Suggested Methods for Rockbolt Testing PART 1. SUGGESTED METHOD FOR DETERMINING THE STRENGTH OF A. ROCKBOLT ANCHOR (PULL TEST) SCOPE. 1. (a) This test is intended to measure the short-term strength of a rockbolt anchor installed under field con itions [1*], Strength is measured by a pull test in which bolt head displacement is measured as a function of the applied bolt load to give a load-displacement curve. The testis usually employed for selection of bolts and also for control on the quality of materials and installation methods (2). (b) At least five tests are required to evaluate an anchor in a given set of rock and installation conditions [1]. The tests are destructive and should not in general ‘be made on bolts that form part of the actual rock- support system. APPARATUS 2. Equipment for installing the test anchors, includ- ing: (a) Equipment for drilling and cleaning the drilthole, conforming to the manufacturer's specifications for optimum performance of the anchor provided that these are compatible with field conditions (3). (b) Equipment for inspection and measurement of the drillhole, anchors and bolts, for example a lamp, steel tape, internal and external calipers and equipment for ‘measuring the quantity of grout if used {) Standard rockbolt assemblies as supplied by manufacturers of the bolts including anchors to be tested, grout and materials for grout injection if required, and equipment for installing the bolts in the ‘manner recommended by the manufacturers [3], 3, Equipment for applying the bolt load, for example as in Fig. 1, including: (a) A hydraulic jack with hand pump and pressure hhose capable of applying a load greater than the strength of both the anchor and the bolt to be tested and with travel of at least 50 mm, (5) Equipment for transferring the load from the jack to the bolt £4]. A spherical seating, bevelled washers and/or wedges under the jack are required to ensure that the applied load is coaxial with the bolt. * Numbers refer to Note lemized a te end of Part 4. Equipment for measuring load and displacement including: (a) A load-measuring device, for example a load cell or a hydraulic pressure gauge connected to the pump and calibrated in load units. Measurement should be accurate to 2%, of the maximum load reached in the test. The device should include a maximum load indi- ator. (b) Equipment for measuring the axial displacement of the bolt head (travel at east 50 mm and accurate to 0.05 mm) [5]. For example, 2 single diel gauge measur- i directly on to the bolt head may be used, alterna- tively the displacement may be obtained as an average from two or three gauges spaced equidistant from the boit as shown in Fig. 1b. 5.(a) A data sheet for recording results (eg. Fig. 2) PROCEDURE 6 Site preparation (a) The test site of sites are selected to ensure that rock conditions are representative of those in which the bolts are to operate (11 ) Holes are dried as specified [3] and at locations convenient for testing (1,3}. The rock face surrounding act hole should be firm and fat and the hole should be perpendicular to the face (5°) (©) Driliholes and anchor materials are inspected before installation to ensure that they conform to speci= fications. Preliminary data, for example the measured dimensions of the drilthole, bolt and anchor and the type and condition of rock at the test location, are recorded on the data sheet (eg. Fig. 2). 8 consign sonnet Fig |. Rockbolt sting equipment 168International Society for Rock Mechanics ROCK ANCHOR TEST Date of fnstatiation: PROJECT ‘ANCHOR: Type ROCK: Clossifeation BOLT: Diameter: BOLE: Diameter: RESULT SHEET Date of test ‘Untesstoned length: — - Pomp Pressure Displacement veadings Reading [Dicplacement ‘TEST RESULTS! Displacement at maximum pull fore: ature of failure ce yields ‘Ower remarks: ‘TESTED BY: ‘taximam pull fore Max. dtoplacerest in tes (CHECKED BY: Fig.2, Rockbot tet datasheet (a) Bolts are installed in the specified manner (3), essential details such as the installation torque (if any) [4] and the date and time of installation, 7. Testing . (a) The loading equipment is assembled, taking care to ensure that the direction of pull is axial to the bolt, ‘that the equipment sits firmly on the rock, and that no part of the bolt or grout column will interfere with the application or measurement of load during the test [5]. (b) An (500kg ) is applied to take up slack in the equipment. The displacement equipment is assembled and checked (6) - {€) The anchor is tsted by increasing the load until a total displacement greater than 40mm fas beea recorded, or until the bolt yields or fractures if this occurs fist (a) Readings of load and displacement are taken atSuggested Methods for Rockbolt Testing reer strengy 99 ood Ro + Sait mand septecemen Fig, 3. Example of anchor rest results graph. ncrements of approximately SKN (500 ke) load or ‘mm displacement whichever occurs first, The rate of oad application should be in the range 5-10 kN/min. Xeadings are only taken after both load and displace- aent have stabilized. The times required for stabiliz- sion should be recorded CALCULATIONS 8.