Straps

ERNATIONAL

01/04

DYWIDAG-SYSTEMS INT

DYDWYWIDIADG

ADSI G

product range

1.1 DYWIDAG THREADBAR Bolt1.2 Self-Drilling hollow-core Bolt1.3 Groutable DCP Bolt1.4 Fiberglass Bolt1.5 Expansion Shell Bolt1.5.1 Expansion Shells1.5.2 Expansion Shell Accessories1.6 Headed Resin Bolt1.7 Tension Rebar Bolt1.7.1 Tension Rebar → Oz-Drive Nut1.7.2 Tension Rebar → Pin Nut1.8 Set Tension Rebar Bolt

2.1 Cable Bolts → 0.6”, 0.7” 7-wire2.2 Cable Bolts → 0.9" 19-wire (Hi-Ten)

3.1 Friction Bolts → 33, 39, 46mm3.2 Ωmega Expandable Anchor

Bar Bolts

Cable Bolts

Friction Bolts

01/044.1 Hanger Brackets4.2 Eyebolts4.3 Bar and Cable Trusses

5.1 Plates → 6” Domed plates5.2 Plates → Other Plates5.3 Plates → Larger Plates5.4 Plates → Butterfly plates5.5 W-Strap5.6 Mesh Strap5.7 Mesh Channel5.8 Welded Wire Mesh5.9 Chain Link Mesh5.10 Longwall Recovery → Geogrid Mats

6.1 DYWIDAG Bolts → Spin adaptors6.2 Cable Bolts → cable tensioner6.3 Cable Bolts → cable spin adaptors6.4 Pull Testing Gear6.5 Cable Truss → tensioner jack6.6 Friction Bolt → installer

6.7 Scaling Bars6.8 Spinners & Nutrunners6.9 General Tools & Hardware

Trusses & Utilities

Plates & Mesh

Tools

DYWIDAG-SYSTEMS INTERNATIONAL

Bolt Summary Overview

Bolt type and size

Grade[ksi]

Ultimate Load [1000lbs]

Yield Load [1000lbs]

Max Bar OD [inches] Features

1.1 DYWIDAG THREADBAR#6 LH 75 44.0 33.0 0.860 DYWIDAG bar has a rugged, self cleaning hot

rolled thread along its entire length. Hardware develops the full section of the bar. Threadbar also shows high ductility as well as good corrosion resistance. Threadbar bolts are usually supplied with a domed anchor nut (mushroom nut) and a deformed plate. They can be used resin grouted or cement grouted, black, galvanized or epoxy coated.

LH means left-hand; RH means right hand thread

#7 LH 75 60.00 45.0 0.990

#8 LH 75 79.0 59.3 1.120

#9 LH 75 100.0 75.0 1.260

#10 LH 75 127.0 95.3 1.430

5/8” RH 160 43.8 36.7 0.693

7/8” RH 160 78.4 64.1 0.906

1" RH 150 127.5 102.8 1.200

1.25" RH 150 187.5 151.2 1.410

2 . 1 Cable Bolt0.5" x 7 270 41.3 37.1 0.520 Cable bolts can be supplied passive with a

preseated head, or tensionable using the cabletensioner underground. Cable can be supplied black or galvanized; wedges develop the guaranteed Fu ofthe cable.

0.6" x 7 270 58.6 52.6 0.620

0.62" x 7 270 62.7 53.2 0.640

0.7" x 7 270 76.2 68.6 0.720

0.9" x 19 124.0 108.0 0.900 Wedge will hold 92,000 lbs.

1 . 2 Self-Drilling Hollow Core BoltR25N 65 45.0 33.7 0.857 The bolt has a hollow core to allow flushing and

grouting the bolt. The bolt uses a disposablelost drill bit. After drilling with the bolt, the bolt is usually cement grouted into the hole. The bar has a standard rope thread to allow forcouplers.

R32N 70 62.9 51.7 1.117

R32S 70 80.9 62.9 1.117

R38N 70 112.4 89.9 1.378

R51N 70 168.6 1.851

2 . 1 Fiberglass Bolt15 to n/a 33.7 N/a 0.787 corrosion resistant, cuttable bolt, bolt is

threaded over 6inch, nut thread develops12kips20 to n/a 45.0 N/a 0.787

30 to n/a 67.5 N/a 0.787

3 . 1 Friction Bolt33mm n/a 22.5 18.0 1.250 A ring or collar is welded to the outer end to hold a

dome plate to the rock surface. Also known as 'split set' this bolt is hammered into hole, black or galvanized

39mm n/a 26.0 20.0 1.375

46mm n/a 37.1 27.0 1.750

Page 2 01/04


Size Grade Ultimate Yield max bolt FeaturesLoad Load diameter

[ksi] [1000lbs] [1000lbs] [inch]

1 . 5 Expansion Shell Bolt5/8" 55 19.2 12.4 0.625 Smooth bar, 6inch thread for expansion shell,

headed end to be used with plate; not resin assisted5/8" 75 22.6 17.0 0.625

3/4" 55 28.4 18.4 0.750

3/4" 75 33.4 25.1 0.750

1 . 6 Headed Resin Bolt#5 gr60 27.6 18.4 0.625 The deformations of reinforcing steel rebar allow

high bond with the resin, passive bolt with a hot-forged head to use with a plate#6 gr60 39.8 26.5 0.750

#7 gr60 54.1 36.1 0.875

1. 7 Tension Rebar Bolt#5 gr60 20.3 13.6 0.625 The deformations of the reinforcing bar bond to

the polyester resin. One end is threaded 6-12inch to allow for tensioning after the resin has set. The bolt capacity is determined bytensile thread area.

#6 gr60 30.1 20.0 0.750

#7 gr60 41.6 27.7 0.875

0.68 gr75 33.4 25.1 0.750

0.81 gr75 46.2 34.7 0.875

1 . 8 Set-Tension Rebar Bolt#5 gr60 27.6 18.4 0.625 Threaded on one end 6inch for an expansion

shell to mechanically assist initially. The deformations of the reinforcing bar bond to the chemical resin. The opposite end has a hot forged head.

