod and the TUBESPILE™
3. Completion of the drilling process after reaching the drilling depth
4. Retraction of the POWER SET Drill Rod from the installed AT - TUBESPILETM Vacuum Lance; the single-use drill bit remains in the borehole
5. Insertion of a filter tube into the AT - TUBESPILETM Vacuum Lance
6. Optional connection of a drainage hose and coupling onto a vacuum pump
Accessories Further Information
■■ Vacuum pump ■■ Brochure POWER SET Self-Drilling Friction Bolt ■■ DYWI® Inject Systems ■■ Brochure AT - TUBESPILETM ■■ Injection packers ■■ Technical data sheet AT - TUBESPILETM ■■ POWER SET Automation Unit
98 AT - Drainage System Introduction
The AT - Drainage System is used for deep reaching drainage and forms part of the AT - Casing System product family. It is used in Tunneling and in Civil Engineering for draining the surrounding ground and consists of an inner steel tube which is wrapped with a PVC-drainage pipe. The AT - Drainage System can be applied temporarily as well as semi-permanently. Examples of application are drainage works parallel to tunnel advances or water saturated slopes.
Fields of Application
■■ Far-ranging drainage works ■■ Drainage with and without vacuum application ■■ Drainage of the ground ahead of the advance and parallel to construction ■■ Reduction of water pressure in fault zones ahead of construction ■■ Stabilization of water saturated slopes ■■ Reduction of the water pressure behind construction walls ■■ Drainage works in all geological conditions
Main Advantages
■■ Installation using conventional drilling machines ■■ Execution of the drilling works can be carried out by on-site personnel guided by application engineers ■■ Time-saving self-drilling installation thanks to simultaneous drilling and casing ■■ Installation also possible in flowing ground conditions ■■ Length of the drainage tubes adaptable to little space
System Description
The AT - Drainage System is installed piecewise by rotary-percussive drilling with conventional drill booms. Cooling, flushing, and back-flushing of the borehole cuttings take place inside the drainage tube.
99 AT - Drainage System System Components
AT - Drainage Starter Unit with Drill Bit
AT - Drainage Extension Tube
AT - Drainage End Tube
Different AT - Drill Adapters
Coupling Adapter and Drill Rods
End Cap
Ready-for-use AT - Drainage System
■■ AT - 76-DR Starter Unit with ■■ By request, the AT - 118-DR System is DR-Extension Tube (standard system) also available as DTH hammer version
Specifications 1)
Standard Inner tube Filter pipe 3) Outer diameter Weight System tube length Material Material [mm] [kg/m] [m] AT - 76-DR Steel ≥ S235 2) PVC 76.1 7 3.0 AT - 118-DR Steel ≥ S235 2) PVC 118 15 3.0
1) Differing dimensions are available on request 2) Minimum values in accordance with EN 10025-2 3) Slot opening width 0.6 / 1.0 / 1.5 [mm]; 3 slots around the whole pipe diameter
100 AT - Drainage System Technical Features
■■ Fast length adaption of AT - Drainage Tubes by piecewise installation ■■ Simple extension of drainage tubes even in limited space ■■ High directional accuracy of drainage drillings ■■ Drainage pipes can be flushed for cleaning when installed as permanent measure ■■ The AT - 118-DR System can be installed using a down-the-hole-hammer or a top hammer
Installation Manual
1. The AT - DR-Starting Unit with Drill Bit is prepared for installation with the first AT - Drainage Extension Tube, the AT - Drill Adapter, and the drill rod on the drill boom 2. Drilling of the first AT - Drainage Extension Pipe 3. The next drill rod including the AT - Drainage-Extension Tube is connected to the previously installed part and is subsequently drilled 4. Repetition of the last step until the planned length of the drainage drilling has been reached
101 AT - Drainage System Accessories
■■ Injection packers ■■ DYWI® Inject Systems ■■ Chain pipe wrench ■■ Drill rod wrench ■■ Rock drilling equipment: shank adapter, coupling, and coupling adapter ■■ Fishing tab
Further Information
■■ Brochure AT - Pipe Umbrella Support System ■■ Technical data sheet AT - Drainage System
102 103 Passive Support
PANTEX Lattice Girders ...... 105
Support Profiles and Rock Bolt Straps ...... 108
LSCTM Elements...... 113
104 PANTEX Lattice Girders
Introduction...... 105
Fields of Application...... 106
Main Advantages...... 106
System Description...... 106
System Components...... 107
Specifications...... 107
Accessories...... 108
Further References...... 108
Introduction
PANTEX Lattice Girders have been developed for special demands in the field of Tunneling. The PANTEX system has been extensively tested and used successfully for numerous tunnel projects throughout the world.
PANTEX Lattice Girders ensure an immediate support in the open span area. Contrary to standard solid-web girders, PANTEX Lattice Girders are entirely integrated in the shotcrete lining; porous zones and shotcrete spray shadows are avoided.
The load-bearing capacity of PANTEX Lattice Girders has been investigated with various loading tests and by numerical analysis. Flexibility regarding geometry and bearing capacity characterizes this passive support system for underground applications.
105 x
2
S
e
1 S
H
1 Fields of Application H
3
S ■■ Passive support system for the y excavated cross section Bar S2 B Stiffener (spider) ■■ Profile template for the excavation geometry ■■ Bearing for pre-support elements
Main Advantages
■■ Immediate support in the excavation Bar S3 area ■■ Utilization as a true-to-form template for shotcrete application ■■ Easy and quick assembling, simple handling ■■ Optimum bond and interconnection with the shotcrete lining ■■ Simple adjustment and shaping to the excavation geometry ■■ Ideal bearing for spiles and lagging boards ■■ Spiles may be installed both above or through the lattice girders
System Description
■■ Load-bearing elements according to ■■ Assembly of the full girder profile by the particular demands in Tunneling connecting single girder elements ■■ Spatial 3 or 4 bar girder construction, ■■ Load transmission even before connected via stiffening elements shotcrete application ■■ 3-bar girder: single bar either at the ■■ Integral part of the shotcrete lining excavation or ground side, depending reinforcement on the application ■■ Proven bond according to the design ■■ 4-bar girder: application as wallplate principles of reinforced concrete beam or stiff cross girder ■■ Reduction of girder buckling lengths by stiffeners
106 System Components
Girder Bars Stiffeners Connections ■■ 3-bar girders: 2 + 1 bars ■■ Smooth or ribbed reinforcing steel ■■ Angle or alternative flat steel ■■ 4-bar girders: 2 + 2 bars ■■ Steel grade B 500 B or higher connection plates ■■ Smooth or ribbed reinforcing steel ■■ 4 bar stiffeners in one part ensure ■■ Steel grade S 235 (EN 10025-2) B 500 B (DIN 488-1) or optimum bearing capacity or higher B 550 B (ÖNORM B 4707) ■■ Bolts: standard grade 8.8 ■■ High strength and great deformability (EN ISO 898-1) ■■ Slotted bolt or customized connections available on request ■■ Base plates: standard or elephant foot version ■■ Special connections available on request
x
2
S
e
1 S
H
1
H
3
S
y B Specifications Gurtstab S2 Aussteifungselement (Spinne) 3-bar girder
1) 2) 3) 4) No. Designation H1 S1 S2 S3 Weight HBAWx Ix Article No. [#] [PS1-S3-S2] [mm] [mm] [mm] [mm] [kg/m] [mm] [mm] [cm²] [cm³] [cm4] [–] 1 P50-20-25 25 20 10.2 95 11.19 28 148 14102025XXXX 2 P50-20-30 30 20 11.9 100 13.35 38 193 14102030XXXX 3 P50-20-36 36 20 14.3 106 16.46 42 246 14102036XXXX 50 10 100 4 P50-25-30 30 25 14.7 105 16.89 42 255 14102530XXXX 5 P50-25-36 36 25 17.1 111 20.00 58 336 14102536XXXX 6 P50-30-36 36 30 20.5 116 24.32 64 424 14103036XXXX 7 P70-20-25 25 20 10.4 115 11.19 37 239 14122025XXXX Gurtstab S3 8 P70-20-30 30 20 12.1 120 13.35 51 306 14122030XXXX 9 P70-20-36 36 20 14.5 126 16.46 54 383 14122036XXXX 70 10 140 10 P70-25-30 30 25 14.9 125 16.89 56 398 14122530XXXX 11 P70-25-36 36 25 17.3 131 20.00 77 517 14122536XXXX 12 P70-30-36 36 30 20.7 136 24.32 83 644 14123036XXXX 13 P95-20-25 25 20 10.8 140 11.19 49 384 14142025XXXX 14 P95-20-30 30 20 12.5 145 13.35 66 485 14142030XXXX 15 P95-20-36 36 20 14.9 151 16.46 69 598 14142036XXXX 95 10 180 16 P95-25-30 30 25 15.3 150 16.89 72 625 14142530XXXX 17 P95-25-36 36 25 17.7 156 20.00 100 799 14142536XXXX30 - 50 18 P95-30-36 36 30 21.1 161 24.32 107 986 14143036XXXX 19 P115-20-25 25 20 11.0 160 11.19 58 525 14162025XXXX 20 P115-20-30 30 20 12.7 165 13.35 78 658 14162030XXXX 21 P115-20-36 36 20 15.1 171 16.46 82 804 14162036XXXX 115 12 220 22 P115-25-30 30 25 15.5 170 16.89 86 842 14162530XXXX 23 P115-25-36 36 25 17.9 176 20.00 120 1,070 14162536XXXX 24 P115-30-36 36 30 21.3 181 24.32 126 1,312 14163036XXXX 25 P130-20-25 25 20 11.2 175 11.19 66 644 14182025XXXX 26 P130-20-30 30 20 12.9 180 13.35 87 805 14182030XXXX 27 P130-20-36 36 20 15.3 186 16.46 91 980 14182036XXXX 130 12 220 28 P130-25-30 30 25 15.7 185 16.89 96 1,027 14182530XXXX 29 P130-25-36 36 25 18.1 191 20.00 134 1,299 14182536XXXX 30 P130-30-36 36 30 21.5 196 24.32 141 1,589 14183036XXXX 1) Designation: PH1-S3-S2, e.g. P130-20-30 ; 2) Weight including stiffeners (average values) 3) Quotient moment of inertia and maximum distance from the neutral axis to the outer fiber ; 4) ”XXXX” … project-specific designation
107 4-bar girder
1) 2) 4) 4) 3) No. Designation H1 S1 S2 Weight HBAWx Wy Article No. [#] [PH1-S2] [mm] [mm] [mm] [kg/m] [mm] [mm] [cm²] [cm3] [cm3] [–] 1 P100-20 20 12.7 140 12.57 65 41 14200020XXXX 2 P100-25 25 14.3 150 19.63 103 56 14200025XXXX 50 10 100 S1
3 P100-30 30 19.4 160 28.27 151 72 14200030XXXX x H
4 P100-36 36 26.7 172 40.72 222 88 14200036XXXX H1 5 P140-20 20 13.1 190 12.57 96 65 14220020XXXX 6 P140-25 25 18.5 200 19.63 151 94 14220025XXXX 75 10 140 7 P140-30 30 25.3 210 28.27 219 124 14220030XXXX 8 P140-36 36 35.1 222 40.72 319 161 14220036XXXX y 9 P190-20 20 13.9 230 12.57 121 90 14240020XXXX 10 P190-25 25 19,3 240 19.63 190 132 14240025XXXX 95 10 180 B 11 P190-30 30 26.1 250 28.27 275 178 14240030XXXX 12 P190-36 36 35.9 262 40.72 399 237 14240036XXXX 13 P230-20 20 14.3 270 12.57 146 114 14260020XXXX 14 P230-25 25 19.7 280 19.63 228 170 14260025XXXX 115 10 220 Gurtstab S2 15 P230-30 30 26.5 290 28.27 330 233 14260030XXXX Aussteifungselement (Spinne) 16 P230-36 36 36.3 302 40.72 479 316 14260036XXXX 17 P260-20 20 14.7 300 12.57 164 114 14280020XXXX 18 P260-25 25 20.1 310 19.63 258 170 14280025XXXX 130 10 220 19 P260-30 30 26.9 320 28.27 372 233 14280030XXXX 20 P260-36 36 36.7 332 40.72 539 316 14280036XXXX 1) Designation: PH1-S2, e.g. P140-30 2) Weight including stiffeners (average values) 3) ”XXXX” … project-specific designation 4) Quotient moment of inertia and maximum distance between outer fiber and neutral axis
Accessories Angle connection plates and base plates Wallplate beamsGurtstab S2
Type Angle Connections Foot Plates ■■ 4-bar girders can be used as wallplate Angle steel Size beams for crown drives Designation Cut length G 2) G (B x L x t) 1) (B x L x t) ■■ Installation of 90° axial rotated 4-bar [PH1] [mm] [mm] [kg] [mm] [kg] girders in the longitudinal direction 1.7 P50 110 100 x 100 x 10 0.8 ■■ Wallplate beams serve as bearing and 1.7 2.1 profile template for installation of the P70 138 2.1 140 x 140 x 10 1.6 girder arch 2.1 ■■ Bend-proof frontal connection allows 2.5 free crown advancing P95 165 2.5 145 x 180 x 10 2.1 80 x 120 x 10 ■■ At the same time, wallplate beams 2.5 30 -50 3.0 are considered as statically effective P115 200 3.0 165 x 220 x 10 2.9 reinforcement for the foot beam 3.0 3.2 P130 210 3.2 180 x 220 x 10 3.2 3.2 1) Cut with 60° miter, weight: 15 [kg/m] 2) Weight per single angle - angle connections consists of 4 angle plates Datum Name Further References Bearb: DDl DSI Austria, Alfred-Wagner-Straße 1, A-4061 Pasching/Linz Gepr: WDk Phone: +43-7229-61049-0 E-Mail: [email protected] Norm ■■ Ongoing internal factory production ■■ Numerical analysis of the static load- Gegenstand der Unterlage / Zeichnung ist unser geistiges control bearing capacityEigentum. and Diesebending Zeichnung testdarf ohne unsere vorherige schriftliche Zustimmung weder vervielfältigt noch Dritten zu Gruppe Format reports availableKenntnis on request gebracht werden. Sie darf auch nicht in anderer ■■ External supervision of the Weise mißbräuchlich verwendet werden. A4 manufacturing process ■■ Allowable tightening(Urheberschutzgesetz torques and v. 09.09.1965) Blatt 1 ■■ Certificate of conformity No. mounting pre-loadI:\50_CAD\1410\141020002002.idw for set metrical set Ersatz für: Ersatz durch: 11 7165-1/1, MPA NRW (Germany), screws: see VDI guideline No. 2230, dating 2012-05-24, for the building sheet 1 product DSI lattice girders type PANTEX / 3 bars
108 Support Profiles and Rock Bolt Straps
Introduction ...... 109
Fields of Application ...... 110
Main Advantages ...... 110
System Description ...... 110
Specifications...... 111
Accessories ...... 112
Introduction
TH Profiles, HEB Profiles, and UNP Profiles are successfully used as passive ground control elements in underground construction.