(a) Tota! displacement values are computed as the 2st progresses by subtracting initial readings from the scremental readings, taking averages if more than one auge is used. (b) The test data are plotted graphically as shown in ig. 3. Anchor strength, defined as the maximum load ‘ached in the test provided that the bolt itself does not field o fal, is recorded on this graph. If the boit yields ¥ (ails the load °X’ at which this occurs is recorded, nd the anchor strength is specified as “unknown but treater than °°” [2], (©) The elastic ciongation of the bolt at a given plied load may be calculated as Pxk axe here £ is the teasioned ungrouted length of bolt + ve-tird the grouted length + length of extension bar sed, Ais the cross-sectional area of bott, is the Modulus of Elasticity of bolt stel straight line X-X is constructed to pass through this sint and the origin of the load-displacement graph jg. 3) Straight lines Y-Y and Z-Z are constructed at = specified yield and ultimate loads of the bolt. Com- ison of the actual test curve with these three lines ows independent assessment of anchor and bolt be- our. (4) For the evaluation of grouted anchors, the results Elongation at load Pis equel to 165 of several tests should be abstracted and presented graphically to show the influence of grout cure time and bonded length on anchor strength (e.g. Fig. 4, REPORTING OF RESULTS 9. The report should include the data sheets and graphs illustrated in Figs. 2-4 together with full details of: (a) rock in which the anchors were tested; (b) the anchors and associated equipment; (6) the drillholes, including length, diameter, method of drilling, straightness, cleanness and. dryness, orientation; (d) the method and time of installation; (e) the method and time of testing; (0) the nature of failure and other observations perti« nent to the test resuits 10. Ifrequired the report ‘may also compare perform- ance of the anchors tested with an arbitrary acceptable performance established by previous extensive testing. Both anchor strength, total displacements, and dis- placement per increment of load should be considered ‘when making this comparison. NOTES 1. It is essential to test anchors under realistic feld conditions. It is, however, permissible to select safe and convenient test locations provided that the rock and the installation methods are identical to those encoun- tered in full-scale utilization of the bolts. If the rock is schistose for example, test holes should be drilled at the same angie to the schistosity as anticipated for boit utilization. If rock conditions are variable the cock should be classified and tests carried out in rock of each class, wf ereemt neeimen ae of / Bab Pat a] Fig 4. Graph showing influence of bond length and cure time on the ‘Hrength of anchors. (The results shown are hyporncial)16 International Society for Rock Mechanics 2, The test is intended to measure anchor perform ance and this is possible only if the bolt, threads, muts and other components are stronger than the anchor. In some circumstances it may be desirable to reinforce the bolt or thread for purposes of anchor evaluation. Otherwise, ifthe bolt is consistendy weaker than the anchor, it may be preferable to replace the feld test with quality control of bolts and other components in a testing faboratory. Laboratory control testing may els be required as a supplement to feld testing for evalu- ation of components, for example their corrosion resst- ance, quality of materials and consistency of diinen- sions, 3. Manufacturer’ specifications for hole dimensions and method of installation should be checked for com- patibility with site operational limitations before test- ing, and if compatible should be closely followed in the tests 4. Some types of anchor must essentially be tensioned luring their installation, and these must be tested using 4 suitable coupling unit and bridging framework to carry load from the jack to the bolt (Fig. La). Wheaever possible, however, anchors should be tested without prectensioning of the bolt, in which case a centre-hole jack installed over the bolt may be used (Fig. 1b). The arrangement shown in Fig, 1a may algo be used to test selected anchors in an operational support system at some time after their installation, provided this does not endanger the support as a whole. The percentage of initially applied boit tension remaining at the time of test may be estimated from the load requized to just loosen the faceplate and washers. $.When testing anchors that in operation are intended to provide a reaction fot exteraal loads (eg, holding anchors for cranes, suspension cables), the test equipment should be designed so that no test reaction forces are applied closer than one.bolt length from the anchor drilhole, 6.The displacement measuring system should be securely mounted and dial gauges should locate on to firm flat rock: glass or metal plates can if necessary be ‘cemented to the rock to provide smooth measuring sur- faces perpendicular to the bolt. All measuring equip- ‘ment must be checked and calibrated at regular inter- vals to ensure that the standards of accuracy required by these “suggested methods" are maintained. PART 2. SUGGESTED METHOD OF DETERMINING ROCKBOLT TENSION USING A TORQUE WRENCH SCOPE ‘ 1.