Republic of the Philippines . 'LR1.

1 DP~H
DEPARTMENT OF PUBLIC WORKS AND HIGHWAYS II. da. d.OI~
CENTRAL OFFICE lIr" r/~ (0.'/ I
Manila

October 30, 2019

MEMORANDUM

TO PROJECTDIRECTORS
REGIONAL DIRECTORS
DISTRICT ENGINEERS
This Department

SUBJECT DPWH Standard Specification for ITEM 453 - ROCK BOLTS

In order to ensure uniformity in the application/ adoption of the Pay Items of Work to be
used/ adopted by those who are involved in the preparation of the Design Plans and
Quantities, Program of Works (POW) and Approved Budget for the Contract (ABC) for
Infrastructure Projects Nationwide, the attached DPWH Standard SpeCification for
Item 453, Rock Bolts is hereby prescribed for this purpose.

This Standard Specification was deliberated and subsequently confirmed by the DPWH
Technical Committee created specifically for this purpose and shall henceforth form part of
the on-going revision of the DPWHStandard Specificationsfor Highways, Bridgesand Airports,
Volume II, 2012 Edition and is now included in the Project and Contract Management
Application (PCMA).

er guidance and compliance.

IN, CESO I
for UPMOOperations
Services

14.1.2 FET/RPF
 DPWH STANDARD SPECIFICATION FOR
ITEM 453 - ROCK BOLTS

453.1 Description

This Item shall consist of furnishing of materials, labor, equipment, and installation of all
grouted rock bolts in accordance with this Specification and as shown on the Plans.

453.2 Material Requirements

453.2.1 Rock Bolts

Rock bolts shall be grade 60 in accordance to the requirements of ASTM A615M, Standard
Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement and
ASTM F432, Standard Specification for Roof and Rockbolt and Accessories. The outer end of
rock bolt shall be threaded counterclockwise along a length of at least 150 mm. Threaded end
of rock bolts shall be coated with grease and packed with PVC cloth or other materials for
protection from damage. The protruding end of anchor and sharp edges of the washers and
bearing plates shall be covered with cement mortar or other materials approved by the
Engineer. The main purpose of covering is to protect the waterproofing sheet from potential
damage.

453.2.2 Bearing Plates, Washer, and Nuts

Bearing plates, nuts and washers shall conform to rolled steel for general structure, Grade D
manufactured according to ASTM A36M, Standard Specification for Carbon Structural Steel,
ASTM A283M, Standard Specification for Low and Intermediate Tensile Strength Carbon Steel
Plates and ASTM A709M, Standard Specification for Structural Steel for Bridges and be of the
sizes and dimensions shown on the Plans.

453.2.3 Mortar

Mortar for grouting of rock bolts shall be approximately one-part cement and one-part sand
mixed with appropriate water and admixture to provide a consistency that shall enable
grouting to continuously flow into the drilled holes. The water cement ratio of the grouting
shall be between 0.35 and 0.45.

A mortar mixture shall have a 28-day compressive strength of 24 MPa tested in accordance
to the applicable requirements of ASTM C579, Standard Test Methods for Compressive
Strength of Chemical - Resistant Mortars, Grouts, Monolithic Surfacings and Polymer
Concretes.

If premix rapid hardening mortar will be used for grouting, it shall conform to the above
requirements and approved by the Engineer.

The Engineer may at any time direct the Contractor to provide and test any number of cement
mortar cubes at no additional cost.
 DPWH Standard Specification for
Item 453 - Rock Bolts
Page 2 of 5

Sand used with cement mortar mixes shall be natural or manufactured sand conforming to
the requirements of ASTM Cl44, Standard Specification for Aggregate for Masonry Mortar,
and having the following gradation:

.
Ta ble 453 1 Gra d·mg Requlrements f or F·me A~ggregates
Finer - % by weight Finer - % by weight
Sieve Size
(Natural Sand) (Manufactured Sand)
No.4 (4.75 mm) 100 100
No.8 (2.36 mm) 95 to 100 95 to 100
No.16 (1.18 mm) 70 to 100 70 to 100
No. 30 (600 ~m) 40 to 75 40 to 75
No. 50 (300 ~m) 10 to 35 20 to 40
No.100 (150 ~m) 2 to 15 10 to 25

No. 200 (75~m) o to 5 o to 10

Cement used for grouting shall conform to the applicable requirements of ASTM C150M,
Standard Specification for Portland Cement.

Water shall be in accordance with Item 714, Water.

453.2.4 Admixtures

Admixtures shall conform to the requirements of ASTM C494M, Standard Specification for
Chemical Admixtures for Concrete, Type C or E.

453.3 Construction Requirements

453.3.1 Submittals

The Contractor shall provide, but not limited to the following information to the Engineer for
his approval not later than 28 days before the intended commencement.

1. Manufacturer's Certificates of rock bolts, bearing plates, washers, and anchor nuts.
2. Detailed description of stressing methods, complete list of equipment to be used and its
calibrations.
3. Cement mortar:
a. Mix design including water cement ratio, compressive strength and sand gradation
and data.
b. Cement and admixtures test results.

453.3.2 Drilling for Rock Bolts

Bore holes shall be drilled to a depth of 300 mm beyond the specified length of rock bolts and
perpendicular to the rock surface within the maximum angle of 15 degrees.
 DPWH Standard Specification for
Item 453 - Rock Bolts
Page 3 of 5

453.3.3 Installation of Rock Bolts

All drill holes shall be completely cleaned of dust, sludge and debris before installation of
grout.