#6 gr60 39.8 26.5 0.750

#7 gr60 54.1 36.1 0.875

0.68 gr75 36.3 27.2 0.750

0.81 gr75 49.9 37.4 0.875

3 . 2 Ωmega Expandable Anchor10 n/a 22.5 n/a 1.375 thin walled steel pipe that is expanded using

water pressure, load transfer is via friction12 n/a 27.0 n/a 1.750

20 n/a 45.0 n/a 1.750

Page 3 01/04


®1.1 DYWIDAG THREADBAR

ASTM F432 gr75

Type #6 #7 #8 #8 50T #9 #10Ultimate Load [1000lbs] 44 60 79 100 100 127

Yield Load [1000lb] 33 45 59.3 70 75 95.3Weight [lbs/ft] 1.5 2 2.7 2.7 3.4 4.3

Max bar diameter [inch] 0.862 0.996 1.122 1.268 1.268 1.433Nominal diameter [inch] ¾ 7/8 1 1.13 1.13 1.25

Ultimate Elongation* 11% 11% 11% 11% 11% 11%typical plate gr3 gr4 gr6

* in 8inch guage length

** larger sizes such as #14, #18 are also available

• Complies to ASTM F-432 and A-615

• Rugged, self-cleaning hot-rolled, left-hand threaded the entire length of the bar

• Unique threadform provides excellent resin mixing, superior bond strength and fast assembly.

• Hex nuts, semispherical anchor nuts and couplers develop the full strength of the bar.

• Also available: expansion shells and eye-nuts

• Excellent ductility

• High toughness:13 ft-lbs charpy V-notch at 77°F according to ASTM A370

• Also available: galvanized or epoxy coated

• Resin or cement groutable

• Point-anchor active or full-column passive

• Superior corrosion resistance: hot rolled rounded thread deformations eliminate local stress raisers. Also mill scale provides additional corrosion barrier

INSTALLATION

The unique threadform allows to spin the bar using a special oval shaped spin adaptor. There are special installation nuts available for example a pin-nut that releases once the resin starts to set.

Page 4 01/04

ten

sio

n [

kip

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1.1 DYWIDAG HARDWARE

Full Load Hardware ASTM F-432

Type #6 #7 #8Cast Anchor nut B06U28810 B07U28810 B08U28810

Hex x length 1.25 x 1.375 1.375 x 1.63 1.5 x 1.75

Cast Hex Nut B06U27701 B07U27701 B08U27701

Hex x length 1.188 x 1.125 1.312 x 1.313 1.438 x 1.625

Cast Coupler B06K31110 B07K31110 B08K31110

Dia x length 1.19 x 3.44 1.44 x 4.19 1.63 x 4.75

Cast Eye Nut n/a B07U95010 B08U95010

inside eye dimension n/a 2 inch 2.25 inch

2-to-1 safe working load [kips] n/a 30 40

Expansion Shell B06K21710B07K21710 orB07K23610

B08K23710

preferred Hole diameter 1-5/8” 1-5/8” or 1-3/4” 2”

Material is ductile iron ASTM A-521 grade 80-55-06

Torque Tension Relationship

16

14 dry

12 lubricated

10

8

6

4

2

050 100 150 200 250 300 350

torque [ft-lbs]

DYWIDAG-SYSTEMS INTERNATIONALPage 5 01/04

®


1.1 DYWIDAG THREADBARhigh grade, right hand

Type 5/8” 7/8” 1” 1-¼”Grade [ksi] 160 160 150 150

Ultimate Load [1000lbs] 43.8 78.4 127.5 187.5Yield Load [1000lbs] 36.7 64.1 102 150

Weight [lbs/ft] 0.97 1.75 3.01 4.39Max bar diameter [inch] 0.693 0.906 1.2 1.46

Ultimate Elongation 7% 7% 7% 7%*gr160 is available upon request.

Elongation is measured in 10 dia. guage length per ASTM A722

• Complies to ASTM A722

• Rugged, self-cleaning hot-rolled, right-hand threaded the entire length of the bar

• Unique threadform provides excellent resin mixing, superior bond strength and fast assembly.

• Anchor nuts and couplers develop the full strength of the bar.

• Excellent ductility

• High toughness: 6.5 ft-lbs charpy V-notch at77°F according to ASTM A370

• Also available: galvanized or epoxy coated

• Resin or cement groutable

• Point-anchor active or full-column passive

• Matched bearing plates

• Superior corrosion resistance: hot rolled rounded thread deformations eliminate local stress raisers.

INSTALLATION

The unique threadform allows to spin the bar using a special oval shaped spin adaptor. There are special installation nuts available for example a pin-nut that releases once the resin starts to set.

Page 6 01/04


ompressive strength

1. 2 SELF DRILLING BOLT

32mm hollow-core bar

Type R32N R32SWeight 2.28 lbs/ft 2.75 lbs/ftBar OD 1.14inch 1.14inch

Cross Sectional Area 396mm2 488mm2

Ultimate Load [1000 lbs] 63 81Yield Load [1000 lbs] 52 63

Max drilling depth 52ft 65ftOther sizes available are 25, 38, 51, 76mm

The DYWIDAG hollow core anchor is a fully threaded hollow bar that initially serves as a drill rod, utilizing a lost bit.

For use in unconsolidated ground or other difficult ground conditions

Excellent for spiling (fore-poling)

Bolt is drilled in and grout ispumped through the center holewith pumpable resin or cement grouts

The couplers are designed to exceed the ultimate load of the bar by 20%. The couplers aredesigned to minimize the loss of drill energy.

