BS 7861-1:2007
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Strata reinforcement support system components used in coal mines – Specification for rockbolting
| Published By | Publication Date | Number of Pages |
| BSI | 2007 | 52 |
This Part of BS 7861 specifies dimensional, material and performance requirements for rockbolting support system components used in coal mines. Components included are steel rockbolts, glass reinforced plastics (GRP) rockbolts, resins, nuts, conical seats and domed washer plates.
This British Standard does not cover the assembly or installation of these components to form a rockbolting support system on site.
PDF Catalog
| PDF Pages | PDF Title |
|---|---|
| 3 | Contents 1 Scope 1 2 Normative references 1 3 Terms and definitions 2 4 Steel rockbolts and components 4 5 Glass fibre reinforced plastic (GRP) rockbolts and components for use in the sides 6 6 Resins and capsules 9 7 System type tests – Steel rockbolts 10 8 System type tests – GRP rockbolts 11 Annexes Annex A (normative) Tensile test on steel bar 12 Annex B (normative) Resistance to brittle fracture 12 Annex C (normative) Breakout facility torque test 14 Annex D (normative) Tensile test to establish flattening and pull through loads of steel domed washer plate assemblies 15 Annex E (normative) Alignment test 17 Annex F (normative) Fire resistance test on non-metallic components 18 Annex G (normative) Torsional strength test on GRP bar 20 Annex H (normative) Tensile strength test on GRP bar 21 Annex I (normative) Minimum tensile strength of GRP rockbolt bar 23 Annex J (normative) Flexural strength tests on GRP rockbolt bar 25 Annex K (normative) Tensile test to establish GRP bolt assembly failure load 26 Annex L (normative) Determination of uniaxial compressive strength (UCS) of resin 28 Annex M (normative) Determination of elastic modulus of resin 29 Annex N (normative) Determination of creep of resin 31 Annex O (normative) Tensile test on rockbolt threaded end 33 Annex P (normative) Shear test on rockbolt/resin system 34 Annex Q (normative) Determination of bond strength and system stiffness 36 Bibliography 44 List of figures Figure 1 – Example of a steel rockbolt assembly in situ 3 Figure B.1 – Charpy impact specimen – machining from bar details 13 Figure C.1 – Arrangement for nut breakout torque test for GRP rockbolts 15 Figure D.1 – Load test arrangement for tensile test flattening and pull through loads of steel domed washer plate 16 Figure E.1 – Alignment capacity of conical seat and domed washer plate assembly 17 Figure F.1 – Draught-free cabinet for flame test 19 Figure G.1 – Arrangement for torsional strength test on GRP bar 20 Figure H.1 – Arrangement for tensile test on GRP bar 22 Figure I.1 – Double embedment tensile test – schematic diagram 24 Figure J.1 – Arrangement for flexural strength test on GRP bar 25 |
| 4 | Figure K.1 – Load test arrangement for GRP components 27 Figure M.1 – Arrangement for elastic modulus test and creep test: machine platen 31 Figure O.1 – Arrangement for tensile test on rockbolt threaded end 33 Figure P.1 – Sectional diagram of shear frame 34 Figure Q.1 – General arrangement of lathe-based pull test apparatus 37 Figure Q.2 – General arrangement of hydraulic pull test apparatus 38 Figure Q.3 – Hydraulic biaxial pressure cell 39 Figure Q.4 – Rock core performance envelope 43 Table 1 – Colour coding of rockbolt length 5 Table 2 – Resin setting times at 27 ˚C 10 Table Q.1 – Standard consumables and criteria for rock core performance testing 42 |
| 5 | Foreword |
| 7 | 1 Scope 2 Normative references |
| 8 | 3 Terms and definitions 3.1 bond strength 3.2 breakout facility 3.3 brittle fracture 3.4 conical seat 3.5 domed washer plate 3.6 equivalent diameter 3.7 flexural strength 3.8 gel time 3.9 hand held machine 3.10 resin 3.11 rockbolt |
| 9 | 3.12 rockbolt assembly Figure 1 Example of a steel rockbolt assembly in situ 3.13 rockbolting support system 3.14 setting time 3.15 system stiffness |
