Atlas Copco Rock Reinforcement Products. Product catalogue. MAI SDA self-drilling anchors Swellex rock bolts

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1 Atlas Copco Rock Reinforcement Products Product catalogue MAI SDA self-drilling anchors Swellex rock bolts

2 Product catalogue Atlas Copco Rock Reinforcement... 3 Quality assurance means safety... 4 MAI SDA self-drilling anchors versus Swellex bolts... 6 MAI SDA self-drilling anchors... 7 Applications...8 Sacrificial drill bits...9 The selection of drill bits...9 Bit specifications...9 Hollow anchor rods...12 Extension couplings...12 Bearing plates...13 Hexagonal nuts...13 Galvanized anchors...13 MAI SDA installation methods Installation alternatives...14 MAI SDA product listing Quick reference...16 MAI SDA R MAI SDA R MAI SDA R MAI SDA T MAI SDA accessories Centralizer...26 Coupling boxes...26 Shanks...26 Grout coupling...27 MAI SDA mortar...27 MAI SDA grout pump Swellex rock bolts Swellex features...30 Applications...31 Premium line...32 Manganese line...32 Bitumen coated...33 Plastic coated...33 Swellex Pm24C - a connectable bolt...33 Swellex Pm24 H - a hanger...33 Swellex installation methods Installation alternatives...34 Swellex product listing Quick reference Swellex Premium line Swellex Pm Swellex Pm Swellex Pm Swellex Pm24C...41 Swellex Pm24H - a hanger...42 Swellex Manganese line Swellex Mn Swellex Mn Swellex Mn Swellex face plates...47 Hanging feature...47 Face plate specifications Swellex installation pumps How to choose the right pump...49 Swellex PSP 240/ Swellex H1/HC Swellex E Quality assurance Letter of compliance...53 Quality control stamps...53 Quality pressure assurance gauge...53 Pull tester...54 Steel sleeves...54 Swellex accessories Mesh washer...55 Colour plugs

3 The Rock Reinforcement center in Feistritz/Drau, Austria The Atlas Copco Swellex plant in Canada Atlas Copco Rock Reinforcement Ongoing development of faster, safer and more exotic tunnelling techniques places a constant pressure on manufacturers to provide more efficient rock support solutions which will help the shortening of cycle time. As ground conditions get more and more demanding, emphasis is placed on flexible and intelligent support systems in which rock and soil reinforcement is expected to contribute to the productivity and safety of the operation. The trend has been to provide rock support and reinforcement systems that are easy to install, assure efficiency and provide safety. For the last 25 years, Atlas Copco has been offering the Swellex TM concept as a unique, safe and reliable system of rock support. As the market leader in underground rock excavation technology, Atlas Copco has also been developing safer and more efficient rock reinforcement products such as the Manganese line rock bolts, which are manufactured from a special type of steel. Another development is the Swellex Premium line of rock bolts, for use where high yield load and stiffness are expected from the reinforcement system. When Atlas Copco bought MAI in 2001, the rock reinforcement center moved to Feistritz/Drau, Austria. This acquisition made it possible to introduce a whole new range of products for Atlas Copco customers, the MAI SDA TM anchors, which are now being developed for mechanized installation by both surface and underground drill rigs, creating fresh applications in rock and soil reinforcement. Atlas Copco s Rock Reinforcement Center in Austria brings together the skills necessary for the development of superior rock reinforcement products to serve the tunnelling, mining and construction industries worldwide. The combined product portfolio includes Swellex rock bolts and MAI SDA anchors with all necessary accessories. The strategy to act as The professional supplier of specific and complete solutions in rock and soil reinforcement has paid off, and the effort to invent and commit ourselves to more productive solutions is stronger than ever. 3

4 Quality assurance means safety Quality assurance for safer reinforcement Safety in a mine is not something Atlas Copco, takes lightly. It s a major issue for those who own and those who work there. A minor fault in a reinforcement bolt may prove fatal. That s why Atlas Copco rock bolts are rigorously tested to ensure the best possible quality and reliability. In fact our Quality assurance system is the most comprehensive on the rock reinforcement market today. ISO - Management systems that work harder ISO standards represent the best management systems for quality and environmental issues. It s therefore not surprising that Atlas Copco is ISO 9001 certified to systematically control overall quality. The company is also ISO certified to minimise the environmental impact of the company. These are applied at every Atlas Copco manufacturing plant as well as every distribution and customer centre. They basically form the basis of the company s Quality Assurance program. Quality control starts at the suppliers... ISO certification is the prerequisite for every Atlas Copco supplier. Whether it s rods for MAI self drilling anchors or steel profiles for Swellex, suppliers have to follow our specified tolerances. To ensure their quality, we test every batch for deviations and register the results....and ends at the clients To confirm that finished bolts can withstand the working pressures stipulated, we carry out destructive tests on samples of Swellex bolts and MAI self-drilling anchors. And if this is not enough, every bolt is stamped with its own number. So should a problem arise, the cause can be efficiently traced back and action can be taken promptly to rectify it. In accordance with ISO9001, Atlas Copco has developed comprehensive instruction and training material to enable end-users to install bolts and anchors correctly and safely. 4

