Secoroc Rock Drilling Tools. Swellex rock bolts

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1 Secoroc Rock Drilling Tools Swellex rock bolts

2 We are your best partner We have been working together with our customers and providing solid solutions for over 140 years. No matter where you are, we can support you with the same product, service and supply due to our widespread presence throughout the world. We are where You are. Look no further, our partnership delivers expertise, knowledge, training and support. We are the total solution to your rock reinforcement needs. Contact your local Atlas Copco representative to discuss and select the best solution for your rock reinforcement needs. 2

3 Atlas Copco's Nick Dillman - Account/Branch Manager for Newfoundland and Labrador 3

4 Swellex rock bolts Today, Swellex is a family of ground support products that covers such demanding applications as high loading, deep support, large rock deformations and corrosive environments. Products that perform 4

5 Swellex quality assurance We believe that assuring quality throughout the complete supply and distribution chain is the best way of ensuring the highest level of safety and productivity for our customers. All Atlas Copco Swellex products are manufactured according to strict ISO standards. Stringent quality control assures that high quality materials are used. Extensive quality testing is performed to assure that the products meet the Atlas Copco brand standards. Each bolt has an alphanumeric code stamped on the bushing head, making it traceable through the recorded results of testing done at each manufacturing stage. Each and every bolt is tested for leakage as part of the production process. This unique operation is augmented by full expansion in open air at 10% above recommended installation pressure. One sample bolt is removed from the production at the beginning of each shift and one when a new batch of steel profile is used. This means that 1% of all bolts are sacrificed in the name of quality assurance. We follow EN and ASTM standards to report elongation and tensile load capacity. Furthermore our bolts are tested in full section, expanded into a borehole dummy to simulate working conditions that are close to, the real use of product. 5

6 We adapt our products to new environments We support specialized applications Swellex innovation We work with our customers We deliver solutions 6

7 The Swellex system Installing a perfect rock bolt 1. Drill the hole. 2. Insert Swellex bolt. 3. Expand the bolt until preset pressure is reached for 6 seconds. 4. Perfect installation completed. The Swellex system The system consists of specific rock bolts made from steel tubes that have been folded onto themselves, bolting accessories and specially designed, high pressure, installation pumps. Swellex rock bolts are placed in drilled holes and expanded using water from the installation pump. The high pressure water causes the bolts to expand, filling the drill hole, consolidating any loose material remaining after drilling and conforms to the irregularities of the hole. A combination of friction and mechanical interlock is generated throughout the entire bolt length. Swellex bolts interact directly with the rock without the need for such auxiliaries as grouting agents or locking devices. Simply monitoring water pressure provides quality control during installation. Interaction during installation 1. Drill the hole. 2. Swellex bolt is placed. 3. Water injected under pressure forms the tube to the irregularities of the bore hole, generating friction and mechanical interlocking. 4. The internal pressure is released leaving a permanently deformed tube that is locked in place providing a strong interaction with the rock mass. 7

8 Swellex pumps ensuring Swellex system efficiency The Swellex pumps are a critical component in assuring safety and productivity of the Swellex system. Swellex Pneumatic pump PSP 300 RDP The Swellex PSP 300 RDP is a well proven sturdy and reliable high pressure water pump. It is especially suited for manual installation of Swellex rock bolts where electricity or hydraulic power are not available. Now equipped with a special valve to prevent damage to the pump when air is connected prior to water. Swellex Electric pumps E1, EC1-L The Swellex E1 pump is a robust, fast and quiet high pressure pump. It can be adapted to any type of rig or equipment where electricity is available. The electric Swellex E1 pump can be used for manual, semi-mechanized or fully mechanized bolting. The Swellex EC1-L pump offers data logging that can be retrieved via a CANbus port or downloaded via USB or Bluetooth. It is offered in versions matching your local electric requirements. Swellex Hydraulic pumps H1, H2R, HC1L The hydraulic Swellex pumps are designed to be used with hydraulic bolting rigs. They are robust and reliable pumps that can be used with a manual installation arm or integrated with the rig s installation system. The H1 is only available in stainless steel version for corrosion resistance. The Swellex H2R pump provides high corrosion resistance, for use with aggressive environment (brine water). The HC1-L is designed to assure the quality of installation by controlling the expansion until the required pressure is reached. It maintains the required pressure for a set period of time to assure perfect installation of the Swellex bolts. 8