Although the importance of conventional steel support has recently decreased, it is still successfully used in deep-level underground coal Mining as well as for special support in Tunneling and cavern construction.
Rock bolt straps and mats are used in combination with rock bolts for securing the excavation surface. In hard rock Mining, rock bolt straps are preferably used, whereas soft rock and coal Mining prefer flexible rock bolt mats or mesh.
109 Fields of Application Main Advantages
■■ Ground support in underground ■■ Flexible adaptation of the beam Mining geometry to the respective excavated ■■ Shaft construction support cross-section ■■ Support of junctions and cross- ■■ Well-proven passive mine support sections ■■ Flexible extension by using yielding ■■ Rock bolt mats and straps for locks connecting individual rock bolts ■■ Large-scale profile cross-sections ensure longer life times
System Description
TH Profile
■■ Mine support steel 31Mn4 according to DIN 21544 ■■ Bent to the corresponding profile ■■ Single overlapping segments are usually connected by two locks ■■ Alternative TH locks are available on request
HEB Profile
■■ I Profile – HEB broad flange girder ■■ Primary material S235JRG2 or S355J2G3 according to EN 10025-2 ■■ Bent to the corresponding profile ■■ Connection of the segments via head plates that are available in different designs ■■ Alternative connection of the abutting segments via laces ■■ Different lace types and lace screws are available on request
UNP Profile
■■ U Profile with inclined inner surfaces of the flanges ■■ Primary material S235JRG2 or S355J2G3 according to EN 10025-2 ■■ Bent to the corresponding profile ■■ Connection of the segments via welded-on and screwed head plates or flange connections ■■ Different lace types and lace screws are available on request
Rock Bolt Straps
■■ Connection of single bolts
110 UNP Profile HEB Profile TH Profile Support Profiles Specifications Type / characteristic Type /characteristic Type /characteristic Type / characteristic Type /characteristic eto ouu W Section modulus eto ouu W Section modulus W Section modulus rfl egtH[m 0101010160180 140 120 100 80 H [mm] Profile height rfl egtH[m 100 H[mm] 124138 Profile height 118 108 H[mm] Profile height rfl it m]4 05 06570 60 55 50 45 B[mm] Profile width rfl it m]100 B[mm] 151171 Profile width 135 124 B[mm] Profile width eta xse[m .515 .017 .41.92 1.84 1.75 1.60 1.55 1.45 [cm] e Neutral axis eta xse[m 52 [mm] e Neutral axis Weight Weight Weight value value value yblUi H2 H2 H2 TH36 TH29 TH25 TH21 Unit Symbol yblUi E 0 E 2 HEB 140 HEB120 HEB 100 Unit Symbol yblUnit Symbol k/]21 [kg/m] m k/]891. 371. 9322.5 19.3 16.4 13.7 10.9 8.9 [kg/m] m k/]20.9 [kg/m] m x x y c³ 61 [cm³] c³ 89.9 [cm³] c³ . . 111. 8322.4 18.3 14.8 11.1 8.5 6.4 [cm³] N 0UP10UP10UP10UP10UNP180 UNP160 UNP 140 UNP120 UNP100 UNP 80 80 25 58 27.4 144 120 120 94 29 58 34.5 216 140 140 136 36 69
H H e
H y e B B B y y x x x 111 Specifications
Rock Bolt Straps
OSRO straps 1)
Length Width Horizontal bar Strapping bar diameter diameter [mm] [mm] [mm] [mm] 1,000 - 6,000 250 - 1,000 6 - 10 5.5
W-straps 1)
Length Width Wall thickness Hole spacing [mm] [mm] [mm] [mm] 1,000 - 3,000 220 - 500 1.5 - 6.0 500 1) Alternative dimensions available on request
Accessories
■■ Alternative profile types and connection elements are available on request ■■ Screws, nuts, and bolts are available in different designs ■■ Rock bolt tension straps and underpinnings ■■ GRP mesh and rock bolt straps
112 LSCTM Elements
Introduction ...... 113
Fields of Application ...... 114
Main Advantages ...... 114
System Description...... 114
System Components ...... 115
Technical Data ...... 115
Technical Characteristics...... 115
Installation Procedure (Conventional Excavation) ...... 116
Further References ...... 116
Introduction
Lining Stress Controllers (LSCTM) have been developed as special supporting measure for highly squeezing rock mass conditions. The primary tunnel lining is divided into several segments by longitudinal construction joints. The purpose of this segmentation is the ability to absorb large deformations occurring during tunnel driving in weak ground.
LSCTM steel elements are installed into these deformation joints. The elements have a defined workload during compression so the primary lining is not damaged. DYWIDAG-Systems International (DSI) has long-time experience in the application of LSCTM elements, which have been successfully used for many projects.
113 Fields of Application System Description
■■ Weak ground combined with Compared to the strength of the primary high overburden lining, the load-bearing resistance of TM ■■ Fault zones (large displacements) LSC Elements is dimensioned at a lower level. Thus, large deformations ■■ Swelling ground can be absorbed by LSCTM Elements ■■ Squeezing ground before the tunnel lining is damaged. The optimum supporting effect is created by selecting the best suited LSCTM Elements Main Advantages and the proper number of compression bodies which determine the overall load- ■■ Maintenance of supporting forces and bearing resistance characteristics. optimum utilization of the load-bearing capacity of the primary lining Single yielding elements are aligned ■■ Controlled stress release and between base plates. These plates fix deformability the position of the yielding elements and limit LSCTM Elements towards the ■■ Steady increase of support resistance tunnel lining. Each yielding element while undergoing large deformations has a factory-set imperfection where ■■ Rapid increase of support resistance controlled deformations start in case in slowly increasing deformations of excessive loading. ■■ Avoidance of excessive tunnel liner overstressing ■■ Custom-specific adaptation of the deformation characteristics of LSCTM Elements in accordance with project requirements ■■ The most effective Lining Stress Controller currently used in Tunneling
114 System Components
■■ Base plates ■■ Yielding elements ■■ Holding bars
Technical Data
Type Unit A-II/3 1) A-II/4 1)
Design load yielding elements Fp [kN] 700 Number of yielding elements [#] 3 4 2) Design load yielding element Fp.total [kN] 2,100 2,800 Deviation load cycle to design load tolF [%] ± 15 Shortening required to reach the design load lp.min [mm] 60 Length [mm] 800 - 1,000 Width [mm] 250 - 350 Height [mm] 430
1) Standard types in conventional Tunneling 2) LSCTM Elements with alternative dimensions available on request
Technical Characteristics
The type, number and length of LSCTM Fp tol Elements is adapted to the load-bearing capacity of the primary lining and the displacements measured at the tunnel wall F [kN] ■■ Load-deformation characteristics can be changed to permit an adaption of the support resistance ■■ Project-specific customization of the LSCTM Element geometry
∆lp dl [mm]
115 Installation Procedure (Conventional Excavation)
1. Adjustment of LSCTM Elements between support segments 2. Temporary fixing in the installation position 3. Installation of additional reinforcement required for load transmission 4. Coverage or insulation of LSCTM Elements to ensure a full utilization of the compression space 5. Application of shotcrete lining 6. Removal of the coverage
Further References
■■ Moritz, B. 1999, “Ductile Support ■■ Schubert, W. 2008. “Design of ■■ Radoncic, N. et al, „Ductile support System for Tunnels in Squeezing Ductile Tunnel Linings”; 42nd US Rock design“; Geomechanics and Rock” Doctoral Thesis, Department of Mechanics Symposium and 2nd U.S.- Tunnelling 2 (2009), No. 5, Civil Engineering, Technical University Canada Rock Mechanics Symposium, DOI: 10.1002/geot.200900054 Graz, Austria San Francisco, U.S.A., June 29 - July 2, 2008
116 117 Injection and Waterproofing Systems
AT - GRP Injection Systems ...... 119
DYWI® Inject Systems - Underground ...... 123
DYWI® Seal Waterproofing System and Bentonite Mats...... 145
118 AT - GRP Injection Systems
Introduction ...... 119
Fields of Application ...... 120
System Description ...... 120
Main Advantages...... 120
System Components...... 121
Specifications ...... 121
Technical Features ...... 121
Installation Procedure ...... 122
Accessories...... 122
Introduction
The AT - GRP-Injection System is an AT-SYSTEM with glass fiber reinforced casing pipes (GRP) which is installed self-drilling. This system is mainly used when steel is not desired in the ground or where injection pipes are excavated by a TBM afterwards.
The injection pipes permit an insertion of any kind of ground influencing injection media into the ground. These injections may serve for ground improvement or waterproofing. The AT - GRP-Injection System can thus be both installed in jointed rock as well as in weak ground conditions.
119 Fields of Application
■■ Ground improvement combined with mechanized Tunneling ■■ Waterproofing measures near openings and excavations ■■ Waterproofing measures in water- bearing fault zones
System Description
The AT - GRP-Injection System is installed piecewise by rotary-percussive drilling with conventional drill booms.
The cooling of the drill bit and flushing of the cuttings take place inside the GRP tube.
Main Advantages
■■ Installation with standard drilling ■■Time-saving installation due to ■■ GRP pipe length may be adapted to machines simultaneous drilling and tubing the space available ■■ Drilling works can be executed (self-drilling) ■■ GRP injection pipes can be cut and by standard personnel under the ■■Installation using a preventer mucked out by a TBM cutting wheel supervision of application engineers is possible
120 System Components
AT - Starter Unit with Drill Bit
AT - GRP Extension Tubes
AT - GRP Tail Casing Tube
Valves in Injection Holes
AT - GRP Drilling Adapter or Preventer Impact Adapter
Various AT - Adapters
Coupling Adapter and Drill Rods
Ready-for-use AT - GRP-Injection System
■■ Standard version AT - GRP-Injection System ■■ AT - GRP-Injection System for use in combination with preventers
Specifications Technical Features
■■ AT - 76-GRP; outer diameter 76 [mm], ■■ The length of the AT - GRP-Injection ■■ High drilling accuracy during installation wall thickness 8 [mm] tubes is easily adapted due to the ■■ TBM drilling equipment may be used ■■ GRP standard tube lengths: piecewise installation for installation 1.0 / 2.0 / 3.0 [m] ■■ Simple extension of GRP tubes even in constricted working space
121 Installation Procedure
1. The AT - Starter Unit with single-use 2. Drilling of the first TA - GRP-Injection 4. Repeat the last step until the designed Drill Bit is connected to the first tube length of the AT - GRP-Injection pipe AT - GRP Extension Tube. This part 3. The next GRP-Injection tube and including the AT - GRP Tail Casing Tube is then prepared on the drill boom the drill rod are connected with the has been installed together with the adapter and the drill previously installed part and are drilled rods subsequently
Standard version AT - GRP-Injection System
AT - GRP-Injection System for use in combination with preventers
Accessories
■■ Injection flow-pressure meter ■■ Sleeve pipe packer ■■ Deep injection packer ■■ Mortar-Mixing pump ■■ DYWI® Inject Systems ■■ Fishing tab ■■ Chain pipe wrench ■■ Drill rod wrench ■■ Rock drilling equipment: shank adapter, coupling, and coupling adapter
122 DYWI® Inject Systems - Underground
DYWI® Inject PURE 8031 - Polyurethane Injection Foam Resin ...... 124
DYWI® Inject PURE 8034 - Polyurethane Injection Resin ...... 127
DYWI® Inject PURE X 8032 and PURE X 8034 - Accelerators ...... 130
DYWI® Inject SILO 8041 - Silicate Injection Foam Resin ...... 131
DYWI® Inject SILO 8042 - Silicate Injection Resin ...... 134
DYWI® Inject GELE 8061 - Acrylate Injection Gel ...... 137
DYWI® Inject Cleaning Agents ...... 139
DYWI® Inject 8096 2-Component High-Pressure Pump Type MT ...... 140
DYWI® Inject 8097 2-Component High-Pressure Pump Type GELE ...... 141
DYWI® Inject Packer and Accessories ...... 142
Fields of Application
Product Segment DYWI® Inject Product Group PURE 8031 PURE X 8032 PURE 8034 PURE X 8034 SILO 8041 SILO 8042 GELE 8061
Accelerator for Polyurethane Accelerator for Silicate Polyurethane Polyurethane Silicate Acrylate Product Designation Injection Foam Polyurethane Injection Foam Injection Foam Injection Resin Injection Resin Injection Gel Resin Injection Resin Resin Resin
Areas of Application in Mining, Tunneling, and Foundation Engineering
Sealing of cracks X X Sealing against water X X X X X X Sealing against pressing water X X X X Sealing of floors or footwalls X X Surface sealing and grout curtains X Sealing of excavations X X X X X Sealing against gas X X Sealing of anchor heads X X Installation of injection anchors X X Rock stabilization X X X X Injections in unconsolidated ground X X X X X Rock consolidation X X X Filling of cavities X X Repair of wet sewers X TBM excavations X X
123 DYWI® Inject PURE 8031 – Polyurethane Injection Foam Resin for Underground Applications
Introduction
DYWI® Inject PURE 8031 is a 2-component polyurethane injection foam resin for sealing against water and for stabilizing unconsolidated rock masses in Mining and Tunneling. The strongly expanding DYWI® Inject PURE 8031 may also be used for stabilizing non-binding soils and as a high quality injection material in case of seepage failures.