5 MAI SDA self-drilling anchors There are two important quality parameters for a MAI self-drilling anchor. Firstly, that anchors can withstand the stipulated working pressure and, secondly, that couplings and bits can be easily threaded. Ultimate load tests are carried out on 1 in 200 of the manufactured anchors. A special test bench pulls these anchors until they break and the results are monitored. Should an anchor fall short of the given tolerances, production is stopped and the fault is rectified. Atlas Copco MAI also offers a hot dip galvanized MAI self-drilling anchor. This galvanised layer has to be the right thickness for the couplings and bits to be threaded on properly. Again, a sample of anchors is removed from the production line during each shift and the thickness of the galvanisation is tested and registered. Swellex rock bolts This expandable rock bolt is more complex to manufacture than a MAI SDA. The steel profile is pressed into shape and a bushing is welded on the open end-piece. As pressurised water is used to install a Swellex bolt in the hole, leakages are not wanted. That s why each and every bolt is tested for leakage as part of the production process. This unique operation is augmented by destructive expansion tests where 1 bolt in 200 is pressurised to the limit to ensure that the batch can withstand a minimum a working pressure of 300 bar. In effect, one sample bolt is removed at the beginning of each shift and one when a new batch of steel profiles is used. This means that 1% of all bolts are sacrificed in the name of quality assurance. We, at Atlas Copco, believe that assuring quality throughout the complete supply and distribution chains is the best way of ensuring the highest level of safety for our customers. Quality assurance means safety 5

6 MAI SDA anchors versus Swellex bolts The Atlas Copco MAI SDA is a unique bolting solution for unstable ground conditions such as sand, gravel, silt, and clays, and in soft to medium fractured rock formations. For projects facing such ground conditions, MAI SDA self-drilling anchors should be considered as the main productivity solution. Atlas Copco Swellex rock bolts, which are quickly and safely installed in rock not tending to collapse, gives immediate support, speeding up operations and boosting revenues. Over the past two decades, the Swellex rock bolting solution has become world famous as the simplest, fastest and most reliable rock reinforcement technology available. MAI SDA installation The MAI SDA solution is designed for optimized installation, tailored to the project s needs. By drilling a hole in collapsing soil or loose rock, with a sacrificial drill bit and a hollow rod, and after the drilling operation injecting grout into the hollow rod and surrounding cavity, makes it a top productivity solution. MAI SDA manual installation Swellex installation The Swellex bolt is a folded steel tube, which is inserted into a pre-drilled hole in the rock. Water is blasted into the tube at high pressure, blowing out the fold and expanding the tube into the exact shape of the hole, adapting to every irregularity. Bolt installation takes less than 30 seconds, and provides full and immediate support along the entire hole length, in ground conditions ranging from the hardest rock to clay even non-cohesive material. 6 Swellex manual installation

7 MAI SDA self-drilling anchors A MAI SDA self-drilling anchor consists of: a hexagonal nut a bearing plate extension couplings, if the anchor consists of several anchor rod sections hollow anchor rod(s) a sacrificical drill bit Plate Nut Rod Coupling Rod Bit 7