Several drill bits are available. Most widely used is the EXX Tungsten carbide chisel bit for handling UCT* up to 12.5N/mm

2 (RQD 100%) and up to 50 N/mm

2 (RQD 75%)

Standard length is 3m (9ft-10”). Longer lengths are available: 4m, 6m

INSTALLATION

Detailed installation instructions are available.

* UCT is unconfined c


ompressive strength

Page 7 01/04


1. 3 DCP BOLTDouble Corrosion Protection by Grouting

The DCP bolt combines ease of installation with durable long-term corrosion protection.

Patent application filed

• The square drive nut sits on domed washer. The nut has grouting channels.

• The domed washer transitions to a steel trumpet that provides a sealing fit with a deformed plastic sleeve.

• The deformations of the plastic sleeve center the bar inside, allow grout to flow inside and outside the sleeve.

• The deformations are designed to transfer the load from the inner to the outer grout.

• The sleeve is a protective barrier against corrosive elements.

• The bolt is installed using an expansion shell for immediate support.

INSTALLATION

The grout nozzle is easily attached over the end of the bar and sealed against the drive nut. Grout is injected through the nut for encasing the bar is completely in grout even at the critical inside of the nut for maximum corrosion protection. The nut comes with aone-way valve to eliminate any grout bleed-off.

Page 8 01/04

Type StandardUltimate Load 33,700 lbs

Nut/Thread tensile Load 11,000 lbsSingle Shear Load 10,000 lbs

Nut beak-out torque 28ft-lbs to 30 ft-lbsWeight 0.433 lbs/ft

Nominal bolt diameter 20mm = 0.787 inchNominal Cross Section 310mm

2 = 0.48 inch

2

lengths 4 - 10ftSpecific gravity [g/cm

3] 1.7 – 1.8

Resin color White (w/ filler)


1. 4 FIBERGLASS BOLT

GRP (glass reinforced polymer) bolts

Threaded Bolt

higher grades up to 67,500 lbs ultimate are available

The 20mm fiberglass bolt is a pull formed (matched die) fiberglass construction, ribbed over its full length to provide maximum load transfer.

• Robust threads 150mm long (6inch)

• Fiber reinforced plastic nuts and bearing plates

• Corrosion resistant, cuttable

• Nuts and threads develop 12,000 lbs

• Also available: Thrustdowel with integral head and18,000 lbs anchor head capacity

• Ultimate strain is 1.8% without yield point.

All 20mm fiberglass bolts are designed as chemical anchors and fully encapsulated. The non-filled resin bolts (green) are suitable for more aggressive environments and are to be used with cement grouts.

Preferred hole diameter is 26-27mm (1 inch). For larger holes, we recommend a22mm dia. fiberglass dowel which is available upon request in the above grades.

Circular bearing plate and Swivel plate is available.

INSTALLATION

Thrust Dowel

Swivel Plate

After inserting the resin cartridges, the bolt is spun and pushed through the resin cartridges. Observe the resin manufacturer’s recommended mixing and hold time. DO NOT OVERMIX.

Product code(s)

Page 9 01/04

Thrust dowel 3ft FT20090015Plate 5” dia F22L215520mm bolt AROA0500


1. 5 EXPANSION SHELL BOLT

Conventional Roof Bolt

Type 5/8” gr75 3/4" gr75 7/8” gr75Ultimate Load 22,600 lbs 33,400 lbs 46,200 lbs

Yield Load 17,000 lbs 25,100 lbs 34,700 lbstypical plate w/ hole* Ø gr2 w/

13/16“Ø gr2 w/ 1“Ø gr3 w/ 1

1/8“Ø

* hole size for underground assembly; pre-assembled bolts require larger hole plates to clear shell.

This conventional roof bolt is made from smooth bar. The hot-forged head has a1-1/8” square shape for standard bolting sockets.

• The opposite end of the bolt has a rolled-on thread (usually 6inch) for an expansion shell. Several types of expansion shells are available for different conditions

• For long-term service life, the bolts may be cement grouted.

INSTALLATION

The conventional bolt is usually not resin-assisted and develops its anchorage immediately after setting the expansion shell. See special notes on expansion shells.

The length of the bore hole must be longer than the bolt by approximately 2inch.

The expansion shell, separately supplied, is screwed onto the bolt so that thebolt thread extends slightly beyond the expansion shell plug.

After inserting the bolt into the hole, the bolt head is rotated to set the shell and to tension the bar.

Product code(s)

Turn to 1.5.1 for selection of available expansion shells

SH63048LH06 5/8” x4ft w/ 6” LH threadSH75048LH06 3/4” x4ft w/ 6” LH thread

Page 10 01/04 SH88048LH06 7/8” x4ft w/ 6” LH thread


1. 5.1 EXPANSION SHELLS

Mechanical Anchors

Type F2B D1L F9FUNC thread 5/8” ¾” 5/8” ¾” ¾” 7/8”Non-seizure

load 17,000 30,000 22,500 30,000 30,000 40,000

Drill hole size 1.375” 1.375” 1.75”Shell length 2.875” 3” 3.25”

Wedge length 1.375” 3.125” 2.25”

Expansion Shell Mechanical Anchors use proven components with a long history of use.

• The non-seizure load is the maximum design load beyond which the threads start to seize.

• Mechanical Anchors rely on competent rock strata in the anchor zone. The suitability of the rock anchor zone and specific mine roof support anchor to be used is best determined by actual in-situ underground testing.

• The above expansion shell anchors are to be set dry (without resin) or with cementgrouting. Please call DSI Technical Support for resin installed expansion shell bolts.

• All anchors comply to ASTM F432.

Page 11 01/04


1. 5. 2 EXPANSION SHELL BOLT

Accessories


Page 12 01/04


1. 6 HEADED RESIN BOLT

Type #5 gr60 #6 gr60 #7 gr60 #8 gr60Ultimate Load 27,600 lbs 39,800 lbs 54,100 lbs 71,100 lbs

Yield Load 18,400 lbs 26,500 lbs 36,100 lbs 47,400 lbsPreferred Hole 1” 1” 1-1/8”, 1-3/8” 1-3/8”

typical plate w/ hole gr2w/ 1“Ø gr2 w/ 1“Ø gr3 w/ 11/8“Ø gr4 w/ 1

3/8“Ø

This roof bolt is made from reinforcing grade bar with a hot forged head to fit standard bolting sockets.