(a) This method may be used to apply a specified tension during rockbo!t installation, or to estimate loss of tension in a previously installed bolt, (b) The same method may be used to verily that anchor strength is greater than a specified value con- sistent with the maximum tension that can be applied with the wrench, Oy eng ets Teas moar a b Fig 5, Calibration of torque wrench APPARATUS 2.(a) A torque wrench, preferably with a maximum appiied torque indicator, capable of giving readings that are repeatable to $% throughout the range of torques to be measured. It should be provided with sockets suitable for the nuts or bolt heads to be tested. should be used only for testing, and should be stored. together with its most recent calibration chart in a dry place so as to preserve its accuracy of reading. (6) Equipment for calibrating the torque wrench (Fig. 5) including a rigidly fixed bolt bead. a weight pan and weights, and a measuring tape. (6) Equipment for determining the relationship between tension and torque (Fig. 6), typically an installed rockbolt and faceplate assembly identical with that to be used in practice, and a hydraulic ram with fhandpump and pressure gauge (to be used for tension measurement) or alternatively a rockbolt load cell. Ten- sion should be measured with an accuracy better than 2% of the maximum reached in the test. ~ PROCEDURE 3. Calibration of the torque wrench (a) With the wrench horizontal, the wrench socket is positioned on a rigid bolt head, A weight pan is sus- ended from the centre of the wrench handle (Fig, 5) and weights are added. The torque reading is noted, also the weight of the pan together with the weights it contains. The procedure is repeated with increasing Weights to obtain at least five torque zeadings covering the range of torques for which the wrench is to be used. The distance L between the centre of the wrench handle and that of the bolt head is recorded (b) Correct torque values are calculated by multiply ing the distance L by the applied weights. A graph is Plotted of correct torque values against torque read- Premen se state ok Fig. 6, Determination of rit tesionvtorqueSuggested Methods ings, and a straight line is fitted to the data points (Fig, 5{b). The gradient ofthis line is measured, equal to the ratio R of correct torque divided by torque reading. Torque readings later obtained when using this wrench should be multiplied-by the ratio R to obtain corrected values. () Torque wrenches should be recalibrated at inter- vals not exceeding six months. 4, Determination of the ratio C of tension to torque {a) The load cell. or altzrnatively a hydraulic ram with the ram extended to three-quarter travel, is pos- itioned concentrically and coaxially over the bolt to be tested, and the face nut is tightened to take up slack in the assembly (Fig. 6). Ram pressure should be increased, to & nomitally small value before the start of the test, and the pump valve firmly closed. {b) The bolt diameter, thread pitch, faceplate and ‘washers and their state of lubrication should be ident- ical with the conditions expected in the actual rockbolt installation, (c) Torque is applied in increasing increments to the nut, taking readings of torque and bolt tension. Torque- application should be smooth and force should be applied through the centre of the wrench handle only. At least five pairs of readings are required, covering the complete range of torques for which the wrench is to be used. (a) A graph of tension versus torque is plotted, show- ing data points and a straight line fitted to these points, The gradient C of this line, the ratio of tension to torque. is measured (Fig. 6(b). (©) The ratio C is determined separately for cach change in bolt diameter, thread pitch. state of lubrica- tion or for any other variation in the bolt/anchor/face- plate assembly that may resuit in a change in the tension/torque ratio, 5. Determination of bolt tension using the torque wrench (a) Ifa torque wrench of the type that applies a pre- set torque is used, the torque setting should be in- creased in small increments until just sufficient to cause the face nut to rotate, The torque setting, the bolt idea- tification and the date are recorded. (0) WF a torque wrench with a maximum applied torque indicator is used, the torque may be apel steadily rather than in increments. Both types of torque wrench should be used with care to ensure that loading js smooth and that force is applied through the centre of the wrench handle. (c) Bolt tension is calculated using the correction R and a value of tension/torque ratio C determined for the identical bolt and faceplate assembly conditions using method 4 above. (@) An approximate check on minimum anchor strength may be obtained by applying an increasing torque, recording this torque as a function of number of rotations until no further torque can be applied, or uni! the anchor shows signs of failing. "Numbers efor Note a the end of P 2 for Rockbolt Testing 167 REPORTING OF RESULTS 6.The report should include diagrams and graphs ag illustrated in Figs. 6 and 7, together with full details of: (@) Torque wrench calibration; type