9 Swellex pumps with intelligence built-in The Swellex EC1-L and HC1-L pumps offer data logging. Data retrieval via CANbus port or download using USB or Bluetooth. "be smart" Control Yellow light = 300 bar No light = 240 bar 3 Swellex HC1-L and EC1-L pumps take control for a perfect installation, every time. Bolts are not released until recommended pressure is reached for a minimum period of time to deliver best performance of the Swellex bolt. 1 Lamp RUN Lamp Start Stop 2 "be smart" Log Swellex HC1-L and EC1-L pumps log installation parameters, providing you with a permanent quality control record for every bolt; monitoring the safety and productivity. "be smart" Get flexible Swellex HC1-L and EC1-L pumps can be used for semi or fully mechanized installation, with separate grip and expansion functions through remote control. These pumps allow easy switching between 240 and 300 bars. They can also be used as a high pressure washer with a dedicated Swellex high pressure washer arm. Pipe, low pressure Pipe, high pressure + + Clockwise = Higher pressure Anticlockwise = Lower pressure 9

10 Swellex premium line high yielding load capacity Swellex premium line General Information Swellex Pm12 Swellex Pm16 Swellex Pm24 Minimum breaking load 110 kn 160 kn 240 kn Minimum yielding load 90 kn 140 kn 200 kn Minimum elongation 10% 10% 10% Expansion pressure 300 bar 240 bar 300 bar The Swellex Premium line rock bolts is designed as daily support for optimum control of the rock mass in mining and tunneling. The Pm line offers high yielding load capacity and a minimum of 10% elongation. Made from special steel, these rock bolts offer high yield load while preserving good elongation properties for safety. The connectable line of Swellex rock bolts, Pm24C, is a true alternative as long secondary support to secure potentially unstable areas or to control dilution while boosting productivity. Swellex manganese line the concept of the ideal rock bolt Swellex manganese line General Information Swellex Mn12 Swellex Mn16 Swellex Mn24 Minimum breaking load 110 kn 150 kn 220 kn Minimum yielding load 90 kn 100 kn 180 kn Minimum elongation 20% 20% 20% Expansion pressure 300 bar 240 bar 300 bar The Swellex Manganese line of rock bolts have been designed and developed to match the "perfect rock bolt" criteria and have set a new benchmark for safety and reliability. The Manganese line offers tensile strength and outstanding elongation capacity. Made from steel having a richer manganese content, and submitted to a specially engineered process, Swellex Mn rock bolts have high tensile strength and improved elongation that provide excellent energy absorbency in challenging mining environments. 10

11 Swellex connectable bolts long support Swellex connectable rock bolt is an ingenious system. It is a true alternative as long secondary support to secure potentially unstable areas or to control dilution while boosting productivity. By simply connecting two, three or more specially adapted Swellex rock bolt segments, you create a custom-made long rock bolt, able to penetrate deep to stable rock. Immediate support It is ideal as secondary reinforcement in difficult areas, as long anchors in stopes for dilution control or where other long anchors have problems with excessive water. Quick installation No curing time! No special crew! Recent tests have shown up to four fold increased productivity when compared to manually and semi-mechanized installed cable bolts. Peace of mind By reaching recommended expansion pressure you are assured of a perfect installation on the entire length of the bolt irrespectively of presence of water in the hole. Swellex connectables General Information Minimum breaking load Minimum yielding load Swellex Pm 24C 240 kn 200 kn Minimum elongation 10% Expansion pressure 300 bar 11

12 Swellex hanger bolts The Swellex hanger bolt offers the possibility to have a strong hanging point using Swellex technology. Installation The Swellex Pm24H is a new generation of Swellex bolt that provides strong hanging capacity. The bolt has a flanged head with a female M36 thread which is first coupled to an expansion bushing for installation. After installation the expansion bushing is replaced by an eye bolt. The rock bolt has a static axial load carrying capacity of 200 kn, however it is limited by the capacity of the eye bolt. Swellex Pm24H can be installed using standard Swellex installation equipment. NOTE: Pm24H reported performances are only valid for axial load with no dynamic or cyclic loading. Swellex hanger bolts General Information Minimum breaking load Minimum yielding load Swellex Pm 24H 200 kn 190 kn Minimum elongation 10% Expansion pressure 300 bar Swellex plasticoated bolts for corrosive environments Mining and tunneling operations are often known for their corrosive environment. The life span of a rock bolt is a key factor in selecting the appropriate rock support. Swellex rock bolts can also be supplied in a corrosion resistant version, Swellex Platicoated bolts. Specialized process A special process with stringent quality control allow a perfect plastic coating with a strong bonding and resistance to protect the entire section of the bolt in the most corrosive environment to extend the bolts' working life for productivity and safety. 12