The diameter of drill holes shall be 1.5 to 2 times of the rock bolt diameter.

Cement mortar grouting of drill holes shall proceed continuously from the end of the drill hole
until the whole length of hole is completely filled.

Soon after filling the drill hole with grout, rock bolt shall be inserted.

In cases where a rock bolt cannot be advanced to the required depth, due to a collapse of the
borehole wall, failure of the rock bolt or other physical difficulties that may, in the opinion of
the Engineer, cause the bolt to be unable to provide the necessary strength, installation shall
be discontinued and the Contractor shall either enlarge the hole, re-grout and reinstall, or
provide an alternative anchor bolt by drilling a new hole nearby the failed rock bolt as directed
by the Engineer.

The failed rock bolt shall be retracted and the hole shall be re-grouted to fill the gap. If the
failed rock bolt cannot be retracted, the failed rock bolt shall be cut flush with the borehole
mouth and covered the cut edge with cement mortar. No additional payment shall be made
for unsuccessful rock bolt installation.

453.3.4 Pullout Test and Quality Control

1. Testing Procedures

The rock bolts shall be tested to confirm the design pullout strength at the minimum age of 3
days. The pullout test shall conform to the requirements specified by ASTM 04435, Standard
Test Method for Rock Bolt Anchor Pull Test. Pullout tests shall be one test for every 50 rock
bolts installed or fraction thereof.

2. Rock Bolt Testing Equipment

All equipment for testing of rock bolts shall be provided by the Contractor and be available at
sites so that testing can be accomplished at any time at the discretion of the Engineer.

The rock bolts can be pulled using a torque wrench or a hydraulic jack, as approved by the
Engineer, capable of applying load up to the pullout load of the tested bolt (threaded portion).
The testing equipment shall be calibrated every three months. The Contractor shall provide
the operating manuals of the torque wrench and/or the hydraulic jack, as the case may be,
including the most recent calibration results to the Engineer for information and approval prior
to the commencement of any rock bolt installation.

3. Evaluation Criteria

Efficiency of grouted rock bolts will be evaluated by pullout testing as stated herein.
 DPWH Standard Specification for
Item 453 - Rock Bolts
Page 4 of 5

4. Treatment of Failed Bolts

Rock bolts, which failed the test, shall remain in place and install a new one at a location
determined by the designer and approved by the Engineer. Corrective work shall not be
subject to payment.

453.3.5 Final Rock Bolt Preparation

After pullout test and confirmation that no additional tunnel deformations are observed by the
Engineer, the Contractor shall proceed with the final rock bolt preparation. It shall consist of
the installation of bearing plate, washer and nut, cutting off the excess length of the rock bolt
flushed with the top surface of the tightening nut, and covering the rock bolt, bearing plate,
washer and nut with cement mortar mix.

453.3.6 Grouting Requirements

The compressive strength for 50mm cube specimen of at least lOMPa at 1 day per batch,
sampled and tested in accordance with ASTM C579, is required before proceeding to the next
tunneling activity. If the compressive strength of the grout failed to attain the requirement,
the hole shall be re-grouted to fill the gap.

453.4 Method of Measurement

The accepted quantity of rock bolts shall be paid per set of the rock bolt installed as indicated
on the Plans.

453.5 Basis of Payment

The accepted quantity, measured as prescribed in Section 453.4 Method of Measurement,

shall be paid for in accordance with the applicable unit prices as indicated in the Bill of
Quantities. The payment shall be full compensation for furnishing all labor, materials, tools,
equipment and incidentals involved in installing the rock bolts (including testing), completely
in placed as shown on the Plans and in this Specification.

Payment shall be made under:

Unit of
Pay Item Number Description
Measurement
al Rock Bolts 2.0 m Ion Set
a2 Rock Bolts 3.0 m Ion Set
a3 Rock Bolts 4.0 m Ion Set
a4 Rock Bolts 5.0 m Ion Set
a5 Rock Bolts 6.0 m Ion Set
, L •

DPWH Standard Specification for

Item 453 - Rock Bolts
Page 5 of 5

References:
1. ASTM F432 - Standard Specification for Roof and Rock Bolts and Accessories
2. ASTM A 615- Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete
Reinforcement
3. ASTM A 709 - Standard Specification for Structural Steel for Bridges
4. ASTM C 579 - Standard Test Methods for Compressive Strength of Chemical-Resistant Mortars, Grout,
and Monolithic Surfacing and Polymer Concrete.
S. ASTM C 494 - Standard Specification for Chemical Admixture for Concrete
6. ASTM 04435 - Standard Test Method for Rock Bolt Anchor Pull Test
7. Standard Specifications for Tunneling-2006: Mountain Tunnels
8. ASTM C 150 - Standard Specification for Portland Cement
9. ASTM A283, Standard Specification for Carbon Structural Steel
10. ASTM C476, Standard Specification for Grout for Masonry and 453.2.4, Admixture
11. ASTM CS79, Standard Test Method for Compressive Strength of Chemical-Resistant Mortars Grout
Monolithic Surfacing, and Polymer Concretes.
12. ASTM CI019, Standard Test Method for Sampling and Testing Grout
13. ASTM Cl44 Standard Specification for Aggregate for Masonry Mortar
14. Item 714 - Water of DPWH Standard Specifications for Highways, Bridges and Airports, Volume II, 2012
Edition