• Good bond with grout for excellent load transfer

• hot forged head (1-1/8” square)

• Passive full-column resin grout


INSTALLATION

For larger hole sizes it is recommended to add a ‘pig-tail’ resin mixer to the end of the bolt.

Product code(s)

Page 13 01/04

RH06048 #6 bolt 4ft long RH07048 #7 bolt 4ft long RH08048 #8 bolt 4ft long


1. 7 TENSION REBAR BOLT

Type #5 #6 #7 0.68 0.81Grade 60 60 60 75 75

Ultimate Load [1000lbs] 20.3 30.1 41.6 33.4 46.2Yield Load [1000lbs] 13.6 20.0 27.7 25.1 34.7

Typical plate gr2 gr2 gr3 gr3 gr4

This roof bolt is made from reinforcing steel bar. One end is roll-threaded to accept a nut. The nut is torqued to tension the bolt after the epoxy resin has set.

• Either six, eight or twelve inches of threads

• Different types of break-away nuts are available

• Point-anchor or fully grouted

• Tensionable

• Load carrying capacity (above) is determined by the threaded area


INSTALLATION

For larger hole sizes it is recommended to add a ‘pig-tail’ resin mixer to the end of the bolt.

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Page 15 01/04


1. 7 TENSION REBAR BOLT

Accessories


Page 16 01/04


1. 7 .1 OZ DRIVE NUTDSI continues to develop torque resistant nuts which provide greater benefits over and above the hot forged mixing square enabling the use of a single spanner operation in installation of chemical rock bolts. A metal disk is inserted into end of the nut and held in place with deformed tabs. These tabs break loose providing a torque release mechanism.

BREAKOUT TORQUE RANGETypical torque required to break loose the disk and thus allow the nut to be tightened. This torque is the maximum mixing torque.

COLOR Stamp *)

White (W) 140 + ft-lbs 190 + Nm

Orange (O) 100 - 140 ft-lbs 135 – 190 Nm

Red (R) 75 – 115 ft-lbs 100 – 155 Nm

Yellow (Y) 60 - 80 ft-lbs 80 - 110 Nm

Blue (B) 35 - 50 ft-lbs 50 - 70 Nm

Purple (P) 25 - 35 ft-lbs 40 - 50 Nm

*) Appropriate color symbols stamped into each disk to indicate torque range, i.e. R= Red; B= Blue, etc.

• DSI OZ Nuts offer the following advantages:

o Up to 30% greater pre-tension for a given ft/lb. of torque.o No residual drag after torque break-out.o Will not seize on bolt threads.o Less strain on operators using hand-held roof bolters

due to a smooth break mode

• OZ Nuts are supplied with the following threads: UNC: 3/4”-10; 7/8”-9; 1”-8 UNC LH or RH DYWIDAG THREADBAR®: # 6, #7, #8

• OZ Nuts are normally supplied attached to the appropriate bolts, but may be suppliedbagged in 100 piece bags.

• Patent protected.

Page 17 01/04


1. 8 SET-TENSION REBAR BOLT

Type #5 #6 #7 0.68 0.81Grade 60 60 60 75 75

Ultimate Load [1000lbs] 27.6 39.8 54.1 36.3 49.9Yield Load [1000lbs] 18.4 26.5 36.1 27.2 37.4

Typical plate gr2 gr2 gr3 gr3 gr4* hole size for underground assembly; pre-assembled bolts require larger hole plates to clear shell.

This roof bolt is made from reinforcing steel bar. One end is roll-threaded 6inch long to accept an expansion shell.

• Hot forged head to accommodate bearing plate• Threaded for expansion shell, designed to be pushed through grout

cartridges.• Installed with or without grout• Point anchored or fully-resin grouted• Tensionable• Matched bearing plates• Does not loosen during blasting or ground vibrations

This design enables to instantaneously set the bolt by expanding the shell. No hold time needs to be observed for curing the grout.

After the resin has set, the hot-rolled deformations of the bar provide a long- term, bond anchorage over the entire bolt length.

INSTALLATION

• Insert the resin cartridge, then insert the bolt (without spinning) to within1/16” or 1/8” of the roof line. Rotate the bolt to expand the shell until thehead is tight against the plate. Use a preset torque to avoid over-torqueing the shell. The rotation to expand the shell is mixing the resin which then starts to set after the shell has been set.


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2 .1 CABLE BOLT

0.6" or 0.7" Passive and Tensionable

Cable Diameter 0.6” gr270 0.7” gr270

Weight 0.74 lbs/ft 1.11 lbs/ftBore Hole Diameter 1" to 1.375" 1" to 1.375"

Cross Sectional Area 140mm2 196mm2

Ultimate Load [1000lbs] 58.6 76.2Yield Load [1000lbs] 46 68.6

Min. Elongation in 2ft 3.5% 3.5%Typical plate gr6 w/ 1-3/8” hole Grade 6

Also available are 0.5”, 0.62” and 0.9” upon request.

• 270 ksi, low relaxation cable per ASTM A416.

• Supplied in any length, black or galvanized cable.

• Point anchored active bolt, tensioned after installation utilizing the hydraulic tensioning jack.

• Point-anchored passive bolt with pre-seated head. Wedge barrel shaped to accept 1-1/8” hex or square male spinner.

tensionable

passive

• Several options for anchoring in the resin are available: The bulbed cable bolt isdesigned for point-anchoring in resin. It may also be fully grouted with slow speedresin, or cement grouts. Bulbing is an effective means to center the bolt in the drill hole, to mix the resin and to develop bond for anchoring the bolt.