8 MAI SDA self-drilling anchors Applications The application circle below displays the three most important areas and industries where the MAI SDA is best utilized Slope stabilization Is used to stabilise mostly unstable rock/soil formations which are normally benched prior to the installation of the "soil nails". The unconsolidated or weathered ground conditions favour the technique of Self Drilling Hollow Core Anchors (SDA) for the fast and simple method of installation compared to the traditional methods of cased boreholes and inserting of a suitable tendon. Foundations with micropiles MAI SDA micro piles can be defined as small diameter replacements, drilled piles, composed of injected grout with the MAI SDA anchor rod as steel reinforcement to resist the design load. The MAI SDA micro piles can be installed in sites with limited headroom, restricted access capability with light drilling equipment which have low noise and vibration and require minimal site preparation. MAI SDA can be installed successfully into most ground conditions including rock and is suitable for tension and compression loads. The big advantage is the combined drilling and grouting making high piling outputs possible. Tunnelling MAI SDA anchors are the most economical solution for the reinforcement of the tunnel circumference and advance roof support for tunnel excavation in overburden and soft factured rock conditions. on Slope stabilization Foundations for avalanche protection Micropiling for tentioned foundations Foundation with micropiles Soil nailing Retaining wall structures Embankement stabilization Micropiling / Underpinning Stabilization of tunnel portals Variation of water level Fore-poling Micr g to prevent buoyancy to Face stabilization Spiling Radial systematic anchoring Root piling Tunneling 8

9 MAI SDA self-drilling anchors Sacrificial drill bits The sacrificial drill bit is the most crucial part of the anchoring system, and is responsible for the productivity of the installation. Atlas Copco MAI maintains a large range of drill bits to suit the changing demands of geology encountered on different projects. In order to improve on performance and cost efficiency, data is collected from projects around the world, and incorporated into the design with the aim to improve penetration rate and bit quality, and to reduce manufacturing costs. The selection of drill bits A successful installation of the self-drilling anchor system (SDA) depends on the selection of the most suitable drill bit. Compared to conventional drill bit types offered globally for maximum standing performance for rock or soil, the criteria for SDA drill bits are defined by consideration of the following factors: High quality for a limited service life Installed MAI SDA length Geology Geometry High quality for a limited service life Since the nature of the drill bit is sacrificial, the maximum stand up time is that required to install one anchor. Geology The unique MAI Anchor system was developed over the years for the sole purpose of the drill bit to penetrate fractured and weathered rock and unconsolidated soil formations. Constantly varying conditions, from clay to gravel and boulders, as well as sand and rock, require a multi-functional bit design that provides: Optimum cutting ability in mixed ground conditions Adaptable flushing and grouting performance Maximum penetration speed Geometry Project design for external skin friction demands a selection of various drill bit diameters. In order to maintain the functionality of the system, the following range of diameters should be selected for the different anchor dimensions. Type MAI SDA R32 MAI SDA R38 MAI SDA R51 MAI SDA T76 Drill bit Ø 51 mm, 71 mm 76 mm, 90 mm 100 mm, 115 mm 130 mm, 150 mm, 175 mm MAI SDA installed length Depending on the SDA applications, standard drilling depths would be in the range of: Tunneling (SDA): 4-10 m Soil and Rock Nailing (SRN): 8-20 m (30 m) Micro Injection Piling (MIP): m Temporary Support Anchors (TSA): m 9

10 MAI SDA self-drilling anchors X type XX type A forged cross-cut drill bit. A two stage cross cut bit. Optimum penetration Achievable for SPT-N values of 0-25 N/mm 2 Optimum penetration Achievable for SPT-N values of 0-35 N/mm 2 R38 Ø 110 mm Diameters R32 Ø 51 mm Diameters R51 Ø 110 mm T76 Ø 130 & 75 mm Suitable conditions Suitable for soft soil types such as sand and small gravel Suitable conditions Suitable for soft soil types such as sand and small gravel. EX type EXX type A machined or cast hardened cross dill bit. The tungsten carbide cross bit. Optimum penetration Diameters Suitable conditions Achievable for SPT-N values of 0-60 N/mm 2 R32 R38 T76 Ø 51 & 76 mm Ø 76 & 90 mm Ø 130 mm Suitable for a majority of applications including narrow bands of soft rock. Optimum penetration Achievable for UCT values of N/mm 2 in the range of 10-50% Diameters R32 Ø 51 mm Suitable conditions Suitable for gravel with large boulders, soft to medium fractured rock formations, hard seams and concrete footings without seel reinforcement. EC type Optimum penetration Hardened tri-cresent drill bit with a unique curved shape of the blade, which results in small-sized cuttings and improves the flushing capability of the borehole. Achievable for SPT-N values of 0-60 N/mm 2 Diameters R32 Ø 51 mm Suitable conditions Suitable for a majority of applications including narrow bands of soft rock. ECC type Optimum penetration Tungsten Carbids Tri-cresent drill bit with a unique curved shape of the blade, which results in smallsized cuttings and improves the flushing capability of the boreholes. Achievable for UCT values of N/mm 2 in the range of 10-50% Diameters R32 Ø 51 mm Suitable conditions Suitable for gravel with large boulders, soft to medium fractured rock formations, hard seams and concrete footings without seel reinforcement. EY type EYY type Hardened tri-blade drill bit with a drop center button face. Hardened tri-blade drill bit with tungsten carbide blades and a drop center configuration with hardened button face. Optimum penetration Achievable for SPT-N values of 0-60 N/mm 2 Optimum penetration Achievable for UCS values of 0-25 N/mm 2 Diameters R32 R38 Ø 76 mm Ø 76 mm Diameters R32 R38 Ø 76 mm Ø 76 & 90 mm Suitable conditions Offers an increased cutting performance in fills and chalk. Suitable conditions Suitable for soft to medium cemented ground conditions incl. fills and chalk. 10