In foundation engineering, such as the stabilization of excavations, DYWI® Inject PURE 8031 is primarily used for sealing cracks and filling of cavities.
Fields of Application Main Advantages System Description
■■ Ground consolidation in Tunneling ■■ Short reaction and curing time ■■ 2-component injection polyurethane- ■■ Rock stabilization and accompanying adjustable by using the accelerator based foam resin ® measures in underground Mining DYWI Inject PURE X 8032 ■■ Water contact for starting the reaction ■■ Injections in unconsolidated ground ■■ Optimum density due to high of mixed components required penetration ability ■■ Sealing of cracks and gaps against ■■ Foaming rate up to 35 flowing or squeezing mountain water ■■ The foam volume can be increased by ■■ Cures quickly upon contact with water up to 35 times ■■ Sealing of dams, retaining walls and ■■ Processed using 1- or 2-component locks ■■ High adhesive capacity even on wet high pressure pumps DYWI® Inject surfaces ■■ Grouting of cracks during repair works Type MT at a volume ratio of 1:1 at bridges and dams ■■ Ecologically inoffensive – CFC and halogen free ■■ Filling of cavities ■■ Suitable for drinking water areas ■■ Stable for storing and processing – resistant against acids and bases
124 DYWI® Inject PURE 8031 – Polyurethane Injection Foam Resin for Underground Applications
Specifications
Characteristics 1) Unit Component A Component B Notes Density [g/cm3] 0.97 1.23 characteristical value at 23 [°C] Viscosity [mPas] 150 250 at 23 [°C] Flash point [°C] > 120 > 200 according to EN ISO 2719 Color [–] yellowish brown color deviations possible Volume-based mixing ratio [–] 1:1 Injection using 1-component high pressure pump DYWI® Inject 8095 Type MT or Application 2-component high pressure pump DYWI® Inject 8096 Type MT Storage Store in original packaging and protected from moisture at temperatures between 5 [°C] and 30 [°C]
1) The indicated values are laboratory values and may deviate on-site
Mixing and Processing
■■ DYWI® Inject PURE 8031 is provided ■■ DYWI® Inject 8095 1-component high according to the mixing ratio pressure pump Type MT may also be (1:1 parts by volume) used ■■ Prior to usage, stir the required ■■ This requires the intensive mixing of amount of DYWI® Inject PURE X 8032 components A and B (including the into component A (cf. table) rim areas) which have to be filled into ■■ Then process component A (with a clean container accelerator) and component B using ■■ The mixed material is highly moisture DYWI® Inject 8096 2-component high sensitive and must not come in contact pressure pump Type MT with water prior to application ■■ If a skin forms on the mixed material due to air humidity, it has to be removed to prevent it from being mixed in or getting into the pump
125 DYWI® Inject PURE 8031 – Polyurethane Injection Foam Resin for Underground Applications
Cleaning and Disposal Health and Safety
® Equipment such as hoses and pistons of When handling DYWI Inject products, Protective clothing, protective gloves, and EG No. 1907/2006 safety data sheets face protection (safety glasses) must be ■■ DYWI® Inject 8096, 2-component must be accessible to everyone worn at all times when handling materials, high pressure pump Type MT must be responsible for material handling, health, cleaning equipment, and disposing of thoroughly rinsed using the cleaning and safety. materials. Where appropriate, protect agent DYWI® Inject Clean 8081 skin using a protection lotion. In case of skin contact, clean immediately with ■ Provided work interruptions are short, ■ water and soap. If the product splashes the mixing unit may be rinsed using into your eye, immediately rinse with component A water and seek medical advice. Make ■■ DYWI® Inject 8095 1-component high sure to present the product safety data pressure pump Type MT must be sheet during medical assistance. cleaned with cleaning agent DYWI® Inject Clean 8081
If pumps are not used during longer periods of time, the complete system should be filled with preservative DYWI® Inject Clean P 8086 for injection pumps.
For instructions regarding residual material and empty containers, refer to the safety data sheets and a separate DSI leaflet on disposal instructions.
Further References
■■ Certificate of drinking water compatibility: KTW D1 (both with and without DYWI® Inject PURE X 8032 accelerator) ■■ Safety data sheet EG No. 1907/2006 ■■ DSI leaflet on disposal instructions
Order Information
DYWI® Inject PURE 8031 Unit Component A Component B Container type [–] Metal Metal Container size [L] 20 20 Article number [–] 803110120020 803110220020
126 DYWI® Inject PURE 8034 – Polyurethane Injection Resin for Underground Applications
Introduction
DYWI® Inject PURE 8034 is a 2-component polyurethane injection resin for permanent sealing in aquiferous ground. In Tunneling and Mining, DYWI® Inject PURE 8034 is successfully used for stabilizing unconsolidated ground. Sealing and repair works on dams, sewers, and shafts are additional areas of application.
Fields of Application Main Advantages System Description
■■ Fast stabilization of fault zones in ■■ Short reaction time and high ultimate ■■ 2-component injection resin, Mining and Tunneling strength polyurethane-based ■■ Permanent sealing of aquiferous ■■ Compact and watertight structure ■■ Foams easily upon contact with water ground ■■ High adhesive strength on wet ground ■■ Cures quickly ■■ Injections in unconsolidated ground ■■ Permanent sealing with a single ■■ Processed using the 2-component ■■ Consolidation of weak ground injection procedure high pressure pump DYWI® Inject ■■ Sealing of cracks and gaps against ■■ High penetration ability due to 8096 Type MT flowing or squeezing mountain water expansion of injection material ■■ Ground improvement in foundation ■■ Ecologically inoffensive – engineering, hydraulic and sewer CFC, halogen and solvent-free construction ■■ Suitable for drinking water areas ■■ Repair of wet sewers ■■ Stable for storing and processing – ■■ Permanent repair of damp tunnels or resistant against acids and bases shaft linings ■■ Sealing against water ■■ Sealing of excavations ■■ Sealing against gas ■■ Installation of injection anchors ■■ Ground consolidation
127 DYWI® Inject PURE 8034 – Polyurethane Injection Resin for Underground Applications
Specifications
Characteristics 1) Unit Component A Component B Notes Density [g/cm3] 1.01 1.23 characteristical value at 23 [°C] Viscosity [mPas] 320 280 at 23 [°C] Flash point [°C] > 140 > 200 according to EN ISO 2719 Color [–] yellowish brown color deviations possible Volume-based mixing ratio [–] 1:1 Liquid limit 45 [s] reaction at 23 [°C] Solid 65 Shore D hardness [Shore] 70/63 after 3 days Compressive strength [N/mm2] approx. 75 uniaxial, after 3 days low upon contact with water Foaming characteristics [–] up to 3 times when thoroughly mixed with approx. 10% of water Processing Injection using 2-component high pressure pump DYWI® Inject 8096 Type MT Storage Store in original packaging and protected from moisture at temperatures between 5 [°C] and 30 [°C]
1) The indicated values are laboratory values and may deviate on-site
Mixing and Processing
■■ DYWI® Inject PURE 8034 is provided according to the mixing ratio (1:1 parts by volume) ■■ Component A and component B are processed using the 2-component high pressure pump DYWI® Inject 8096 Type MT ■■ A homogenous mixing of both components is ensured by an adequate material flow through the mixing unit ■■ Component B is highly moisture sensitive and must not come in contact with water ■■ If a skin forms on the mixed material due to air humidity, it has to be removed to prevent it from being mixed in or getting into the pump
Cleaning and Disposal
Provided work interruptions are short, the mixing unit can be rinsed using component A. In case of longer interruptions, rinse - respectively clean - the hoses and pistons of both components thoroughly using cleaning agent DYWI® Inject Clean 8081.
If pumps are not used over a longer period of time, the complete system should be filled with preservative DYWI® Inject Clean P 8086 for injection pumps.
For instructions regarding residual material and empty containers, refer to the safety data sheets and a separate DSI leaflet on disposal instructions.
128 DYWI® Inject PURE 8034 – Polyurethane Injection Resin for Underground Applications
Health and Safety Further References
® When handling DYWI Inject products, Protective clothing, protective gloves, and ■■ Certificate of drinking water EG No. 1907/2006 safety data sheets face protection (safety glasses) must be compatibility: KTW B, C must be accessible to everyone worn at all times when handling materials, responsible for material handling, health, cleaning equipment, and disposing of ■■ Safety data sheet EG No. 1907/2006 and safety. materials. Where appropriate, protect ■■ DSI leaflet on disposal instructions skin using a protection lotion. In case of skin contact, clean immediately with water and soap. If the product splashes into your eye, immediately rinse with water and seek medical advice. Make sure to present the product safety data sheet during medical assistance.
Order Information
DYWI® Inject PURE 8034 Unit Component A Component B Container type [–] Metal Plastic Metal Plastic Container size [L] 20 970 20 970 Article number [–] 803410120020 803410110970 803410220020 803410210970
129 DYWI® Inject PURE X 8032 and PURE X 8034 – Accelerators
Introduction System Description
DYWI® Inject PURE X 8032 and PURE X ■■ By addition of accelerators, the 8034 are curing accelerators for injection resin can be adapted to given ground conditions, temperature, and 2-component polyurethane injection(foam) on-site demands resins. The accelerator allows a fast ■■ Product features and characteristics curing for immediate support inTunneling, may be modified by adding Mining and foundation engineering. accelerators ■■ The reaction time depends on the Especially in underground applications, material and ambient temperature, the immediate curing of the injection resin presence of water, and the amount of caused by DYWI® Inject PURE X 8032 added accelerator and PURE X 8034 allows a safe sealing of cracks and cavities even in areas PURE X PURE X under high water pressure. 8032 8034 PURE 8031 X – PURE 8034 – X
Fields of Application Main Advantages Further References
■■ Injections at low temperatures ■■ Flexible application with regards to ■■ PURE X 8032: certificate of drinking ■■ Rapid stabilization of weak rock, fault various on-site conditions water compatibility: KTW D1 with ® zones, talus, and soil in Tunneling ■■ Immediate curing of the DYWI Inject PURE 8031 ■■ Controlled Injections in injection(foam) resin ■■ DYWI® Inject PURE 8034 may foam unconsolidated ground ■■ Considerable improvement of strength when adding the accelerator ■■ Sealing of cracks and gaps against properties at an early stage PURE X 8034 flowing or squeezing mountain water ■■ Easy admixing using conventional ■■ Safety data sheet EG No. 1907/2006 ■■ Sealing of floors or footwalls equipment ■■ DSI leaflet on disposal instructions ■■ Sealing of dams, retaining walls, and locks
Characteristics DYWI® Inject PURE X 8032
Characteristics at volume fraction 0 [%] 5 [%] 10 [%] 15 [%] 20 [%] DYWI® Inject PURE X 8032 1) Foaming factor 2) approx. 10 20 - 25 30 - 35 30 - 35 30 - 35 Reaction times [s] 3) Start End Start End Start End Start End Start End 5 [°C] 90 305 48 180 36 105 31 95 26 82 10 [°C] 83 245 41 150 30 90 25 85 20 75 20 [°C] 52 235 27 135 19 82 17 70 14 60
Characteristics DYWI® Inject PURE X 8034
Characteristics at volume fraction 0 [%] 5 [%] 10 [%] 15 [%] 20 [%] DYWI® Inject PURE X 8034 1) Foaming factor 4) 1 approx. 10 approx. 15 approx. 20 approx. 25 Reaction times [s] 5) Start End Start End Start End Start End Start End 10 [°C] 100 115 30 40 23 32 19 28 15 22 20 [°C] 50 65 15 22 12 20 10 15 9 14 1) The indicated values are laboratory values and may deviate on-site ; 2) When adding 10% of water under free expansion 3) Characteristical values after water contact when adding 10% water ; 4) Under free expansion and in a dry environment 5) Charakteristic values in a dry environment
Order Information
Accelerator Unit DYWI® Inject PURE X 8032 DYWI® Inject PURE X 8034 Container type [–] Metal Metal Container size [L] 4 4 Article number [–] 803210520004 803410520004
130 DYWI® Inject SILO 8041 – Silicate Injection Foam Resin for Underground Applications
Introduction
DYWI® Inject SILO 8041 is a 2-component silicate injection foam resin for immediate sealing against flowing water. As a result of its highly reactive foaming, DYWI® Inject SILO 8041 is perfectly suitable for the immediate filling of cavities in Mining and Tunneling. DYWI® Inject SILO 8041 is also used as a sealant in damp soil layers and for ground stabilization.