| 10 | 4 Steel rockbolts and components 4.1 Rockbolt 4.1.1 Rockbolt bar 4.1.1.1 Composition 4.1.1.2 Profile 4.1.1.3 Diameter 4.1.1.4 Straightness 4.1.1.5 Tensile properties a) the minimum yield strength shall be 640 N/mm2; b) the tensile strength shall be at least 20% greater than the yield strength on each tensile test; c) the elongation after fracture (A) shall be a minimum of 18% and the elongation at maximum force (Agt) shall be a minimum of 8%. 4.1.1.6 Resistance to brittle fracture a) no more than two of the individual values shall be lower than 27 J; b) no more than one individual value shall be lower than 19 J; c) the average value of all tests shall be no lower than 27 J. 4.1.2 Manufacture 4.1.2.1 Proximal end 4.1.2.2 Distal end |
| 11 | 4.1.2.3 Length Table 1 Colour coding of rockbolt length 4.1.2.4 Corrosion protection 4.1.3 Supplier identification 4.2 Nut 4.2.1 General 4.2.2 Nut breakout type test a) high torque range 100 Nm to 185 Nm; b) low torque range 35 Nm to 80 Nm. |
| 12 | 4.3 Domed washer plate/conical seat 4.3.1 Material 4.3.2 Form 4.3.3 Supplier identification 4.3.4 Performance requirements 4.3.4.1 Assembly load a) flatten under a load of 50% to 70% of the nominal breaking load of the bar, based on the equivalent diameter and a stress of 770 N/mm2; b) allow pull-through of the rockbolt, nut and conical seat assembly under a load (the maximum tensile load or pull-through load) of 70% to 95% of the breaking load of the bar, based on the equivalent diameter and a stress of 770 N/mm2. 4.3.4.2 Alignment 5 Glass fibre reinforced plastic (GRP) rockbolts and components for use in the sides 5.1 Rockbolt 5.1.1 Rockbolt bar 5.1.1.1 Composition 5.1.1.2 Profile |
| 13 | 5.1.1.3 Diameter 5.1.1.4 Straightness 5.1.1.5 Electrical resistance 5.1.1.6 Fire resistance 5.1.1.7 Torsional strength 5.1.2 Manufacture 5.1.2.1 Proximal end 5.1.2.2 Distal end 5.1.2.3 Length 5.1.3 Type tests 5.1.3.1 Tensile strength 5.1.3.2 Flexural strength |
| 14 | 5.2 Nut, conical seat and domed washer plate 5.2.1 Material properties 5.2.1.1 Electrical resistance of the nut, conical seat and domed washer plate 5.2.1.2 Fire resistance of domed washer plate 5.2.2 Form of the nut, conical seat and domed washer plate 5.2.3 Supplier identification 5.2.4 Breakout facility for the nut 5.2.5 Type tests 5.2.5.1 Nut breakout test 5.2.5.2 Assembly load test 5.2.5.3 Alignment test |
| 15 | 6 Resins and capsules 6.1 General 6.2 Capsule material 6.3 Capsule size 6.4 Shelf life of resins 6.5 Packaging of capsules a) manufacturer’s name; b) type of resin; c) size of capsule; d) quantity of capsules; e) colour code, as specified in Table 2; f) gel and setting time at 27 ˚C (see 6.6); g) shelf life and storage conditions; h) date of manufacture; i) weight; j) batch or time reference; k) manufacturer’s identification; l) the symbols, risk and safety phrases as required under the current legislation [2]; m) installation procedure, taking into account the Control of Substances Hazardous to Health Regulations 2002 [3]. |
| 16 | 6.6 Gel and setting times of mixed resin Table 2 Resin setting times at 27 ˚C 6.7 Mechanical performance criteria for resins 6.7.1 Uniaxial compressive strength (UCS) 6.7.2 Elastic modulus 6.7.3 Resistance to creep 6.7.4 Re-testing of resin 7 System type tests – Steel rockbolts 7.1 Tensile test of threads 7.2 Shear test |
| 17 | 7.3 Bond strength and system stiffness 8 System type tests – GRP rockbolts 8.1 Tensile test of threads 8.2 Shear test 8.3 Bond strength and system stiffness |
| 18 | Annex A (normative) Tensile test on steel bar A.1 Principle A.2 Apparatus A.3 Procedure A.3.1 Sample size A.3.2 Method A.4 Results Annex B (normative) Resistance to brittle fracture B.1 Principle B.2 Apparatus |
| 19 | B.3 Procedure B.3.1 Sampling Figure B.1 Charpy impact specimen – machining from bar details B.3.2 Method B.3.3 Results |
| 20 | Annex C (normative) Breakout facility torque test C.1 Procedure for steel rockbolts C.1.1 Sample size C.1.2 Method C.1.3 Results C.2 Procedure for GRP rockbolts C.2.1 Sample size C.2.2 Method C.2.3 Results |
| 21 | Figure C.1 Arrangement for nut breakout torque test for GRP rockbolts Annex D (normative) Tensile test to establish flattening and pull through loads of steel domed washer plate assemblies D.1 Apparatus |
| 22 | Figure D.1 Load test arrangement for tensile test flattening and pull through loads of steel domed washer plate D.2 Procedure D.2.1 Sample size D.2.2 Method D.3 Results |