11 MAI SDA self-drilling anchors ES type ESS type Optimum penetration Cast and hardened hemispherical button profile drill bit. Suitable for silt, sand and gravel, but also for soft rock formations. Achievable for SPT-N values and UCS values of 0-60 N/mm 2 Optimum penetration Tungsten carbide hemispherical button profile drill bit. Suitable for penetrating a larger range of soils and bolders, and also soft to medium rock formations as found commonly along slopes in mountainous regions. Achievable for SPT-N values and UCS values of 0-50 N/mm 2 ES-F bit ES-D bit ESS-F bit ESS-D bit Configuration Flat face Configuration Drop center Configuration Flat face Configuration Drop center R32 Ø 51 mm R32 Ø 51 mm Diameters Suitable conditions R38 R51 Ø 76 mm Ø 100 mm Silts, sand and gravel: Compact or cemented soils or soft rock. Diameters R51 Ø 115 mm Suitable conditions Silts, sand and gravel: With small boulders or soft rock. Diameters Suitable conditions R38 R51 Ø 76 mm Ø 100 mm Diameters R38 Ø 115 mm T76 Ø 120 mm R51 Ø 115 mm Silts, sand and gravel: Compact or cemented soils or soft rock. Suitable conditions Silts, sand and gravel: With small boulders. Driving head Optimum penetration This driving head was developed for soft clay applications. NB! Consider a method of simultaneous driving and grouting for optimum grouting results. Achievable for SPT-N values of 0-20 N7mm² Diameters R32 Ø 65 mm Suitable conditions Suitable for soft clay applications with anchor lengths up to 8 meters. SPT-N= Standart Penetration Test, UCT=Unconfined Compressive Strength, RQD=Rock Quality Designation Index 11

12 MAI SDA self-drilling anchors Hollow anchor rods The anchor rod features a hollow bore for flushing, or simultaneous drilling and grouting, and has a left-hand rope thread for connection to standard drill tooling. It is manufactured from API standard heavy walling steel tubing, cold rolled to form a standard ISO rope thread profile. The rolling process refines the grain structure of the steel, increasing the yield strength, and producing a durable drill rod suitable for a range of applications. The standard rope thread of the anchor rod produces an excellent bond between the rod and grout, as well as enabling connection to all Atlas Copco Boomer face drilling rigs and Atlas Copco Roc surface drill rigs, and use with a wide range of drill steel accessories. Rendered photo on its way Hollow anchor rods The anchor rod is produced in 12 m lengths and then cut to size depending on customer requirements. Standard delivery lengths are 1 m, 2 m, 3 m, 4 m and 6 m. Recommended maximum rod lengths depend on diameter and can be up to 6 m. Additional lengths up to 12 m are available on request. Extension couplings The coupling features a patented design that enables direct end-to-end energy transmission between each bar, reducing losses and ensuring maximum percussive energy at the drill bit. To enable the correct seating of each bar within the coupler, all bars are chamfered with precision to enable the bar ends to have contact. An extension coupling 12

13 MAI SDA self-drilling anchors Bearing plates The bearing plates are formed steel plates with a centre hole, allowing articulation of seven degrees in all directions. All functional parts are constantly tested, in line with the Atlas Copco rigorous quality assurance policy. Bearing plates Hexagonal nuts The hexagonal nut is manufactured with chamfered edges on both ends from high precision steel, and tempered to meet any stringent demands of the anchor specifications and the daily operations of underground works. All nuts exceed the ultimate strength of the bar by 20%. A hexagonal nut Galvanized anchors Corrosion is a very complex process, and corrosion rates are very hard to predict accurately. However, predictive methods can be helpful to evaluate the need for corrosion protected rock bolts. For this reason Atlas Copco has developed a hot dip galvanizing corrosion protection. The full range of SDA bars with couplings and nuts are available with this corrosion protection. Galvanized anchors 13