Fields of Application Main Advantages System Description
■■ Filling of cavities in Mining and ■■ Short reaction times even at low ■■ Silicate based 2-component injection Tunneling temperatures foam resin ■■ Stabilization of unconsolidated ground ■■ Formation of a flexible foam with fine ■■ Strongly foaming up to a foaming rate as reinforcement ahead of the tunnel cell structure of 30 face ■■ Foam formation even without water ■■ Rapid curing ■■ Sealing of aquiferous rock and soil contact ■■ Processed by using the 2-component layers in underground applications ■■ Adhesion even on damp ground types high pressure pump DYWI® Inject ■■ Ground support ■■ Chemical stability 8096 Type MT ■■ Filling of cavities in foundation ■■ Cuttable after curing engineering ■■ Ecologically inoffensive – ■■ Sealing of excavations CFC, halogen and solvent-free ■■ TBM excavations ■■ Suitable for drinking water areas ■■ Stable for storing and processing
Specifications
Characteristics 1) Unit Component A Component B Notes Density [g/cm3] 1.15 1.23 characteristical value at 23 [°C] Density at max. expansion [g/cm3] 0.04 characteristical value at 23 [°C] Viscosity [mPas] approx. 100 approx. 250 characteristical value at 23 [°C] Flash point [°C] cannot be determined > 200 according to EN ISO 2719 Color [–] milky dark brown color deviations possible Volume-based mixing ratio [–] 1:1 Processing Injection using 2-component high pressure pump DYWI® Inject 8096 Type MT Storage Store in original packaging and protected from moisture at temperatures between 5 [°C] and 30 [°C]
1) The indicated values are laboratory values and may deviate on-site
131 DYWI® Inject SILO 8041 – Silicate Injection Foam Resin for Underground Applications
Characteristics
Start of End of Foam factor under Reaction data 1) Liquid limit Solid foaming foaming free expansion Unit [s] [s] [s] [s] [–] 10 [°C] 39 18 60 150 24 20 [°C] 30 15 52 125 30 30 [°C] 22 13 42 115 22
1) The indicated values are characteristical values determined under laboratory conditions and may therefore deviate on-site
Mixing and Processing
■■ DYWI® Inject SILO 8041 is provided according to the mixing ratio (1:1 parts by volume) ■■ Component A must already be mixed slowly and thoroughly in the container (at a maximum of 300 [rpm]) ■■ Ideally, component A is processed mixing steadily at all times ■■ Component A and B are processed using 2-component high pressure pump DYWI® Inject 8096 Type MT ■■ A homogenous mixing of both components is ensured by a special mixing unit for silicate systems ■■ Component B is highly moisture sensitive and must not come in contact with water ■■ If a skin forms on the mixed material due to air humidity, it has to be removed to prevent it from being mixed in or getting into the pump
Cleaning and Disposal
Provided work interruptions are short, the mixing unit can be rinsed using component A. In case of longer interruptions, rinse - respectively clean - the hoses and pistons of the A side thoroughly with water. Analogously, the B side is rinsed - respectively cleaned - using cleaning agent DYWI® Inject Clean 8081.
If pumps are not used over a longer period of time, the complete system should be filled with the preservative DYWI® Inject Clean P 8086 for injection pumps after cleaning. As cured material can only be removed mechanically, both pump and accessories have to be cleaned immediately after completion of the injection works.
For instructions regarding residual material and empty containers, refer to the safety data sheets and a separate DSI leaflet on disposal instructions.
132 DYWI® Inject SILO 8041 – Silicate Injection Foam Resin for Underground Applications
Health and Safety Further References
When handling DYWI® Inject products, ■■ Certificate of drinking water EG No. 1907/2006 safety data sheets compatibility: KTW D1 must be accessible to everyone ■■ Safety data sheet EG No. 1907/2006 responsible for material handling, health, ■■ DSI leaflet on disposal instructions and safety.
Protective clothing, protective gloves, and face protection (safety glasses) must be worn at all times when handling materials, cleaning equipment, and disposing of materials. Where appropriate, protect skin using a protection lotion. In case of skin contact, clean immediately with water and soap. If the product splashes into your eye, immediately rinse with water and seek medical advice. Make sure to present the product safety data sheet during medical assistance.
Order Information
DYWI® Inject SILO 8041 Unit Component A Component B Container type [–] Metal Plastic Metal Plastic Container size [L] 20 970 20 970 Article number [–] 804110120020 804110110970 804110220020 804110210970
133 DYWI® Inject SILO 8042 – Silicate Injection Resin for Underground Applications
Introduction
DYWI® Inject SILO 8042 is a 2-component silicate resin with excellent adhesive properties that cures quickly and solidly. It is specifically used in underground applications for filling boreholes or other small cavities. Additionally, the non-foaming DYWI® Inject SILO 8042 is used for stabilizing unconsolidated ground in Mining and Tunneling. DYWI® Inject SILO 8042 is also used as bonding medium for injection anchors.
Fields of Application Main Advantages System Description
■■ Fast stabilization of fault zones in ■■ Cures quickly and solidly ■■ Silicate based 2-component injection Mining and Tunneling ■■ Good adhesive properties resin ■■ Injections in unconsolidated ground ■■ Achieves ultimate strength after a few ■■ Non-foaming ■■ Injection works during tunnel driving minutes ■■ Fast and stable curing ■■ Fixing of rock anchors in Tunneling and ■■ High stability ■■ Processed using the 2-component ® Mining ■■ Already reacts at low temperatures high pressure pump DYWI Inject 8096 Type MT ■■ Sealing of damp ground areas ■■ Good chemical persistency ■■ Stabilization of unconsolidated ground ■■ Ecologically inoffensive – in foundation engineering CFC, halogen and solvent-free ■■ Sealing against squeezing water ■■ Suitable for drinking water areas ■■ Sealing against gas ■■ Stable for storing and processing
134 DYWI® Inject SILO 8042 – Silicate Injection Resin for Underground Applications
Specifications
Characteristics 1) Unit Component A Component B Notes Density [g/cm3] 1.44 1.23 characteristical value at 23 [°C] Mixing density [g/cm3] 1.28 - 1.31 characteristical value at 23 [°C] Viscosity [mPas] 210 180 characteristical value at 23 [°C] Flash point [°C] cannot be determined > 200 according to EN ISO 2719 Color [–] colorless dark brown color deviations possible free temperature development Heat development [°C] max. 107 with 1 [L ]of material at 23 [°C] 62 uniaxial, after 1 hour Compressive strength [N/mm2] 70 uniaxial, after 3 days Tensile strength [N/mm2] 10 after 3 days 20 after 6 hours Bending tensile strength [N/mm2] 25 after 3 days Volume-based mixing ratio [–] 1:1 Processing Injection using 2-component high pressure pump DYWI® Inject 8096 Type MT Storage Store in original packaging and protected from moisture at temperatures between 5 [°C] and 30 [°C]
1) The indicated values are laboratory values and may deviate on-site
Mixing and Processing
■■ DYWI® Inject SILO 8042 is provided according to the mixing ratio (1:1 parts by volume) ■■ Component A must already be mixed slowly and thoroughly in the container (at a maximum of 300 [rpm]) ■■ Ideally, component A is processed mixing steadily at all times ■■ Component A and component B are processed using 2-component high pressure pump DYWI® Inject 8096 Type MT ■■ A homogenous mixing of both components is ensured by a special mixing unit for silicate systems ■■ Component B is highly moisture sensitive and must not come in contact with water while or before mixing ■■ If a skin forms on the mixed material due to air humidity, it has to be removed to prevent it from being mixed in or getting into the pump
Characteristics
Shore D Shore D Reaction data 1) Liquid limit Non-adhesive Solid after 1 hour after 24 hours Unit [s] [s] [s] [Shore] [Shore] 10 [°C] 68 150 210 56 / 52 56 / 53 20 [°C] 35 80 120 70 / 65 70 / 68 30 [°C] 25 44 70 62 / 60 65 / 61
1) The indicated values are characeristical values determined under laboratory conditions and may therefore deviate on-site
135 DYWI® Inject SILO 8042 – Silicate Injection Resin for Underground Applications
Cleaning and Disposal Health and Safety
Provided work interruptions are short, When handling DYWI® Inject products, the mixing unit can be rinsed using EG No. 1907/2006 safety data sheets component A. In case of longer must be accessible to everyone interruptions, rinse - respectively clean - responsible for material handling, health, the hoses and pistons of the A side and safety. thoroughly with water. Analogously, the B side is rinsed - respectively cleaned - Protective clothing, protective gloves, and using cleaning agent DYWI® Inject Clean face protection (safety glasses) must be 8081. worn at all times when handling materials, cleaning equipment, and disposing of If pumps are not used over a longer materials. Where appropriate, protect period of time, the complete system skin using a protection lotion. In case should be filled with the preservative of skin contact, clean immediately with DYWI® Inject Clean P 8086 for injection water and soap. If the product splashes pumps after cleaning. As cured material into your eye, immediately rinse with can only be removed mechanically, water and seek medical advice. Make both pump and accessories have to be sure to present the product safety data cleaned immediately after completion of sheet during medical assistance. the injection works.
For instructions regarding residual material and empty containers, refer to the safety data sheets and a separate DSI leaflet on disposal instructions.
Further References
■■ Certificate of drinking water compatibility: KTW D1 ■■ Safety data sheet EG No. 1907/2006 ■■ DSI leaflet on disposal instructions
Order Information
DYWI® Inject SILO 8042 Unit Component A Component B Container type [–] Metal Plastic Metal Plastic Container size [L] 20 970 20 970 Article number [–] 804210120020 804210110970 804210220020 804210210970
136 DYWI® Inject GELE 8061 – Acrylate Injection Gel for Underground Applications
Introduction
DYWI® Inject GELE 8061 is a 3-component polyacrylate injection gel for the efficient sealing against ground water. The surface area is completely sealed by injecting the gel into the ground using injection lances forming a curtain sealing.
Fields of Application Main Advantages System Description
■■ Sealing against water ■■ Cures quickly ■■ Polyacrylate based 3-component ■■ Sealing of floors or footwalls ■■ Reaction time may be flexibly adapted injection gel ■■ Sealing of surfaces and for curtain ■■ High degree of interlacing ■■ Swells upon contact with water injections ■■ High gel strength ■■ Excellent expandability and persistency ■■ Sealing of excavations ■■ Suitable for drinking water areas ■■ Processed using the 2-component ■■ Injections in unconsolidated ground ■■ Stable for storing and processing high pressure pump DYWI® Inject 8097 Type GELE
Specifications
Characteristics 1) Unit Component A Component B Notes Density [g/cm3] 1.2 1.0 characteristical value at 21 [°C] Viscosity [mPas] 27 1 at 21 [°C] Viscosity of mixture [mPas] 9 at 21 [°C] Color [–] yellowish clear color deviations possible Reaction time [s] 38 at 21 [°C] A1 : A2 Mixing ratio: parts per weight [–] 20 : 1 5% in water Parts by volume [–] A : B <> 1:1 Processing Injection using 2-component high pressure pump DYWI® Inject 8097 Type GELE Storage Store in original packaging and protected from moisture at temperatures between 5 [°C] and 25 [°C]
1) The indicated values are laboratory values and may deviate on-site
137 DYWI® Inject GELE 8061 – Acrylate Injection Gel for Underground Applications
Mixing and Processing
■■ DYWI® Inject GELE 8061 is supplied in Component A: Component B: 3-components (A1, A2 and B) ■■ Immediately before processing, ■■ Component B (powder) must be ■■ Components A1 and A2 are provided component A2 must be completely dissolved in fresh and clean tap water according to the mixing ratio filled into component A1, with both using a wooden or stainless steel (20:1 parts per weight) components being mixed during filling stirrer directly before processing ■■ Mixing of components A and B is ■■ Afterwards, component A must be kept ■■ Component B is replenished with facilitated by using two equally sized away from sunlight to avoid ultraviolet water until the fill level equals containers for mixing the individual rays causing undesirable reactions component A components ■■ The mixed components should be processed immediately using the 2-component high pressure pump DYWI® Inject 8097 Type GELE at a mixing ratio of 1:1 parts by volume
Cleaning and Disposal Further References
Provided work interruptions are short, the mixing set and flexible connecting hose of ■■ Certificate of drinking water the 2-component high pressure pump DYWI® Inject 8097 Type GELE must be rinsed compatibility: KTW D1 ® thoroughly with water. The DYWI Inject 8097 pump has an additional rinsing pump ■■ Safety data sheet EG No. 1907/2006 for this purpose operated by the mixing set. After completion of the injection works, ■■ DSI leaflet on disposal instructions the complete pump system must be cleaned with water. Both intake hoses of pumps A and B are placed in a bucket with clean fresh water.