• The Bond head is an additional bulb that can be formed on the end of the cable bolt.

• Bulbs are provided to fit hole sizes: 1” hole: strip cage1-3/8” hole: plunge bulb1-3/4” hole: bond head

Bond Head at end to fit specific Hole diameter

Plunge bulb for 1-3/8” hole

Product code(s)

Page 19 01/04

CB16PTP


Page 20 01/04


2 .1 CABLE BOLTAccessories


Page 21 01/04


2 .1 CABLE BOLT

Installation Accessories


Page 22 01/04


2 .1 The Wedge Anchorage of the cable bolt

The anchorage of most cable bolts consists of a wedge barrel and a 2- or 3-part wedge. The wedge segments grip the cable by means of tooth shaped threads which are forced into the surface of the cable wires.

The clamping force W is highly dependent on the friction between wedge and wedge hole. For normal friction conditions, the clamping force W is more than 4 times the cable pulling force V and it adjusts with the pulling force V.

Warning: If friction increases (due to corrosion), a larger F will reduce the clamping force. As V increases all other forces can only increase if the wedge can seat deeper into the barrel. If the wedge is restrained to do so (i.e. by corrosion or dirt-accumulation), the clamping force can not increase with the pulling force causing slippage when the load on the cable bolt gradually increases during service life.

To avoid slippages during use, it is important that the cable bolt is fully stressed at time of installation to a force equal to 0.5 Fu.

When a wedge is properly seated, radial cracks may develop indicating adequate seating.

The wedge can be supplied with a rubber O-ringor a metal spring ring holding the wedge segments together.

Page 23 01/04


2 . 2 HI-TEN STRAND BOLTHI-TEN stands for HIGH PRE-TENSION

Diameter 0.9 inchUltimate Load 124,000 lbs

Yield Load 108,000 lbsUniform elongation 3-4%

Weight 1.9 lbs/ft

• The HI-TEN cable bolt has a semisphericalbarrel with a wedge and will carry loadsbetween 46 and 50 Tons.

• Dywidag HI-TEN cable bolts are designed for long rock boltsand are capable of beingpost-tensioned after installationto loads up to 28 tons using the DSI hydraulic tensioning unit.

• A square end allows the bolt to be rotated to mix resin grout.

• The HI-TEN cable bolt is designed to be point -anchor grouted and pre-loaded. It may also be fully grouted with slow speed resin grouts, or cementitous grouts.

• An excellent choice to supplement existing strata reinforcement. Compatible domed plates are available from DSI.

• Patent Pending

Page 24 01/04


Page 25 01/04


3 .1 FRICTION BOLT

Type 33mm 39mm 46mmDiameter 1.3 inch 1.54 inch 1.85 inch

Weight 1.03 lbs/ft 1.19 lbs/ft 1.87 lbs/ft

Bore Hole Dia. 1.1875 -1.25 1.375 - 1.5 1.69 – 1.79

Cross Sectional Area2204mm

0.32 inch2

2225mm0.35 inch

2355mm

2

0.55 inch2

Ultimate Load 22,500 lbs 26,000 lbs 27,000 lbs

Yield Load 18,000 lbs 20,000 lbs 37,000 lbs

Recommended bit 1.375” – 1.5” 43-45 mmTypical plate gr2 w/ 1.5” hole gr2 w/ 1-5/8” hole gr3 w/ 2” hole

3ft 4ft

6ft

9ft

To indicate length friction bolts can be color coded or the ring slot can be indexed as shown.

Friction Bolts can be load tested by fitting a special ring to the bolt prior to installation. The test is carried out using a center hole hydraulic jack.

Suitable for installation with hand-held rock drills (stopers) and other rotary-percussive drills.

Standard deformed plates (ASTM-F432) are supplied with the bolts.

Hot dip galvanizing is available to provide corrosion protection.

INSTALLATION

The hole length shall be longer than the bolt by 6inch to allow for any rock fretting during installation. The bolt is inserted into the hole. The driving dolly is fitted into the rock drill’s chuck and then the bolt (with accessories) is placed onto the dolly. Using full percussion and thrust the bolt is driven into the hole until the domed plate is firmly against the rock surface. Care shall be taken to ensure the rock drill’s feed/thrust is collinear with the hole axis otherwise the bolt may be bent or buckle during installation.

Product code(s)

33mmx18”: FB3304539mm: x6ft FB3918046mm x 8ft: FB4624039mm x 4ft + plate FB39122D1541

Page 26 01/04


3 . 2 ΩMEGAEXPANDABLE FRICTION ANCHOR

Type 11 tons 13.5 tons 22.5 tonsUltimate Load 22,500 lbs 27,000 lbs 45,000 lbs

Ultimate Elongation 25% 25% 25%Optimal Borehole dia. 35-38mm 45-51mm 45-51mm

Delivery Lengths 3-26ft 3-26ft 3-26ftWeight 1.29 lbs/ft 1.72 lbs/ft 2.54 lbs/ft

Installation Pressure 4350 psi 3625 psi 4350 psiTypical plate grade 2 grade 2 grade 4

Thin walled, folded steel pipe is seated at the end installed in hole and expanded with water pressure.

Matched bearing plates

The anchorage is effective over the entire anchor length.

ΩMEGA anchors are not susceptible to blasting shock waves.

The anchors work by friction without bonding agent.

ΩMEGA anchors can accommodate a high borehole diameter tolerance.

INSTALLATION

Anchor plates available are: longhole: 6x6 x0.157” or 0.25”, roundhole 6x6x0.315” or 8x8x 0.39”

Pneumatic or electric high-pressure water pumps are required to set the ΩMEGAanchors.

ΩMEGA

Order information

Imported productLead time 8-10 weeksElectric or pneumatic pump also available

Page 27 01/04


4 . 1 a KEYHOLE BRACKETS

Service Line Keyhole Brackets areused in conjunction with service line slots pre-punched in W-Strap vee’s.