14 MAI SDA installation methods Manual installation 1. Drilling with water flushing. 2. Adding a coupling to extend the anchor with another rod. 3. Connecting to grout pump and inject the mixed grout. 4. Once grout has hardened, the anchor is perfectly installed. Semi-mechanized installation Improved quality of grouting The anchoring or bolting industry has a demand for increasing the efficiency and quality of the installation of bolts. In addition increased safety by minimizing work in unprotected areas are becoming more important to contractors when installing bolts in difficult rock/soil conditions. Better filling of borehole annulus due to in-situ mixing process Consistent load transfer over the whole bolt length between soil/rock and bolt Improvement of corrosion protection providing longer service life A change from the conventional post grouting method to a semi-mechanized installation method using an IRIA (Integrated Rotary Injection Adapter) method provides an adaptable installation process, which offers an improved solution and as such added value to the Customer: SDA installation becomes one work cycle performed only by the drill feed No additional work cycle for post grouting Reduced operation cost for additional equipment (working platforms etc.) Better adjustment of the installation process in respect with the changing geology Flexible selection and adjustment of flush media as needed (water, air or grout) 14 The option to introduce high speed stabilization with SDA versus cased borehole drilling solutions No separate drilling equipment needed, same crew No subcontractors and no investments in capital equipment Providing technology to introduce high speed curing grout formulas Back pressures during grouting can be absorbed by drill feed and boomer, thus enabling higher grout pressures, thus allowing lower W/C factors reducing the curing time, providing earlier load bearing of SDA resulting in a reduced excava tion cycle time.

15 MAI SDA installation methods Manual installation of anchors with a Boomer drill rig Semi-mechanized installation of anchors with a Boomer drill rig and IRIA 15

16 MAI SDA self-drilling anchors Quick reference Anchor rods R32 L R32 N R32 S R38 N R51 L R51 N T76 N T76 S Unit Outer diameter mm Average internal diameter mm Cross-sectional area mm 2 Ultimate tensile load (UL) kn Yield load (YL) kn kg Extension couplings R32 L R32 N R32 S R38 N R51 L R51 N T76 N T76 S Unit Diameter mm Length mm kg Nuts R32 L R32 N R32 S R38 N R51 L R51 N T76 N T76 S Unit Key size mm Length mm kg Anchor plates R32 L R32 N R32 S R38 N R51 L R51 N T76 N T76 S Unit Dimension 150x x x x x x x x250 mm Thickness mm Hole diameter mm kg Anchor drill bits Type of bit R32 L R32 N R32 S R38 N R51 L R51 N T76 N T76 S X R32/51 R32/51 R32/ XX R38/110 R51/110 R51/110 T76/175 T76/175 EX R32/51 R32/51 R32/51 R38/76 R32/76 R32/76 R32/76 R38/ T76/130 T76/130 EY R32/76 R32/76 R32/76 R38/ EXX R32/51 R32/51 R32/ EYY R32/76 R32/76 R32/76 R38/76 R38/ EC R32/51 R32/51 R32/ ECC R32/51 R32/51 R32/ ES F R32/51 R32/51 R32/51 R38/76 R51/100 R51/ ES D R51/115 R51/ ESS F R32/51 R32/51 R32/51 R38/76 R51/100 R51/100 T76/120 T76/120 ESS D R38/115 R51/115 R51/ Driving head R32/65 R32/65 R32/

17 MAI SDA self-drilling anchors Hammers Shank adapters Adapter couplings Anchor rod R32 COP 1238-R32/R38 R32-R32 Extension coupling R32-R32 Anchor rod R32 Bit example R32 COP 1838-R32/R38 R38-R32 COP 1440-R32/R38 COP 1238-R32 COP 1838-R32 MAI SDA R32 anchor rods Size Length (m) Outer Ø Inner Ø 1 Area 2 (mm 2 ) UL 3 (kn) YL 4 (kn) R32 L R32 L R32 L R32 N R32 N R32 N R32 S R32 S R32 S Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) R32 L R32 L R32 L R32 N R32 N R32 N R32 S R32 S R32 S ,0 mm 21,5 mm L version 32,0 mm 18,5 mm N version 32,0 mm 15,0 mm S version 1 Average internal diameter / 2 Cross sectional area / 3 Ultimate load / 4 Yield load MAI SDA R32 extension couplings Size Type Length Outer Ø R32 L&N R32 S Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) R32 N&S Products in bold are stock items, other items are produced to order. 17