For instructions regarding residual material and empty containers, refer to the safety data sheets and a separate DSI leaflet on disposal instructions.
Health and Safety
When handling DYWI® Inject products, EG No. 1907/2006 safety data sheets must be accessible to everyone responsible for material handling, health, and safety.
Protective clothing, protective gloves, and face protection (safety glasses) must be worn at all times when handling materials, cleaning equipment, and disposing of materials. Where appropriate, protect skin using a protection lotion. In case of skin contact, clean immediately with water and soap. If the product splashes into your eye, immediately rinse with water and seek medical advice. Make sure to present the product safety data sheet during medical assistance.
Order Information
DYWI® Inject GELE 8061 Unit Comp. A1 Comp. A2 Comp. B Container type [–] Plastic Plastic Plastic Container size [kg] 21.50 1.05 1.00 Article number [–] 806110112150 806110310105 806110210100
138 DYWI® Inject Cleaning Agents
Introduction
DYWI® Inject cleaning agents are characterized by high dissolving power and are used for the efficient cleaning of DYWI® Inject pumps. For instructions regarding mixing and use, cleaning and disposal as well as health and safety, refer to the product descriptions of the DYWI® Inject product range.
DYWI® Inject Clean 8081 DYWI® Inject Clean X 8082 DYWI® Inject Clean P 8086
■■ Final cleaning agent with high ■■ Exceptional post-application cleaning ■■ Preservative for DYWI® Inject Pumps dissolving power agent – not suitable for daily cleaning during prolonged downtimes ■■ Suitable for removing liquid PURE of injection pumps injection resins from injection pumps ■■ Partial dissolving or swelling of cured injection resins (preparation for further mechanical cleaning) ■■ Longer contact time is recommended for cured injection resins – Attention: high dissolving power may affect plastic parts
Further References Order Information
® ■■ DYWI Inject Cleaning Agents are DYWI® Inject DYWI® Inject DYWI® Inject DYWI® Inject Unit solvent-free Cleaning Agent Clean 8081 Clean X 8082 Clean P 8086 ■■ Safety data sheet EG No. 1907/2006 Container type [–] Metal Metal Metal ■■ Please make sure to observe DSI storage Container size [kg] 14.5 14.5 5.0 and leaflet on disposal instructions Article number [–] 808110921450 808210921450 808610920500
139 DYWI® Inject 8096 – 2-Component High Pressure Pump Type MT for Injection Resins
Introduction
DYWI® Inject 8096 2-component high pressure pump type MT is an air driven pump with a fixed mixing ratio for processing DYWI® Inject resins and foam resins.
Fields of Application Main Advantages System Description
■■ Injections in Mining, Tunneling, and ■■ Robust design and little susceptibility ■■ Brace operated piston pump foundation engineering to damage ■■ Pneumatically driven ■■ Easy operation and handling ■■ Independent intake of both ■■ High performance components
System Components Specifications and Order Information
■■ 2-component high pressure pump Characteristics Unit Value Notes ■■ Hose set with bypass flushing device Mixing ratio [–] 1:1 Dimensions [cm] 50 x 50 x 100 W x H x L ■ For details on how to use the ■ Weight [kg] approx. 140 2-component high pressure pump Injection pressure [bar] 0 - 220 ® DYWI Inject 8096 type MT, refer to Pump capacity [L/min] 12 at 100 [bar] the operation manual Air requirement [L/min] 6000 at 4 - 6 [bar] ■■ Spare parts and accessories are Article number 809610620140 incl. starter set available on request ■■ When using PURE and SILO injection resins parallel, usage of sepapte pumps is recommended
140 DYWI® Inject 8097 – 2-Component High Pressure Pump Type GELE for Injection Gels
Introduction
DYWI® Inject 8097 2-component high pressure pump Type GELE is an air driven pump with a fixed mixing ratio for processing DYWI® Inject gels.
Fields of Application Main Advantages System Description
■■ Injections in Mining, Tunneling, and ■■ Robust design and little susceptibility ■■ Double piston pump foundation engineering to damage ■■ Pneumatically driven ■■ Additional flushing pump ■■ Independent intake of both ■■ High performance components ■■ Stainless steel pump
System Components Specifications and Order Information
■■ 2-component high pressure pump Characteristics Unit Value Notes including flushing pump Mixing ratio [–] 1:1 ■■ Hose set with mixing head Dimensions [cm] 50 x 100 x 55 W x H x L Weight [kg] 50 ® ■■ For details on how to use the DYWI Injection pressure [bar] 0 - 200 Inject 8097 2-component high Pump capacity [L/min] 8 pressure pump Type GELE, refer to the Air requirement [L/min] 375 at 6 - 8 [bar] operation manual Article number 809710620050 incl. starter set ■■ Spare parts and accessories are and mixing head available on request
141 DYWI® Inject Packer and Accessories
Introduction
Static mixers assure an optimum mixing of the components. The connection to a packer or injection lance is accomplished by a threaded connection.
Injection packers are used for the targeted injection of resins and gels into the foundation.
Injection hose systems are used for sealing of construction joints in concrete.
Fields of Application Main Advantages System Description
■■ Mechanical packer for grouting ■■ Safe and neat injection into the ground ■■ Mixing tube: optimum homogenization structures ■■ Targeted grouting of components ■■ Inflatable packer for grouting rock and ■■ Mechanical packer: mechanical soil tensioning in the structure, extension ■■ DYWI® Inject SEAL injection hose by metal or plastic injection lances system for sealing of construction ■■ Inflatable packer: tensioning by the joints in combination with the DSI injection medium at a defined pressure, Waterproofing System extension via conventional injection lances or DYWI® Drill Injection Lances
System Components Further references DYWI® Inject SEAL injection hose system
■■ Mixing tube with static mixer ■■ National test certificates ■■ Threaded connection ■■ Safety data sheet EG No. 1907/2006 ■■ Injection lance: conventional tube ■■ DSI leaflets on application instructions lance or DYWI® Drill Injection Lance ■■ Injection packer ■■ Multiple injection hose system: cement injection ■■ Single-use injection hose system: resin injection (PURE and GELE)
Specifications
Mechanical Inflatable DYWI® Inject Packer Unit Packer Packer Material [–] Metal Metal or plastic Diameter [mm] 17 / 19 36 / 40 Optimum borehole diameter [mm] 18 / 20 42 - 46 / 46 - 52 Max. expansion [mm] 20 / 23 60 / 70 Length [mm] 150 / 250 330 Max. flow rate [L/min] approx. 10 approx. 20 Opening pressure [bar] – approx. 40
142 DYWI® Inject Packer and Accessories
Installation Procedure
■■ Mechanical packers for grouting structures are anchored in the borehole by screwing, firmly pressing the fabric reinforced rubber sleeves to the borehole wall ■■ This procedure ensures that the packer remains in the borehole even at high injection pressures. Smaller deviations in terms of borehole shapes or borehole diameters are compensated to prevent material from emerging out of the borehole ■■ Inflatable packers for deep boreholes automatically tension in the borehole at an opening pressure of approximately 30-40 [bar] Order Information
Article Description Article Number DYWI® Inject Inflatable Packer Ø 40 [mm], Type K 809110610040 DYWI® Inject Inflatable Packer Ø 36 [mm], Type M 809110620036 DYWI® Inject Injection Lance Plastic, L = 2,000 [mm] 809190612000 DYWI® Inject Injection Lance Plastic, L = 1,000 [mm] 809190611000 DYWI® Inject Injection Lance Steel, L = 500 [mm] 809190620500 DYWI® Inject Injection Lance Steel, L = 1,000 [mm] 809190621000 DYWI® Inject Injection Lance Steel, L = 1,500 [mm] 809190621500 DYWI® Inject Threaded Connection DN 10 - 1/4", for HP-Pump Type MT 809190921000 DYWI® Inject Threaded Connection DN 10 - M16 x 1,5, for HP-Pump Type GELE 809190922000 DYWI® Inject Mechanical Packer 17 x 150 [mm], with pan head nipple 809210621517 DYWI® Inject Mechanical Packer 19 x 150 [mm], with pan head nipple 809210621519 DYWI® Inject Mechanical Packer 19 x 250 [mm], with pan head nipple 809210622519 DYWI® Inject Single-Use Plastic Packer 18 x 50 [mm] 809210611850 DYWI® Inject Mixing Tube DN 10 - 12 [mm], Type PURE 809390720300 DYWI® Inject Mixing Tube DN 10 - 8 [mm], Type SILO 809390720500 DYWI® Inject Static Mixer 12 [mm], Type PURE 809390820012 DYWI® Inject Static Mixer 8 [mm], Type SILO 809390820008 DYWI® Drill Injection Lances on request – DYWI® Inject SEAL Multiple Injection Hose for cement injection Ø 19 [mm], L = 100 [m] 809490661901 DYWI® Inject SEAL Multiple Injection Hose for cement injection Ø 19 [mm], L = 1,000 [m] 809490661902 DYWI® Inject SEAL Multiple Injection Hose for cement injection Ø 11 [mm], L = 100 [m] 809490661101 DYWI® Inject SEAL Multiple Injection Hose for cement injection Ø 11 [mm], L = 1,000 [m] 809490661102 DYWI® Inject SEAL Injection Hose for resin injection Ø 11 [mm], L = 50 [m] 809490671101 DYWI® Inject SEAL Injection Hose for resin injection Ø 11 [mm], L = 2,500 [m] 809490671102 DYWI® Inject SEAL Ventilation Hose Type R, Ø 11 [mm], 20 [bar], L = 50 [m] 809490681101 DYWI® Inject SEAL Ventilation Hose Type W, Ø 11 [mm], 20 [bar], L = 50 [m] 809490681102 DYWI® Inject SEAL Shrinking Hose Ø 11/19 [mm], L = 30 [m] 809490691119 DYWI® Inject SEAL Plug for ventilation hose Ø 11 [mm] 809490611101 DYWI® Inject SEAL Plug for ventilation hose Ø 19 [mm] 809490611901 DYWI® Inject SEAL Hose Clamp for injection hose Ø 11 [mm] 809490621101 DYWI® Inject SEAL Hose Clamp for injection hose Ø 19 [mm] 809490621901 DYWI® Inject SEAL Shutter Packer for injection hose Ø 11 [mm], two-part 809490611111 DYWI® Inject SEAL Injection Nipple for two-part shutter packer 809490611112 DYWI® Inject SEAL Rubber Plate Type G 809490611113 DYWI® Inject SEAL Plastic Connector for hose Ø 11 [mm] 809490611121
143 144 DYWI® Seal Waterproofing System and Bentonite Mats
Introduction ...... 145 DYWI® Seal Waterproofing System ...... 146 Fields of Application...... 146 Main Advantages ...... 146 System Description...... 146 System Components ...... 147 Technical Features ...... 147 DYWI® Inject SEAL Injection Hose System ...... 148 Order Information DYWI® Inject Accessories ...... 148
DYWI® Seal Bentonite Mats ...... 149 Fields of Application...... 149 Main Advantages ...... 149 System Description...... 149 System Components ...... 150 Technical Features ...... 150 Specifications...... 151 Technical Data Sodium Bentonite ...... 151 Installation Procedure ...... 152 Further References ...... 152
Introduction
The DYWI® Seal Waterproofing System is a needle-punched non-woven impregnated membrane. The membrane structure comprises water absorbing and water swelling polymers.
An optional one-side polyethylene film on top of the needle-punched non-woven membrane and the self-healing properties of the DYWI® Seal Waterproofing System ensure optimum performance for various water sealing applications.
Bentonite mats, also referred to as geosynthetic clay liners (GCL’s), are geosynthetic barriers used for various sealing and waterproofing applications in underground Mining and Civil Engineering. DYWI® Seal Bentonite Mats are a composite consisting of two layers of geo-textiles filled with sodium bentonite.
The application range of DYWI® Seal Bentonite Mats comprises waterproofing, gas sealing, and usage as a vapor barrier. Bentonite mats are a proven and versatile sealing system that has been used in many construction projects around the world.