The Keyhole Brackets are used for suspension of light mine services using chain.

A safety factor of 6:1 has been applied to the failure load on the design.

Loads are valid for static loads only with no allowance being made for shock load or vibration.

Corrosion protection may be provided by hot dip galvanizing.

NOTES

For details of Keyhole Brackets, load limitations and other factors please contact DSI Ground Support Systems.

Product code(s)

MH8030 6”x4”x5/16” L x 4”

Page 28 01/04


4 . 1 b KEYHOLE BRACKETS

UTILITY HANGERS


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4 . 2 a EYE BOLTS

16mm Eye Bolts are available for hanging light service lines in mining applications.

• Available with a rolled thread M16 x 150mm to accept 16mm expansion shell mechanical anchors. Note: the slotted option as per 24mm Eye Bolts is not available for 16mm

• Inside diameter of the eye is 75mm

• Nominal bolt length is measured from under eye to end of bolt.

• Feed material around eye is lapped back for a minimum of50mm along bolt shank before being fillet welded on bothsides.

• Manufactured from round bar feed AS1442/U1040 material

• May be supplied hot dip galvanized.

PACKAGING

Bundles of 10 units or larger quantities on pallets.


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4 . 2 b EYE BOLTS


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4 . 3 a SanJuan EZ TRUSS

ASTM F432 gr6

The DYWIDAG SanJuan EZ Truss combines ease of installation with superior support performance. It can be installed safely from the bolter without exposure to unsupported roof at anytime.

Patent application pending in USA

INSTALLATION

The truss shoe and the inclined bolt can be installed first and separately from the truss. Then a dead ended pre-seated wedge-barrel is swung into the truss shoe. It self-centers inside the truss shoe. This can be done using the cable as an extension without leaving the protection of the bolter. Then both cables are fed through the cable truss coupler in the middle. Wedges are installed into barrels against the cable truss coupler and stressing may commence using a hydraulic tensioning unit. The truss shoe is designed to accommodate #7 or #8 bar and angles between 45 and 60 degrees to the horizontal.

Product code(s)

Truss Shoe CTS06Truss Set 0.6” cable and #7 DYWIDAG bar w/ shoe and coupler EZ TRUSS


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4 . 3 bTRUSSES AND SLINGS

Cable Truss ⇒• Full load “dog-bone” cable

coupler• Hydraulic jack to tension• Ring-eye plate or wood at

bends to transfer cornerforces

Patented in US and Canada

⇐ Bar Sling

• Full Load Truss coupler

• Torque wrench to tension truss at coupler

Patented in US and Canada

Product code(s)

CTC06 cable truss coupler (dogbone) B08K32910 #7or #8 cast truss coupler B09U32010 #8 or #9 cast truss coupler

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5 . 1 6X6 DEFORMED PLATE

rated per ASTM F-432

Grade Hole Diameter[inch]

Net weight[lbs]

2 0.8125, 0.9375,1.000, 1.125,1.250, 1.500, 1.625, 1.600

1.45

3 1.000, 1.125 24 1.125, 1.250, 1.375, 1.500 3.186 1.250, 1.375 3.8

Deformed plates are proof tested according to ASTM F-432 on a continuing basis using an in-house testing machine. The deflection under load is recorded.

• Identification stamp G1-#2: G1 identifies the DSI plant in Salt Lake City. The #2 identifies a grade 2 plate.

• Eccentric loop to allow the attachment of light service lines.

• User friendly rounded corners.

• Designed to fit into the butterfly plate. The combination of deformed plate and butterfly is called a “dragonfly” plate.

• Corrosion protection may be provided by hot-dip galvanizing the finished plate or by using pre- galvanized material.

• Embossed plates for low-profile requirements are available upon request

PACKAGING

Domed Plates are tied with wire clips and palletized.

Product code(s)

6x6 gr2 hole 13/16” D0606145136x6 gr3 hole 1” D0606195166x6 gr4 hole 1-1/8” D0606312186x6 gr6 hole 1-1/4” D060637520

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5 . 2 BEARING PLATES


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5 . 3 BEARING PLATES

larger plates and flat plates

Bearing size Thickness available Max hole size Max weight

6 x 6” up to 1-1/8” flat 1-3/8” 10.9 lbs8 x 8” up to 1” flat 1.5” 17.4 lbs8 x 8” Grade 6 deformed 1-3/8”

10 x 10” up to 7/8” flat 1-9/16” 24 lbs

Plates made from ASTM A36 or A572 gr50 steel. The above maximum thicknesses are available in ASTM A36 steel.

Plates are available black or galvanized or epoxy-coated.

Welded on studs are also available upon request.

Net weight: 0.28 lbs/inch3

Product code(s)

8x8 gr6 domed hole 1-3/8” D88381388x8 flat hole 1.5” F8838150


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5 . 4 BUTTERFLY PLATE

Length x Width Thickness HoleDiameter

Net weight black

Net weight galv.

300 x 278mm12 x 11inch

1.9mm 50mm =2inch

2.87 lbs 2.95 lbs

400 x 278mm15.75 x 11inch

1.9mm 50mm =2inch

3.73 lbs 3.83 lbs

The butterfly plate is a light-weight plate with a large surface area. It is used as an intermediate plate to increase the surface coverage of a bolt.

• DSI Butterfly plates feature both longitudinal and transverse V-shaped deformations for added strength and greater ability toconform to irregularities in the rock surface.

• The deformed design renders a greaterstrength, placing the perimeter of the Butterfly Plate in tension.

• User friendly rounded corners.

• Can be used with both flat and domed plates (up to 150mm, 6inch square)

• Butterfly plates are can be placed directly to the rock surface or used withWelded Steel Mesh.

• Butterfly plates are supplied with slots for supporting of light service lines.

• Corrosion protection may be provided by hot-dip galvanizing the finished plate or by using pre-galvanized material.