| 23 | Annex E (normative) Alignment test E.1 Principle E.2 Apparatus Figure E.1 Alignment capacity of conical seat and domed washer plate assembly E.3 Procedure E.3.1 Sample size E.3.2 Measurement |
| 24 | E.4 Results Annex F (normative) Fire resistance test on non-metallic components F.1 Principle F.2 Apparatus F.3 Procedure F.3.1 Sample size F.3.2 Method |
| 25 | F.4 Results Figure F.1 Draught-free cabinet for flame test |
| 26 | Annex G (normative) Torsional strength test on GRP bar G.1 Principle G.2 Apparatus Figure G.1 Arrangement for torsional strength test on GRP bar G.3 Sample size |
| 27 | G.4 Procedure G.5 Results Annex H (normative) Tensile strength test on GRP bar H.1 Principle H.2 Apparatus H.3 Test specimens H.4 Procedure |
| 28 | H.5 Results Figure H.1 Arrangement for tensile test on GRP bar |
| 29 | Annex I (normative) Minimum tensile strength of GRP rockbolt bar I.1 Principle I.2 Apparatus a) a tensile testing machine calibrated in accordance with BS EN ISO 7500-1, having a suitable recording facility; b) a suitably calibrated test rig which permits application of load at a steady rate and in an axial direction relative to the tube assembly. I.3 Procedure I.3.1 Sample preparation I.3.2 Testing |
| 30 | I.3.3 Results Figure I.1 Double embedment tensile test – schematic diagram |
| 31 | Annex J (normative) Flexural strength tests on GRP rockbolt bar J.1 Principle J.2 Apparatus Figure J.1 Arrangement for flexural strength test on GRP bar J.3 Sample size |
| 32 | J.4 Procedure J.5 Results Annex K (normative) Tensile test to establish GRP bolt assembly failure load K.1 Principle K.2 Apparatus |
| 33 | Figure K.1 Load test arrangement for GRP components K.3 Procedure K.3.1 Sample size K.3.2 Method K.4 Results |
| 34 | Annex L (normative) Determination of uniaxial compressive strength (UCS) of resin L.1 Principle L.2 Apparatus L.3 Procedure L.3.1 Preparation of test specimens L.3.2 Method |
| 35 | L.4 Results Annex M (normative) Determination of elastic modulus of resin M.1 Principle M.2 Apparatus M.3 Procedure M.3.1 Preparation of test specimens |
| 36 | M.3.2 Method M.4 Results |
| 37 | Figure M.1 Arrangement for elastic modulus test and creep test: machine platen Annex N (normative) Determination of creep of resin N.1 Principle N.2 Apparatus |
| 38 | N.3 Procedure N.3.1 Preparation of test specimens N.3.2 Method N.4 Results |
| 39 | Annex O (normative) Tensile test on rockbolt threaded end O.1 Principle O.2 Apparatus Figure O.1 Arrangement for tensile test on rockbolt threaded end O.3 Procedure O.3.1 Sample size O.3.2 Loading |
| 40 | O.4 Results Annex P (normative) Shear test on rockbolt/resin system P.1 Principle P.2 Apparatus Figure P.1 Sectional diagram of shear frame |
| 41 | P.3 Procedure P.3.1 Sample size P.3.2 Preparation of test assemblies P.3.3 Curing P.3.4 Method P.4 Results |
| 42 | Annex Q (normative) Determination of bond strength and system stiffness Q.1 Principle Q.2 Apparatus |
| 43 | Figure Q.1 General arrangement of lathe-based pull test apparatus |
| 44 | Figure Q.2 General arrangement of hydraulic pull test apparatus |
| 45 | Figure Q.3 Hydraulic biaxial pressure cell |
| 46 | Q.3 Procedure Q.3.1 Rock core preparation Q.3.2 Installing rock core in biaxial cell Q.3.3 Drilling Q.3.4 Bolt installation |
| 47 | Q.3.5 Pull testing Q.3.6 Core examination Q.4 Results |
| 48 | Q.5 Rock core performance criteria Table Q.1 Standard consumables and criteria for rock core performance testing |
| 49 | Figure Q.4 Rock core performance envelope |
| 50 | Bibliography [1] The Health and Safety at Work etc. Act 1974. London: TSO [2] The Chemicals (Hazard Information and packaging for Supply) Regulations 2002. London: TSO [3] The Control of Substances Hazardous to Health Regulations 1995. London: TSO [4] Shuter, DM. Enhanced standards for rockbolts HSL report MM/00/09 September 2001 [5] Shuter, DM, Geary W and Heyes PF. Engineering performance of Mining Rockbolts. In the proceedings of the 29th International Conference on Safety in Mines Research Institute. Szczyrk, Poland 8-11 October 2001. ISBN 83-87610-32-1 [6] International Society for Rock Mechanics Commission on Standardization of Laboratory and Field Tests, “Suggested Methods for… |