145 DYWI® Seal Waterproofing System Fields of Application
■■ Protection of structures against ground water ■■ Permanent waterproofing of tunnels ■■ Water sealing for groundwork operations ■■ Waterproofing of excavation pits, dams, or for slope stabilization ■■ Application in structural engineering: waterproofing of basements, parking garages, or flat roofs
Main Advantages
■■ Quick and easy to install ■■ Waterproofing safety even when the ■■ Special formulations for salty water ■■ Very easy handling on-site due to system is damaged during installation conditions available on request light-weight design ■■ Special welding equipment or ■■ Economic alternative to synthetic ■■ Trouble-free installation even during specially trained personnel are not liners, bituminous products, and operation required coatings ■■ Self-healing properties of the ■■ Safe solution for sealing shrinkage ■■ Environmentally sound hydrophilic, water reactive polymers cracks and voids in concrete waterproofing system ■■ Innovative sealing technology
System Description
■■ Penetrating ground water causes an immediate reaction of the swelling polymers - the DYWI® Seal Waterproofing System is absolutely watertight ■■ SAP (Super Absorbent Polymers) feature optimum swelling capacity ■■ Permanent protection against penetrating water ■■ Sealing effect up to 2.5 [bar] water pressure - higher pressure resistance available on request ■■ Installation independent of climate conditions and temperatures ■■ Overlapping areas are glued to achieve an absolutely watertight effect ■■ Tough and resistant ■■ High shear strength
146 DYWI® Seal Waterproofing System System Components
■■ Swelling, needle-punched non-woven ■■ Optional one-side UV resistant synthetic membrane PE or any other polyolefin or ■■ White polypropylene fibres are fully PVC sheathing available impregnated with swelling polymers ■■ Approved injection tubes and ■■ Water absorbing swelling polymers accessories are optionally available on request ■■ Flexible roll dimensions up to 5 [m] width - standard version 2 x 50 [m] ■■ Patented technology ■■ DYWI® Seal Waterproofing System: ■■ Unproblematic waste disposal as synthetic swelling membrane standard plastic material ■■ DYWI® Seal Waterproofing System ■■ Installation procedure: with film (silver) - CE label according see separate DSI installation manual to EN 13967 (ÜZ-5/1195/12, MPA Braunschweig): ”DSI Waterproofing System”
Technical Features 1)
Characteristics Unit Value Notes Surface weight [g/m²] > 450 EN 1849-2 Thickness [mm] > 1.5 EN 1849-2, at 20 kPa surcharge Ultimate load, longitudinal (MD) [N/5 cm] > 550 EN 12311-2 Ultimate load, transversal (CD) [N/5 cm] > 1000 EN 12311-2 Ultimate load strain, longitudinal (MD) [%] > 70 EN 12311-2 Ultimate load strain, transversal (CD) [%] > 55 EN 12311-2 Article No. [–] 800510100502
1) Specifications only apply to the DSI Waterproofing System
147 DYWI® Seal Waterproofing System DYWI® Inject SEAL Injection Hose System
The DYWI® Inject SEAL injection hose system is used for sealing construction joints in combination with the DYWI® Seal Waterproofing System.
■■ Multiple injection hose system: cement injection ■■ Single-use injection hose system: resin injection (DYWI® Inject PURE and GELE) ■■ National test certificates ■■ Safety data sheet EG No. 1907/2006 ■■ DSI leaflets on application instructions
Order Information DYWI® Inject Accessories
Article Description Article No. DYWI® Inject Mechanical Packer 10 x 70 [mm], with high-pressure zerk 809210627010 DYWI® Inject Mechanical Packer 13 x 70 [mm], with high-pressure zerk 809210627013 DYWI® Inject Mechanical Packer 13 x 115 [mm], with high-pressure zerk 809210621113 DYWI® Inject Mechanical Packer 17 x 150 [mm], with pan head nipple 809210621517 DYWI® Inject Mechanical Packer 19 x 150 [mm], with pan head nipple 809210621519 DYWI® Inject Single-Use Steel Packer 14 x 85 [mm], incl. Installation wrench 809210628514 DYWI® Inject Single-Use Plastic Packer 10 [mm], with cone-head nipple 809210611001 DYWI® Inject Single-Use Plastic Packer 18 [mm], with pan head nipple 1/4" 809210611800 DYWI® Inject Single-Use Plastic Packer 14 [mm], with pan head nipple 1/4" 809210611400 DYWI® Inject Aluminum Adhesive Packer 48 [mm], with cone-head nipple M8 809210634800 DYWI® Inject Plastic Adhesive Packer 44 [mm], with cone-head nipple M6 809210614400 DYWI® Inject Plastic Drive Packer 14/18 [mm], with 1/4" threaded connection 809210611418 DYWI® Inject SEAL Multiple Injection Hose for cement injection, d. 19 [mm], L = 100 [m] 809490661901 DYWI® Inject SEAL Multiple Injection Hose for cement injection, d. 19 [mm], L = 1,000 [m] 809490661902 DYWI® Inject SEAL Multiple Injection Hose for cement injection, d. 11 [mm], L = 100 [m] 809490661101 DYWI® Inject SEAL Multiple Injection Hose for cement injection, d. 11 [mm], L = 2,500 [m] 809490661102 DYWI® Inject SEAL Injection Hose for resin injection, d. 11 [mm], L = 50 [m] 809490671101 DYWI® Inject SEAL Injection Hose for resin injection, d. 11 [mm], L = 2,500 [m] 809490671102 DYWI® Inject SEAL Ventilation Hose Type R, d. 11 [mm], 20 [bar], L = 50 [m] 809490681101 DYWI® Inject SEAL Ventilation Hose Type W, d. 11 [mm], 20 [bar], L = 50 [m] 809490681102 DYWI® Inject SEAL Shrinking Hose d. 11/19 [mm], L = 50 m L = 30 [m] 809490691119 DYWI® Inject SEAL Plug for ventilation hose d. 11 [mm] 809490611101 DYWI® Inject SEAL Plug for ventilation hose d. 19 [mm] 809490611901 DYWI® Inject SEAL Hose Clamp for injection hose d. 11 [mm] 809490621101 DYWI® Inject SEAL Hose Clamp for injection hose d. 19 [mm] 809490621901 DYWI® Inject SEAL Shutter Packer for injection hose d. 11 [mm], two-part 809490611111 DYWI® Inject SEAL Injection Nipple for two-part shutter packer 809490611112 DYWI® Inject SEAL Rubber Plate Type G 809490611113 DYWI® Inject SEAL Plastic Connector for hose d. 11 [mm] 809490611121
148 DYWI® Seal Bentonite Mats Fields of Application Main Advantages
Geotechnics and Special Mining ■■ Easy handling and application Foundations ■■ Temporary sealing of overburden pile ■■ Bentonite sodium granulate features extraordinary swelling potential ■■ Sealing of storage tanks and reservoirs foundations ■■ High long-term shear strength ■■ Base and surface sealing of waste ■■ Sealing of heap leach pads and slurry ■■ Resistant to chemicals, except dumps, composting plants, or landfill ponds saltwater and hydrochloric acid caps ■■ Sealing of backfill headings and stopes ■■ Environmentally sound waterproofing ■■ Waterproofing at dams and canals ■■ Permanent waterproofing in the lowest underground Mining level system ■■ Waterproofing applications around ■■ Rehabilitation works in abandoned ■■ Long-term field-proven sealing system tunnel portals and building sites mines
System Description
■■ Mechanically bonded composite, ■■ Flexible installation of ■■ The sealing layer is covered once consisting of pulverized or granulated DYWI® Seal Bentonite Mats, which are installation has been completed bentonite, embedded and fixed simply rolled out ■■ Permanent sealing mechanism by between two layers of geo-textile ■■ Additional sealing of the overlapping single reaction of the sodium bentonite area with sodium bentonite powder upon water contact
149 DYWI® Seal Bentonite Mats System Components
■■ Woven or non-woven PP carrier layer ■■ Granulated or pulverized sodium bentonite filling ■■ Non-woven PP cover layer ■■ Additional PE membrane cover optionally available ■■ Unproblematic waste disposal: standard plastic material
Technical Features
■■ The main parameters of DYWI® Seal Bentonite Mats are their weight, swelling capacity, and the coefficient of permeability ■■ Supply of an additional bag of bentonite powder with each roll for application in the overlapping areas ■■ Minimum durability of 25 years at a pH value range between 4 and 9 and a temperature of < 25 [°C] ■■ Application in combination with DYWI® Seal Waterproofing System on request
150 DYWI® Seal Bentonite Mats Specifications 1)
Characteristics Unit DS-3500 DS-3700 DS-4000 DS-4500 DS-4700 DS-5000 Remarks Woven PP carrier layer [g/m²] 100 100 100 100 100 100 Sodium bentonite [g/m²] 3,500 3,700 4,000 4,500 4,700 5,000 Non-woven PP cover layer [g/m²] 200 200 200 200 200 200 Total weight 2) [g/m²] 3,750 4,100 4,250 4,750 5,000 5,300 ASTM D 5993 Dry thickness [mm] 6 6 6.2 6.5 7 7 EN ISO 9863-1,2 Index flux [m³/m²/s] ≤ 3.2 x 10-9 ≤ 3.2 x 10-9 ≤ 3.0 x 10-9 ≤ 3.0 x 10-9 ≤ 3.0 x 10-9 ≤ 3.0 x 10-9 ASTM D 5887 Permeability [m/s] ≤ 5.0 x 10-11 ≤ 5.0 x 10-11 ≤ 5.0 x 10-11 ≤ 4.0 x 10-11 ≤ 3.0 x 10-11 ≤ 1.8 x 10-11 ASTM D 5887 Tensile strength, MD 2) [kN/m] ≥ 10.4 ≥ 10.4 ≥ 10.4 ≥ 10.4 ≥ 10.4 ≥ 10.4 Dry; EN ISO 10319 Tensile strength, CD 2) [kN/m] ≥ 8.4 ≥ 8.4 ≥ 8.4 ≥ 8.4 ≥ 8.4 ≥ 8.4 Dry; EN ISO 10319 Ultimate tensile strain [%] 20 20 20 20 20 20 EN ISO 10319 Grab strength [N] > 400 > 400 > 400 > 400 > 400 > 400 ASTM D 4632 CBR puncture strength 2) [kN] ≥ 1.8 ≥ 1.8 ≥ 1.8 ≥ 1.8 ≥ 1.8 ≥ 1.8 EN ISO 12236 Peel strength 2) [N/10 cm] ≥ 65 ≥ 65 ≥ 65 ≥ 65 ≥ 65 ≥ 65 EN ISO 10319 Standard roll dimensions [m] 45 x 5.1 45 x 5.1 40 x 5.1 40 x 5.1 40 x 5.1 40 x 5.1 Length x width
Alternative types and dimensions within the indicated range can be provided on request
Characteristics Unit Range Woven PP carrier layer [g/m²] 100 - 200 Sodium bentonite [g/m²] 100 - 6,000 Non-woven PP cover layer [g/m²] 100 - 200 Optional additional PE membrane cover [g/m²] 180 - 2,500 Total weight 2) [g/m²] 1,200 - 6,300 Dry thickness [mm] 3.0 - 8.5
1) The indicated values are laboratory values and may deviate on-site 2) Characteristic 10% fractile value
Technical Data Sodium Bentonite 1)
Characteristics Unit Value Remarks Montmorillonite content [%] ≥ 80 CUR 33 Moisture Content [%] ≤ 12 DIN 18121-1,2 Water absorption capacity [%] ≥ 650 DIN 18132 Swelling Capacity [ml/2 g] ≥ 24 ASTM D 5890 Fluid loss [ml] ≤ 18 ASTM D 5891
1) The indicated values are laboratory values and may deviate on-site
151 DYWI® Seal Bentonite Mats Installation Procedure
1. Preparation of the foundation basis ■■ Removal of sharp rock blocks, organic material, and obstacles that are larger than 50 [mm] ■■ Moisture-free compaction of the ground to a factor of 0.9 of the Proctor density (Proctor compaction test)
2. Installation ■■ DYWI® Seal Bentonite Mats must be protected from all weather conditions ■■ Installation may only be performed in dry surface conditions ■■ DYWI® Seal Bentonite Mats are rolled out without folds on level ground, which has been previously prepared ■■ The woven part faces the ground; in case of one-sided coated mats, the coating faces up ■■ Panel must be laid out parallel to slopes and secured accordingly in anchor trenches
3. Overlapping ■■ Overlapping of single panels between the two boundary lines printed in the edge area ■■ The overlapping area must be increased if settlements are expected ■■ Filling of the overlapping zone with additionally supplied bentonite powder ■■ Coverage of DYWI® Seal Bentonite Mats immediately after the installation is complete, layer thickness > 25 [cm]
4. Connection with concrete structures and tube notches ■■ See DSI leaflet on the installation of DYWI® Seal Bentonite Mats
Further References
■■ Leaflet on storage and installation of DYWI® Seal Bentonite Mats ■■ DYWI® Inject Systems
152 153 154 Service, Accessories and Equipment
Introduction ...... 155
Technical Service ...... 156
Rock Drilling Equipment ...... 157
OMEGA-BOLT® High-Pressure Pump ...... 158
Cement Grout ...... 159
Injection Adapters and Flushing Heads...... 161
Mortar-Mixing Pump...... 162
Flow-Pressure Meter...... 163
Cable Bolt Tensioner...... 164
Pull Testing Equipment ...... 165
Introduction
DYWIDAG-Systems International (DSI) provides its customers with a large variety of ground control systems for Mining and Tunneling as well as with competent technical service, equipment and accessories for the installation and application of rock reinforcement and rock support elements.