of torque wrench, methods used for calibration and results + - (0) Determination of the sension/torque ratio C; methods used and results obtained (0) The rockbolis tested; types, locations, dates installed, rock characteristics, methods used for drilling and installation, appearance and concition of the face- plate assembly at time of testing (d) The method used for tension determination; tabu lated values of bolt identification, applied torque to cause rotation of the nut, corresponding boit tension and any other observations pertinent tothe test results, 7.1f the method is used as a check on minimum anchor strengths, data should be included in the form of graphs of torque versus nut rotation, with scales con- verted to show bolt tension versus displacement. The report may compare these results with an arbitrary ac- ceptable performance established by previous extensive testing, The complete bolt tension versus displacement curve should be considered when making such a com- parison. PART 3, SUGGESTED METHOD FOR MONITORING ROCKBOLT TENSION USING LOAD CELLS SCOPE, 1. This method is for monitoring changes in tension that occur in a rockbolt over an extended period of time following installation (17. APPARATUS 2. (a) Rockbolt load cells to monitor tension in ap- proximately one bolt in ten of the support system to be studied (special considerations may require the instru- mentation of a greater or lesser percentage of bolts) The load cells may, for example, be of mechanical, photoelastic. hydraulic, electric or rubber compression pad type, depending on requirements of cost and accu- racy. The cells should have reversible and preferably linear calibrations (see paragraph 3) and should incor- orate a spherical seating or other provision to ensure that load transfer and measurement is reproducible. ‘They should be capable of withstanding the effects of nearby biasting, water and dust over long periods of time. PROCEDURE 3. Calibration of load cells {a) Calibration is required when selecting a suitable type of foad cell, and each load cell to be installed should if possible be individually calibrated before use. (b) Short-term calibration of each cell is performed in a testing laboratory by increasing the load in inere-International Society for Rock Mechanics Fig. 7. Load cal ealfration, ments, taking readings of “observed” and “true” load values [2]. Tension is released and incremental read~ ings taken during uoloading. A further cycle of toad- ing and unloading is made, and a graph piotied showing data points and curves fitted to these points Fig. 7. (6) A check should also be made on the stability of readings over extended periods of time. Tension is i ‘reased {0 a value approximately equal (o that to be measured on site, and is maintained at this value for as long a time as is practical. Any “drift” in reading is noted. The effect of water on the cell should be ob- served, also the effect of coupling and uncoupling any electrical connections. 4, Installation and monitoring (a) Load ceils are installed on selected rockbolts at the time of installation of the support system. Care should be taken to ensure that spherical seatings are correctly positioned and lubricated. Bolts that have been instrumented should be clearly and permanently ‘numbered, and may be painted for ease of recognition. Boit length, diameter, and type of anchor should also be noted. (b) Tension readings should be taken immediately following installation and again a few hours later. Further readings may be taken at intervals depending ‘on the rate at which readings are changing. In the vici- nity of an advancing face, for example, readings should be of the order of hours, whereas if steady values are ‘ecorded for bolts in inactive areas the interval between readings may be increased to days or weeks. Each read- ing should be accompanied by a record of bolt aumber, location, and the date and time of observation. fee naa % ont ten Tome, wees Fig. 8 Graph of bot tension loss. CALCULATIONS 5.(a) Bolt tension readings are corrected using the calibration charts. Graphs of boit tension versus time are piotted for each bolt (Fig. 8). For comparison the loss or'gain of tension may be reduced to 2 percentage of the initial installed value. REPORTING OF RESULTS 6. The report should include: : (a) Details ofthe load cells used, calibration methods and resulis. (0) Locations of the rockbolis monitored. {6) Details of rock characteristics, bolt and anchor types and dimensions, dates and methods of installation and grouting. (4) Monitoring resuts in the em of tabulated values and a graph of bolt tension versus time for exch bolt monitored. NOTES 1. Tension may fail below that applied at the time of rockbolt installation due to loosening and slip either of the anchor or of the faceplate assembly, for example as a result of rock creep, anchor corrosion, frelting of rock from beneath the faceplate, or blasting vibration, Ten- sion may also either rise of fall as a result of bulk rock dilation or contraction associated with the progress of nearby excavation, 2. Details of the calibrating devices and their pre- cision should be included in the report. i aati a 3 i 4 3 i 4