PACKAGING

Butterfly Plates are tied with wire clips and palletized.

Product code(s)

12x12” black BUTT300S USA12x12” galv. BUTT300GS USA12x16” black BUTT400SWA12x16” galv. BUTT400GS

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5 . 5 W-STRAP

Steel Mat, Bacon-Strip, “Monster Mat”

Type Roof Mat Monster MatMaterial thickness 16 or 14ga 12 ga

Typical Width 9-10 inch wide 14inchDelivery lengths 9-20 ft 9-20 ftMats per bundle 25 10

• Steel Mat is commonly used whenadditional support is required inconjunction with rock bolts. These steel straps are pulled against the rock surface by the bolts and tend to conform to major irregularities in the rock and rounded tunnel shapes.

• Steel Mats provide a large surface confinement to loose rock.

• Standard hole pattern is multi holes 1ft on center, starting 6inch from the end, 1.75”hole diameter; oblong holes as well as special, hole distances and diameters can besupplied upon request. Service line slots can also be provided upon request.

INSTALLATION

Typically the Roof Mat bears against the rock surface. A roof bolt plate is placed against the Mat and a roof bolt is installed. Depending on the roof conditions, a steel mesh can be placed behind the Roof Mat for additional surface control.

Product code(s)

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DYWIDAG-SYSTEMS INTERNATIONALRM1207216B 11.75x72” 16ga black RM1207216G 11.75x72” 16ga galv RM1210816B 11.75x108” 16ga black RM1210816G 11.75x108” 16ga galv


5 . 6 a MESH STRAP

Deformed mesh strap

Dimensions 20inch x 15ftWeight 36 lbs

Grid 3 x 2 inchTransverse wire ∅5mm @ 75mm

Longitudinal wire4 x ∅8mm and6 x ∅5mm

Other sizes are available upon request.

• Allows to set and add bolts where needed.

• Combines light weight with strength

The design also allows for bolts to be placed anywhere along the roof strap or module.

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5 . 6 bMESH STRAP

Deformed mesh strap


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5 . 7 MESH CHANNEL

Deformed Mesh


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5 . 8 WELDED WIRE MESH

Typical sheet size4x8, 6x9, 6x10 ft6x16, 6x17 ft

Aperture size 3x3 or 4x2 or 4x4 inchWire gage 10 gage to 2.5 gageWire size W1.4 to W5

Wire diameter 0.135 inch to 0.25 inch

Typical gages and conversion: Gage nom dia. lbs/ft Wire size

6 0.192 0.099 W 2.96.5 0.185 0.091 W 2.77 0.178 0.085 W 2.5

7.5 0.171 0.078 W 2.38 0.162 0.070 W 2.19 0.1483 0.059 W 1.7

• Welded Wire Mesh is supplied in a variety of configurations. Sheet sizes as well aswire gage and spacing is mine specific to fit the underground condition. The spacingsare variable in both directions (longitudinal wire and cross wire).

• To minimize injury risk during handling, the mesh sheets are flush-cut all around (0- to ¼” overhang).

• Wire and weld are produced and tested according toASTM A82 and A185.

• Wire Mesh is typically supplied in stacks of 25 or 50 sheets.

• It can be advantageous to design spacings so that plates can be placed onto the grid. Other mesh layouts consider reinforcing spacings or locator spacings so that the sheet is strongeraround its edges and to match the rock bolt pattern.

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Typical roll sizes 4ft to 9ft wide; 25-50ft longDiamond size 2”, 2.25”, 2.375”

Wire gage 9 gage to 11 gageBlack or galvanized

Wire diameter 0.148 inch to 0.25 inch

Gage nom dia. lbs/ft2”

diamond2.25”

diamond2.375

diamond


5 . 9 a CHAIN LINK WIRE MESH

• Economical

• Versatile

• “Shotcretable”

Typical gages and conversion:

Weights in lbs/ sqft

9 0.1483 0.059 0.7 0.646 0.6110 0.135 0.0492 0.6 0.543 0.5111 0.120 0.0384 0.46 0.377 0.356

Chain link screening offers an economical and durable solution for roof support or rib support. Chain link mesh is often used to engage more surface area for each roof bolt. Also, chain link has proven to be well suitable for shotcrete applications.

• Chain Link Wire Mesh is supplied in a variety of configurations. Sheet and roll sizes as well as wire gage and diamond opening is mine specific to fit the underground condition.

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5 . 9 b WIRE MESH


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5 . 10 LONGWALL RECOVERY

Polyester or SUPRGRID™

DSI Grades tensile strength (ASTM-D4595) aperture size weightMD XMD MDXMD Ultimate

All Polyesterat 2% strain

1)

lbs/ftultimate

kN/m Elongation inch oz/yd2mm g/m

2

35/35 280 280 35 35 11x11% 1.77 45 8 271

80/80 650 650 80 80 11x11% 1.38 35 19 644

200/80 1,600 650 200 80 11x11% 1.38 35 23 780

200/140 1,600 1,100 200 140 11x11% 1.38 35 32 1085

200/200 1,600 1,600 200 200 11x11% 1.38 35 38 1288

SUPRGRID 2)

100/80 3,400 650 100 80 3x11% 1.38 35 12 407

100/100 + 10 3) 3,400 800 100 100 3x11% 1.53 39 14 475

100/200 3,400 1,600 100 200 3x11% 1.38 35 27 915

½” wire rope 6x19 13,000 lbs 3% 0.46 lbs/ftMD = Machine Direction, XMD = Cross Machine Direction1) 2% strain is equivalent to 10” convergence given 10ft

unsupported span during shield recovery.2) SUPRGRID with XMD in Polyester

3) Reinforcing bands add ultimate 10,000 lbs on 18” centers

DYWIDAG GridMesh is comprised of high tenacity yarns, woven into a stable interlocking grid structure and then fire-retardant coated with PVC for protection during installation.