155 Technical Service
A DSI team of experienced technicians and supervisors provides technical support as well as on-site product management. Our service team is available for general and product-specific questions in the following areas:
■■ Design, testing, and evaluation of rock bolt systems ■■ Self-Drilling reinforcement technology ■■ Layout and optimization of lattice girder support ■■ Pipe umbrella support and drainage drilling works ■■ Accomplishment and monitoring of injection works ■■ Testing of product usage properties
156 Rock Drilling Equipment Fields of Application
■■ Blasthole drilling ■■ Production drilling ■■ Extension drilling ■■ Overburden drilling ■■ Pre-Drilling
System Components Shank adapters Extension drilling equipment Drill bits in retrac design ■■ Shank adapters ■■ Couplings Drill bits in flat face ■■ Adapter couplings ■■ Extension drilling equipment ■■ Coupling adapters ■■ Drill bits ■ Drill bits in either flat face or retrac design ■ Cross drill bits ■■ Pre-Drilling bits for the AT-SYSTEM ■■ Various adapters and driver tools for Couplings Adapter couplings Coupling adapters Cross drill bits rock bolts ■■ Individual drill bits available on request
Order Information
Article Description Available Thread Types 2) Required Information 3) Thread (connecting thread type; version M or F), Shank adapters R32, R38, R51, T32, T38, T51 rock drill type, length [mm] 1), 3) Couplings R32, R38, R51, T32, T38, T51 Thread (connecting thread type) Coupling adapters F/F 1) R32, R38, R51, T32, T38, T51 Thread (connecting thread type A and B) Extension rods M/F 1) R32, R38, R51, T32, T38, T51 Thread (type connecting thread); length [mm] 3) Extension rods M/M 1) R32, R38, R51, T32, T38, T51 Thread (type connecting thread); length [mm] 3) Adapter M/F 1) R32, R38, R51, T32, T38, T51 Thread (connecting thread type A and B) Adapter M/M 1) R32, R38, R51, T32, T38, T51 Thread (connecting thread type A and B) Button drill bits version flat face R32, R38, R51, T38, T51 Thread (connecting thread type), drill bit diameter Button drill bits version retrac R32, R38, R51, T38, T51 Thread (connecting thread type), drill bit diameter Cross drill bits R32, R38, R51, T38, T51 Thread (connecting thread type), drill bit diameter Pre drill bits R32, R38, R51, T38, T51 Thread (type connecting thread), drill bit diameter Driver tools R32, R38 Rock bolt type, thread (type connecting thread)
1) ”F” ... female (inner) thread; ”M” ... male (outer) thread 2) Special thread types available on request 3) Special lengths available on request
157 OMEGA-BOLT® High-Pressure Pump Introduction
OMEGA-BOLT® Expandable Rock Bolts are preferably installed using the electrical type 300E high-pressure pump. This compact high-performance pump with an 11 [kW] electric motor is designed for a maximum working pressure of 300 [bar].
The maximum inflation pressure is adjusted by a spring pressure gauge; additionally, a pressure limiting valve prevents overload. The regulation is effected by a combination switch on/off and emergency shutdown, respectively. Protection against dry running ensures a secure operation of the low-noise and low-vibration high-pressure aggregate.
Main Advantages
■■ Tough design and easy handling ■■ Fast installation due to high pump performance ■■ An optimum expansion of the OMEGA-BOLT® Expandable Friction Bolt is ensured
Accessories System Description
■■ Setting arm The installation equipment for the OMEGA-BOLT® Expandable Rock Bolt consists ■■ Setting head of the following components: ■ Type EFB-120 or EFB-160/240 ■■ OMEGA-BOLT® high-pressure pump 300E (water pump and electric motor) ■■ High-pressure hoses in different lengths available ■■ High-pressure hose ■■ Spare parts available on request ■■ Setting arm with setting head ■■ Alternative high-pressure pumps ® available on request After insertion of the OMEGA-BOLT Expandable Rock Bolt into the borehole, the setting arm is fitted to the bolt’s head. By operating the valve lever on the setting ■■ OMEGA-BOLT® pull testing equipment arm, the bolt is hydraulically expanded (unfolded) using high-pressure water, which is available on request induced into the inside of the folded bolt tube. After reaching the defined maximum setting pressure, the valve lever is released and the setting head is pulled away from the bolt’s head.
Further References Specifications
® ■■Brochure OMEGA-BOLT Characteristics Unit Value Expandable Friction Bolt Dimensions (L x W x H) [mm] 800 x 400 x 455 ■■Operating manual OMEGA-BOLT® Weight [kg] 90 High-Pressure Pump Type 300E Max. flow rate [l/min] 21 Operating pressure 1) [bar] 300 ■■Spare parts list OMEGA-BOLT® Max. operating pressure [bar] 320 High-Pressure Pump Type 300E Power supply [V] 3 ~ 400 Nominal power [kW] 11 Electrical connection [A] 25 Pumping rotation speed [rpm] 1,400
1) Required tube connection 3/4", water connection pressure: 2 [bar]
158 Cement Grout Introduction
In engineering and underground Depending on the application or the In contrast to customary products, cement construction, cement grout is required supporting member type, cement grout features both an excellent overhead for establishing a force and form fit bond grout is applied either before or after workability as well as early strength. between a supporting member and the the installation using an injection hose. foundation soil or rock mass. Mixing and transport of cement grout are carried out using mortar-mixing pumps, which are constructed specifically for the requirements in the construction industry.
System Description Fields of Application Main Advantages
■■ Hydraulically bonded cement grout ■■ Grouting of rock bolts in Mining and ■■ Universally applicable ■■ Portland cement with high quality Tunneling ■■ Increased early strength mineral additives ■■ Pressure grouting of anchors and soil ■■ Thixotrope – excellent overhead ■■ Bonding medium for cement grout nails workability embedded anchors and rock bolts ■■ Rock and foundation soil consolidation ■■ Swellable ■■ Injection works with high demands ■■ Frost-proof XF3 regarding early strength
Specifications
■■ Mixing liquid: water Characteristics 1) Unit Value ■■ Shelf life in dry conditions: 6 months Yield [kg/L] ca. 1.6 3 ■■ Packaging: paper bag of 25 [kg] or Bulk density [kg/dm ] ca. 1.4 bigbags of up to 1,000 [kg] Granulation [mm] 0.8 Liquid requirement [ml/kg] ca. 205 - 220 Mixing time [min] ca. 1.5 - 3.0 Processing time [min] ca. 30 Swelling [%] ca. 0.5 - 1.0 UCS after 1 day [N/mm2] ca. 30 UCS after 7 days [N/mm2] ca. 45 UCS after 28 days [N/mm2] ca. 55 Bending tensile strength after 28 days [N/mm2] ca. 9.0
1) The indicated values are laboratory values and may deviate on-site
159 Cement Grout Mixing and Processing Technical Features
■■ For pre-mixing, a compulsory mixer ■■ Tested in combination with SN-Anchors or a high quality continuous mixer is with special ALWAGRIP rib geometry recommended (see load-displacement diagram) ■■ After curing, immediate processing ■ Specific rib area between 0.02 and is advantageous due to thixotropic 0.04 (cf. RVS 8T, Federal Ministry for stiffening Transport, Innovation and Technology, Austria) ■■ When the cement grout begins to stiffen, it must not be mixed up with ■■ Examination of the inner bond of two water by any means different anchor steel types, depending on curing times ■■ Results of pull-out tests after 12 hours curing time with a bond length of 500 [mm]
250
200
150
100 Tension force [kN] force Tension
50
0 0 25 50 75 100
Displacement [mm]
Rock bolt steel Ø 25 [mm] FA 650/820 with special ALWAGRIP rib geometry Ribbed reinforcement steel Ø 25 [mm] B 500 B
Further References
In general, the common basic principles of concrete technology as well as the relevant standards and guidelines must be observed. This brochure gives only general information based on internal experience and examination under standard conditions at the time of pressure application, and does not consider individual applications.
According to external circumstances – especially the foundation soil, nature of processing, and environmental conditions – results can deviate from the indications presented.
■■ Blümel, M.; Schweiger, H.F.; Golser, H.: Effect of Rib Geometry on the Mechanical Behaviour of Grouted Rock Bolts, World Tunnel Congress ´97, 23rd General Assembly Accessories of the International Tunnelling Ass., Vienna, Austria, 1997 ■■ Payer, M., Maydl, P.: Untersuchungsbericht - Ausziehversuche von SN-Mörtelankern. ■■ Mortar-Mixing pumps Auftrags-Nr.: 77.645/08, Prüfdatum: 2008-04-22 - 2008-06-13. Technische Versuchs- ■■ Injection adapters und Forschungsanstalt für Festigkeits- und Materialprüfung, Graz University of ■■ Flushing heads Technology. Graz, Austria, 2008
160 Injection Adapters and Flushing Heads Main Advantages Fields of Application Rotary Injection Adapters
■■ Injection adapters: subsequent ■■ Simultaneous drilling and injecting injection following the self-drilling ensures an ideal bond with the loose installation of the DYWI® Drill rock or soil Hollow Bar System ■■ Penetration of the injection material ■■ Flushing heads (rotary injection into the surrounding foundation soil adapters): drilling and injecting in one ■■ Ground improvement and homogenous operational step distribution of the injection material
System Components flushing head Order Information
■■ Flushing head housing Description Article Code Article No. ■■ Flushing shaft with connecting thread Post Injection Adapter, R32/R38 IA-R32-15/22 300060012001 for the hollow bar and the shank Post Injection Adapter, R51 IA-R51-30/45 300060012002 adapter Rotary Injection Adapter, HEX22M-R32F-045 RIA-HEX22M-R32F-LI 301061221045 Rotary Injection Adapter, XDDD-R32-080 1) RIA-XDDD-R32-080-LI 1) 301060021080 ■■ Gasket and wiper (internal) Rotary Injection Adapter, XDDD-R38-080 1) RIA-XDDD-R38-080-LI 1) 302060021080 ■■ Fixing bracket with connection thread Rotary Injection Adapter, XDDD-R38-085 1) RIA-XDDD-R38-085-LI 1) 302060021085 for the injection hose Rotary Injection Adapter, XDDD-R51-085 1) RIA-XDDD-R51-085-LI 1) 303060021085 1) 1) ■■ Grease fitting Rotary Injection Adapter, XDDD-R51-110 RIA-XDDD-R51-110-LI 303060021110 Rotary Injection Adapter, XDDD-R51-140 1) RIA-XDDD-R51-140-LI 1) 303060021140 ■■ Dampening rubber Rotary Injection Adapter, XDDD-T76-110 1) RIA-XDDD-T76-110-LI 1) 304060021110 Rotary Injection Adapter, XDDD-T76-140 1) RIA-XDDD-T76-140-LI 1) 304060021140 Flushing head Flushing Shaft Type RIA, R32F-R32F FS-RIA-R32F-R32F-080 301060142080 housing Fixing bracket Flushing Shaft Type RIA, R38F-R32F FS-RIA-R38F-R32F-080 301060242080 Flushing Shaft Type RIA, T38F-R32F FS-RIA-T38F-R32F-080 301060442080 Flushing Shaft Type RIA, T45F-R32F FS-RIA-T45F-R32F-080 301060542080 Flushing shaft Flushing Shaft Type RIA, R38F-R38F FS-RIA-R38F-R38F-080 302060241080 Flushing Shaft Type RIA, R51F-R38F FS-RIA-R51F-R38F-085 302060341085 Flushing Shaft Type RIA, T38F-R38F FS-RIA-T38F-R38F-080 302060442080 Flushing Shaft Type RIA, T45F-R38F FS-RIA-T45F-R38F-080 302060542080 Flushing Shaft Type RIA, H55F-R38F FS-RIA-H55F-R38F-085 302060641085 Flushing Shaft Type RIA, T51F-R38F FS-RIA-T51F-R38F-085 302061041085 Flushing Shaft Type RIA, R51F-R51F FS-RIA-R51F-R51F-085 303060341085 Flushing connection Flushing Shaft Type RIA, H55F-R51F FS-RIA-H55F-R51F-085 303060641085 Grease fitting (connecting thread) Flushing Shaft Type RIA, T51F-R51F FS-RIA-T51F-R51F-085 303061041085 Flushing Shaft Type RIA, H64F-R51F FS-RIA-H64F-R51F-110 303060741110 Flushing Shaft Type RIA, C64F-R51F FS-RIA-C64F-R51F-110 303060841110 Flushing Shaft Type RIA, H90F-R51F FS-RIA-H90F-R51F-140 303060941140 Flushing Shaft Type RIA, H92F-R51F FS-RIA-H92F-R51F-140 303061141140 Flushing Shaft Type RIA, RT70F-R51F FS-RIA-RT70F-R51F-140 303061241140 Flushing Shaft Type RIA, H64F-T76F FS-RIA-H64F-T76F-110 304060741110 Flushing Shaft Type RIA, C64F-T76F FS-RIA-C64F-T76F-110 304060841110 Flushing Shaft Type RIA, H90F-T76F FS-RIA-H90F-T76F-140 304060941140 Flushing Shaft Type RIA, H92F-T76F FS-RIA-H92F-T76F-140 304061141140 Flushing Shaft Type RIA, RT70F-T76F FS-RIA-RT70F-T76F-140 304061241140 Flushing head-080 FH-RIA-080 301060031080 Flushing head-085 FH-RIA-085 301060031085 Flushing head-110 FH-RIA-110 301060031110 Flushing head-140 FH-RIA-140 303060031140 Rotary Injection Adapter, Seal kit head-080 RIA-SK-080 301060051080 Rotary Injection Adapter, Seal kit head-085 RIA-SK-085 301060051085 Rotary Injection Adapter, Seal kit head-110 RIA-SK-110 301060051110 Rotary Injection Adapter, Seal kit head-140 RIA-SK-140 303060051110 1) Consisting of: flushing shaft, flushing head and sealing kit; Further References X ... connection thread shank adapter ( R; T; H; RT; C ) / DDD ... inner thread diameter [mm]
■■ Brochure DYWI® Drill Hollow Bar System ■■ User manual DYWI® Drill Hollow Bar System
161 Mortar-Mixing Pump Introduction
The electric mortar-mixing pump MP06 is used in underground construction and foundation engineering for filling anchor boreholes and for injection works. To a limited degree, it can also be used for applying shotcrete.