13 Swellex accessories completing the solution Swellex face plates and wire mesh washers Swellex face plates are offered in versions to match the different environments and requirements. Performance plates are engineered to maximize the Swellex system load capacity and to meet and exceed ASTM standard. Mid performance plates will offer high load capacity while value plates offer good performance in specific environments. Swellex Mesh washers are used for the installation of wire mesh on already installed Swellex rock bolts. They are offered in different versions and sizes to match the Swellex bolt range. Swellex pull test One strong advantage of the Swellex system is that it can be tested at any time. Swellex pull testing equipment is used to perform destructive pull tests, non-destructive pull tests and anchorage pull tests. Destructive pull test are used to appraise bolt condition and maximum capacity. Non-destructive pull tests are used to validate that the bolt meets minimum required performance. Anchorage pull test are used on bolts installed with special retaining sleeves to determine anchorage capacity per length. 13

14 Swellex application project The Church of St. Peter in Turkey From a distance, the cave in the side of Turkey s Mount Starius, close to the Syrian border, looks no different to the many others that are found in this part of ancient Europe. However, this one is no ordinary cave. Measuring 13 m deep, 9.5 m wide, and 7 m high, it is believed to be one of the first founding churches of the Christian faith and a place where none other than the first apostle, St. Peter, once preached the gospel. What is known for sure is that the site, which now has walls, colonnades and an altar, was established as The Church of St. Peter in the 4th century. Today, it is a museum and one of the most popular tourist attractions in the country, but in recent years it has 14 been subjected to frequent rockfalls which threaten to destroy the church for all time. Immediate support To save and protect this iconic site, a spectacular rescue operation was recently carried out in order to eliminate the immediate risk of more rockfall and to secure the mountainside for as long as possible. For this work, Turkish contractor Kuzey Dagcılık, used professional mountaineers armed with modern rock stabilization technology from Atlas Copco. Suspended from climbing ropes high on the mountainside, they drilled a series of 48 mm holes into the rock face with Atlas Copco drill bits, using stabilizer bolts on the rock drills to prevent deviation. Each hole took approximately 10 minutes to complete. Atlas Copco Swellex rock bolts were hoisted up the rock face and inserted in the holes. Next, a Swellex pump was hoisted up and used to inflate the bolts. The total installation time was about five minutes per bolt. In this way, the section of the rock face, that posed the greatest danger to the church, was stabilized. To achieve this objective, the mountaineers needed only 25 plastic coated Pm24 Swellex bolts, 3 m and 3.6 m in length. As soon as the bolts had been inflated, they provided immediate support to the weight of the rock mass and, on some sections, wire mesh was also used. Conclusion: According to Fatih Tomba, Site Manager, the possibility of further rockfall has been averted. We came here to clean up the surface of the mountain-

15 side and found that there were huge sections of rock that were in danger of falling at any moment, he explained. It obviously needed immediate attention. In Tomba view, there was no alternative to the Swellex bolt, saying: It was the only rock bolt that could do the job properly. If we had used standard rock bolts I think they would have come down along with the rock mass. Due to the inflatable design and immediate support capability of the Swellex bolts we are confident that this won t happen. Our solution 3 m and 3.6 m plastic coated Pm24 Swellex rock bolts PSP 300 Swellex pump The Starius Mountain in Turkey consists of limestone formation. The cracks were between big rocks and main rock body. To decrease the rate of corrosion, generated by acidic effect of underground waters, plastic coated Swellex rock bolts were chosen to save and protect the 4th century Church of St. Peter from rockfalls. 15

16 We stand by our responsibilities towards our customers, towards the environment and the people around us. We make performance stand the test of time. This is what we call Sustainable Productivity. Atlas Copco Secoroc AB Box 521, SE Fagersta, Sweden Phone: c Subjected to alterations without prior notice. Atlas Copco Secoroc AB. All rights reserved