GridMesh is used for longwall recovery mats as well as rib control. Longwall recovery mats are fabricated and assembled to mine-specifications.

• Light weight - reduces cost and handling time for longwall moves compared to traditionalchain link.

• No sharp edges, reducing injury hazard associated with chain link.

• Conforms easily to the roof or ribs due to the multifilament yarn design.

• Stronger than other polymer grids: Since the longitudinal and transverse members are crossed and independent, there is less ripping out at the intersections than with other polymer grids.

• Fast pick-up: High Tenacity Polyester Grid develops a minimum of 40% of ultimate strength at 5% strain significantly reducing rock movement. Suprgrid develops more strength faster matching the stiffness of wire ropes. 2% strain is equivalent to 10” convergence given 10ft unsupported span during shield recovery.

GridMesh is available in rolls made to custom length. The width also can be customized to specific needs but common are 6ft, 8ft and 12ft with 15ft being the maximum width. The grid is produced in the USA with a lead-time of 4-6 weeks.

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6. INSTALLATION TOOLS

DYWIDAG tools are specifically designed and tested to work with DYWIDAG ground support systems. Using original DYWIDAG tools will guarantee optimal installation times and performance results.

6.1 DYWIDAG bar spin adaptors and nut wrenches

6.2 DYWIDAG Cable Tensioner

6.3 Cable spin adaptors (passive, tensionable)

6.4 Pull Testing Gear

6.5 Cable Truss jack

6.6 Friction bolt installer

6.7 Scaling Bars

6.8 Rebar/Threadbar Spinners and Nut-Runners

6.9 General Tools and Hardware

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6 . 1 DYWIDAG SPIN ADAPTOR

Bar Spanner to mix epoxy resin

The DYWIDAG Spin Adaptor is an installation tool to properly mix epoxy resin cartridge.

The Spin adaptor for DYWIDAG bolts takes advantage of the oval shape of the bar. Thespin adaptor has a oval shape to fit the bar and allows spinning without any special end preparation of the bolt. DYWIDAG Spin Adapators are made from high strength steel that is heat treated and hardened for long lasting durability

• DYWIDAG spanners allow for resin mixing

• DYWIDAG bar installing wrench to suit #6, #7 and #8 DYWIDAG bolts

• Drive end to suit various bolter drives: 7/8” hex, 1-1/8” square or 1-1/8” hex or as required.

• When mixing resin, observe the mixing time and number of revolutions recommended by the resin manufacturer.

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6 . 2 a CABLE TENSIONER Mark2

A light weight and unique way for pre-loading cable bolts, the DSI Cable Tensioner Mark2 grips the end of the cable bolt and tensions it, leaving only a short tail protruding from the bearing plate (approx. 6 inch). The Cable Tensioner is a single hydraulic ram driven by an air/hydraulic pump or by machine hydraulics.

• The complete jack weighs 25 lbs. The entire kit (matrix) weighs 51lbs.

• Two grip handles allow for operation by one person.

• Unit locks on the cable, until lanyard ispulled to release spring loadedgrippers.

• Can be configured for all cable bolts, from 0.6” to 0.7” and the DSI 0.9” HI- TEN cable bolt.

• Capacity: 48,500 lbs

• Bleed off: 15% i.e. cable lock-off load is 85% of pulling force due to seating loss. (for a typical 12ft bolt)

OPERATION

Install the plate and wedge barrel with wedge on the end of the cable bolt.

Push the Cable Tensioner on. It will self-lock onto the cable.

Tension bolt to the desired load per hydraulic gage included with the unit.

air actuated hydraulic pump

View of lanyard

After stressing, the Cable Tensioner is easily removed by pulling on the lanyard to release the internal grippers.

Product code(s)

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Matrix (kit) TEN22152US (51lbs) Tensioner jack TENNUNIT22152US Pump TENFP280 (11lbs)


6 . 2 b CABLE TENSIONER CBJ-

1

High Pressure System


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6 . 3 CABLE SPIN ADAPTOR

Cable Spanners to mix epoxy resin

for tensionable bolts

for passive bolts

Cable Bolt wrenches allow to mix epoxy resin cartridges.

Cable bolt installing wrenches to suit 0.6”, 0.7” and 0.9” cable.

• The spanners suit both passive and tensionable cable bolts.

• The spanners for tensionable cable bolt have 8” long throat to leave a cable tail protruding after installation and mixing long enough to tension with the DYWIDAG cable tensioner.

• Drive end to suit various bolter drives: 7/8” hex, 1-1/8” suqre or 1-1/8” hex or as required.

• Overall spanner length is designed to suit mine specific needs.

• The cable drive spanners have a patented hardened, internal hex pattern that allows to spin cables without end-preparation which reduces cost for the bolt.

• When mixing resin, observe the mixing time and number of revolutions recommended by the resin manufacturer.

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6 . 4 PULL TEST GEAR

• Center hole jack• Pump• Pressure gauge• Chair• Hoses• Claw with pull rod

Complete DYWIDAG pull test gear to conduct underground pull testing of

• Cable Bolts• DYWIDAG Bolts• Headed and Threaded Bolts• Friction Bolts

Pull gear is set up for testing of nominated bolts to allow non-destructive or destructive load testing. We recommend regular pull testing of bolting system.

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6 . 5 CABLE TRUSS TENSIONER

for 0.6" cable truss coupler

Ram Area: 6.77 inch2

30 ton center hole jack (double acting)

Auto-release internal grippers

Open throat banana nose with centering ring to fit cable truss coupler (dogbone)

Total Weight: 56 lbs

We recommend to stress 0.6” cable trusses to 20 tons minimum.


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6 . 6 FRICTION BOLT

INSTALLATION ACCESSORIES


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6 . 7 SCALING BARS


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6 . 8 Rebar Bolt Tools

FOR STOPERS/JACKLEGS


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6 . 9 General Tools

AND HARDWARE


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Straps

Documents

Transcript of Straps