Main Advantages
■■ Tough design and galvanized pump casing ■■ Low empty weight ■■ Simple operation and maintenance due to modular design ■■ Low start-up and cleaning times ■■ Low filling and overall height ■■ High delivery rate at continuous pressure ■■ Variable discharge ■■ All-purpose equipment
Specifications Gunite Pipes
Characteristic Value Unit Type MP06 ■■ Wear-resistant steel tubes Nominal power [kW] 5.5 ■■ Nominal diameter 50 and 60 [mm] 1) Gear motor [rpm] 190 ■■ Welded-on collars and carbofer couplings Power supply 2) [V/Hz] 400/50 Electrical connection [A] 3 x 12 (5 pole) ■■ Length app. 9 [m] Min. fuse protection [A] 3 x 32 ■■ Accessories and special lengths available on request Remote control [–] Optional (cable or radio) Spiral pump type [–] MP2 to MP20 Max. grain size [mm] 8 Flow rate 3) [l/min] 6.3 - 63.3 Max. delivery pressure [bar] 50 Max. transport distance 3) [m] 60 Casing length [mm] 1,000 Total length [mm] 1,950 Height [mm] 860 Grid height [mm] 95 Width [mm] 650 Weight [kg] 190 Article No. [–] 300070011001
1) Rotational speeds from 132 - 290 [rpm] optional 2) Country-specific adaptation possible 3) Depends on the consistency and grain size of the material, the W/C-ratio, spiral pump type, and rotation speed (based on the nominal value) ■■ Conveyor mixer optionally available ■■ Required Water pressure 2.5 - 4 [bar] ■■ Optional pressure control pump ■■ Further information is included in the operating manual of the mortar-mixing pump MP06
162 Injection Flow-Pressure Meter Introduction System Description
The injection flow-pressure meter Flow rates and injection pressures are permits an exact and comprehensible recorded separately for each injection documentation of ground improvement borehole. The manipulation-proof as well as a comprehensible control digital data recording is operated via a system of the specified injection user-friendly and simple touch-screen termination criteria. terminal. Subsequent to the injection works, the readout of the stored data is carried out via a serial interface as well as a computer-based raw data analysis.
System Components
■■ Flow meter ■■ Pressure transmitter ■■ Operating and analysis unit ■■ Readout lead ■■ Tripod ■■ Technical documentation ■■ User manual ■■ Software package
Technical Data Flow Meter and Pressure Tranducer
Component Charateristics [Unit] Nominal Value / Description Length x width x height [mm] 250 x 430 x 400 Casing Description stainless steel / material No. X5CrNi18-10 / 1.4301 Thread connectors 1" external thread Power supply max. 24 [V] (DC) Transducer Plug-in connection to evaluation and operating unit 16-pin (shielded, intrinsically safe wire) Flow medium Cement suspension Flow meter Max. flow rate (100%) [m³/h] 3.53 Max. deviation at 46% or 100% flow rate 0.06 and 0.02 Max. pressure [bar] 100 Pressure transducer Deviation measuring range (related to nominal value) [%] < 0.6
Technical Data Operating and Evaluation Unit
Component Charateristics [Unit] Nominal Value / Description Length x width x height [mm] 380 x 210 x 600 Casing Length x width x height incl. stand [mm] 600 x 500 x 1,450 Description stainless steel / material No. X5CrNi18-10 / 1.4301 Connection power with pump 5.7 Connection power without pump [kW] 0.3 Electric Power supply 3 x 400 [V] / 50 [Hz] Plug-in connection CEE 5 / 32 [A] Touchscreen Display screen Backlighted LCD graphic display with 256 colors Manuel modus (own user interface) or automatic modus Control and Read out and record the plotted data with a data cable to the computer via COM1 data processing
163 Cable Bolt Tensioner Introduction
Cable bolt tensioners are used for prestressing or active pre-tensioning Mining cable bolts. These devices for use in underground operations are characterized by low weight, robust construction and user-friendliness. DYWIDAG-Systems International provides different systems of cable bolts, depending on individual applications.
Fields of Application System Components
■■ Pre-Tensioning of type CB15.3 and 1) Tensioning head Type CB15.7 DYWIDAG Cable Bolts 2) Hollow plunger cylinder 320 [kN] ■■ Prestressing of cable bolts with free 3) Handholds hollow plunger cylinder 320 [kN] length 4) Bearing plate 5) Wedge casing 6) Domed plate (schematic) 7) High-flow coupling 8) Hydraulic hose L = 6 [m], incl. 2 high-flow coupling connectors 9) Hydraulic pump with integrated manometer and pressure relief valve
1) 8) 9)
2)
3)
4)
5)
6) 7) 7)
Specifications Accessories Further References
■■ Maximum force: 320 [kN] ■■ DYWIDAG Cable Bolts ■■ User manual cable bolt tensioners ■■ Total weight tensioner head and ■■ Hydraulic spare parts ■■ Brochure DYWIDAG Cable Bolts tensioner: approx. 16 [kg] ■■ Tensioning equipment for up to 640 [kN] ■■ When tensioning or pre-tensioning, the available on request forces that are permitted for the cable bolts in use must be observed
164 Pull Testing Equipment Introduction
Pull testing equipment is required for pull out tests on anchors and rock bolts.
Pull out tests on anchors and rock bolts are performed for supervision of the rock bolting quality. Depending on the type and design of the rock bolt in use, different testing equipment is utilized.
Depending on the operation purpose, modularly designed sets of different pull testing equipment can be adapted to the whole range of rock bolts provided by DYWIDAG-Systems International.
Fields of Application
■■ Pull out tests ■■ Supervision of quality criteria of installed rock bolts ■■ Research and development in the field of ground control technology
System Components
The pull testing equipment consists ■■ Hydraulic components ■■ Supporting frame of a series of mechanic and hydraulic ■ Hollow plunger cylinder ■ Depending on test requirements and components and is designed for an ■ Hydraulic hose test forces, the frame is available ultimate test force of up to approx. 60 [t]. ■ Electric pump or hand pump, either as a tripod or a tubular frame with gauge in different sizes ■ Gauges are provided on demand ■■ Mechanic components with a calibration certificate ■ Intermediate discs ■ Angle compensation plates ■ Balance rods and adapters for rock bolts that are to be tested
System Components Hand Pump
1) Bearing plate hollow plunger 1) 2) 3) 4) 5) 4) 7) 8) cylinder/nut 2) Thrust piece 3) Hydraluic hollow plunger cylinder, single acting 6) 4) High-flow coupling 5) Hydraulic hose incl. 2 high-flow coupling connectors 6) Manometer piece 7) Manometer (incl. calibration certificate) 8) Hand pump
165 System Components Electric Pump
1) Bearing plate hollow plunger 1) 2) 3) 4) 5) 4) 7) 8) cylinder/nut 2) Thrust piece 3) Hydraluic hollow plunger cylinder, single acting 6) 4) High-flow coupling 5) Hydraulic hose incl. 2 high-flow coupling connectors 6) Manometer piece 7) Manometer (incl. calibration certificate) 8) Compact electric pump
Order Information
Rock Bolt Hydraulics 1) Tripod or Bearing Cylinder 2) Pull Adapter 3)
Max. Max. 320 [kN] 640 [kN]
GEWI® Mining Anchors X X GEWI® coupling, rod, and nut Mechanical Anchors Type ALWAG X X Pull adapter, washer, and nut 4) SN-Anchors X X X Pull adapter, washer, and nut 4) Resin Rock Bolts X X Pull adapter, washer, and nut 4) DYWIDAG Threadbar Anchors X X GEWI® coupling, rod, and nut DYWIDAG GRP Solid Bars X X Pull adapter, washer, and nut 4) DYWIDAG GRP Hollow Bars and S-D Hollow Bars X X X DYWI® Drill coupling, hollow bar, and nut 4) OMEGA-BOLT® Expandable Friction Bolts X X OMEGA-BOLT® pull head, washer, and nut POWER SET Self-Drilling Friction Bolt X X POWER SET pull testing eqipment Friction Stabilizers X X X POWER SET pull testing eqipment CT-BoltTM Combination Rock Bolts X X Pull adapter, washer, and nut 4) Cable Bolt, System Barrel & Wegde X X X X See section cable tensione DYWIDAG Tensionable Strand Anchors X X X X See section cable tensione DYWI® Drill Hollow Bar System X X X X DYWI® Drill coupling, hollow bar, and nut
1) Proof force 0 - 320 [kN]: hollow plunger cylinder type RCH-302, proof load: 0 - 640 [kN], hollow plunger cylinder type RCH-603 2) Tripod or bearing cylinder according to hydraulics (320/640) 3) Schematic display. Coupling and pull head, pull rod, washer and nut are adapted to each anchor and rock bolt
4) Recommentation: max. proof force ... Fp,0.2 of the anchor or rock bolt
Further References
■■ DSI leaflets on pull tests ■■ System sketch of test assemblies ■■ Data sheets and operating procedures
Remarks/Links
■■ Pull tests must only be carried out in compliance with the present instructions by skilled personnel ■■ DSI has experienced technical personnel for planning, operation, and analysis of pull tests
166 PL 179 351 B, AT-E 217 681, PL-B 185 256, AT-B 409 785, AT-B 411 781, AT-E 0 257 213, AT-E 0 314 555, CH EP-B 1 311 740, DE 501 08 565.3-08, AU 2002338538, CA-B 2,442,320, ZL 02808431.4, P20030813A, JP 4036756, KR-B 779 340, PL-B 197 261, RU-B 2278941, SK-B 286 790, US-B 7,080,697, ZA 2003/7608, AT-E 0 332 436, CH EP-B 1 381 756, DE 502 07 438.8-08, ES 2262838 T5, FI EP-B 1 381 756, FR EP-B 1 381 756, GB EP-B 1 381 756, GR 3058466 B2, IT 32816BE/2006, SE EP-B 1 381 756, SI P 2002 3 0409, TR 2006 03585 T4, AT-B 504 022, DE-C 101 05 827, AT-B 500 691, DE 101 19569, AT-B 505 959, HK 1066581, AT-U 8404, AT-B 501 875, AT-U 9287, AT-E 0 363 580, AT-E 0 372 442, DE 50 2004 004 906.0-08, PL EP-B 1 682 745, AT-B 505 072, AT-E 0 202 045, EP-B 1 034 096, DE 598 00 872.1, AT-U 10 289, AT-U 9597, AT-E 0 417 186, AT-E 0 514 836, CH EP-B 0 1 888 878, CZ EP-B 0 1 888 878, DE EP-B 0 1 888 878, ES EP-B 0 1 888 878, FI EP-B 0 1 888 878, FR EP-B 0 1 888 878, GB EP-B 0 1 888 878, IT EP-B 0 1 888 878, PL EP-B 0 1 888 878, SE EP-B 0 1 888 878, SI EP-B 0 1 888 878, SK EP-B 0 1 888 878, TR EP-B 0 1 888 878, US-A 7,874,380, CA 2,609,737, AU 2006255521, ZA 2007/09811, AT-E 0 549 545, CH EP-B 1 886 056, DE 50 2006 004 522.2-08, PL EP-B 1 886 056, US-2009-0230679-A1, CA 2,608,676, AU 2006251841, EP 06 804 333.0, AU 2006281954, CA 2,619,175, US 11/990,392, AT-B 508 617, EP 08 733 231.8, AT A 1763/2009, AT-U 12 096, AT-U 12 097, AT A559/2010, AT GM340/2010, DE 10 2009 038 813.3, DE 10 2007 012 220, DE 10 2007 029548, AT-U12444, PCT/AT2011/000164, AT-E 0 494 455, BG EP-B 1 546 508, CH EP-B 1 546 508, CZ EP-B 1 546 508, DE 603 35 638.9-08, ES 2358738 T3, FI EP-B 1 546 508, FR EP-B 1 546 508, GB EP-B 1 546 508, GR 3074651, IT 22416BE/2011, PT EP-B 1 546 508, SE EP-B 1 546 508, SI EP-B 1 546 508, SK EP-B 1 546 508, TR 2011 02236 T4, AT-U 12443, PCT/AT2011/000240, EP 09 833 985.6, EP 12 002 889.9, EP 10 847 636.7, AT A 1802/2011, EP 10 740 119.2, US 13/389,881, EP 10 854 657.4, CA 2,772,658, EP 10 787 258.2, EP 12 450 021.6, AT GM 138/2012, AU 2010314788, CA 2,791,524, US 13/514,211
Status: 2012-12
167 please donothesitate tocontactus. further information on particularproducts, use ofourproducts. Shouldyourequire of thistechnicaldata andanyimproper for lossesordamagesattributedtothe use without notice.We donotassumeanyliability non-binding andmaybesubjecttochange provided herein shallbeconsidered purposes only. Technical dataandinformation This brochure servesbasicinformation Please note: E-mail Fax Phone 4061 Pasching/Linz,Austria Alfred-Wagner-Strasse 1 GmbH DYWIDAG-Systems International Austria
[email protected] +43-7229-610 4980 +43-7229-610 490
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