18 MAI SDA self-drilling anchors MAI SDA R32 bits MAI SDA R32 nuts & plates Nut Size Type Length Key size R32/SW46 L&N&S Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) R32/SW46 L&N&S Anchor plate Size Type Size Type Dimension Thickness Outer Ø Hole Ø R32 L 150x R32 L&N 200x R32 S 200x Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) Drill bit R32 L&N&S X Drill bit R32 L&N&S EX Drill bit R32 L&N&S EX Drill bit R32 L&N&S/L74 EXX Drill bit R32 L&N&S EY Drill bit R32 L&N&S EYY Button bit R32 L&N&S ES-F Button bit R32 L&N&S ESS-F Button bit R32 L&N&S ESS-F Split arc bit R32 L&N&S EC Split arc bit R32 L&N&S ECC Ram head R32 L&N&S Driving head R32 N 200x R32 S 200x MAI SDA R32 accessories RIA-Kits Type RIA-Mono "ext R32/ext R32" L&N&S RIA-Mono "Seals 55x67x6 NBR 70" L&N&S RIA-Combi "Body" L&N&S RIA-Combi "Shank ext. R32/ ext. R32" L&N&S RIA-Combi "Shank int. R32/ int. R32" L&N&S RIA-Combi "O-ring/ Ø39,2x5,7 NBR 70" L&N&S RIA-Combi "Seals S605 45x55x8" L&N&S Products in bold are stock items, other items are produced to order.

19 MAI SDA self-drilling anchors Coupling box Adapters Shank adapters Type Quick coupling NW25 1" IT "female" L&N&S Coupling box R25-R32 with middle stop L=200 mm L&N&S Coupling box R32-R32 with middle stop L=200 mm L&N&S Coupling box R32-R38 with middle stop L=200 mm L&N&S Coupling box R32-T45 with middle stop L=200 mm L&N&S Drill bit adapter R38/R32 L&N&S Injection adapter R32/1" L&N&S Shank R25 male/sk22 L&N&S Shank R25 male/sk25 L&N&S Centralizer R32/ Ø72 L&N&S Pull test equipment Type Load testing unit Max load 300 kn, stroke 63 mm, bore 53 mm Load testing unit Max load 600 kn, stroke 76 mm, bore 53 mm L&N S IRIA-Kits and parts COP Conversion kit Type Reference COP 1238 L&N&S Rock Drills AB Örebro COP 1440 L&N&S Rock Drills AB Örebro COP 1838 L&N&S Rock Drills AB Örebro BSH 110 Type Reference BSH 110 SDA L&N&S Rock Drills AB Örebro BSH 110 Bushing halves Type Reference R32 L&N&S Rock Drills AB Örebro Shank adapters Type Reference COP 1238-R32F L&N&S Secoroc AB Fagersta COP 1838-R32F L&N&S Secoroc AB Fagersta COP 1440-R32F L&N&S Secoroc AB Fagersta Integrated injection adapter Type Reference IRIA kit for COP 1238, 1838 and 1440 L&N&S Rock Drills AB Örebro IRIA seals kit, complete for COP 1238 and COP 1838 L&N&S Rock Drills AB Örebro IRIA Shank adapters Type Reference COP 1238-R32F L&N&S Secoroc AB Fagersta COP 1838-R32F L&N&S Secoroc AB Fagersta Products in bold are stock items, other items are produced to order. 19

20 MAI SDA self-drilling anchors Hammers Shank adapters Adapter couplings Anchor rod R38-R38 R38 COP 1238-R38 Extension coupling R38-R38 Anchor rod R38 Bit example R38 COP 1838-R38 MAI SDA R38 anchor rods Size Length (m) Outer Ø Inner Ø 1 Area 2 (mm 2 ) UL 3 (kn) YL 4 (kn) R38 N R38 N R38 N Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) R38 N R38 N R38 N ,0 mm 19,0 mm N version 1 Average internal diameter / 2 Cross sectional area / 3 Ultimate load / 4 Yield load MAI SDA R38 extension couplings Size Type Length Outer Ø R38 N Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) R38 N MAI SDA R38 bits Size Type Outer Ø Drill bit R38 N XX Drill bit R38 N EX Drill bit R38 N EX Drill bit R38 N EY Drill bit R38 N EYY Drill bit R38 N EYY Button bit R38 N ES-F Button bit R38 N ESS-F Button bit R38 N ESS-D MAI SDA R38 nuts & plates Nut Size Type Length Key size R38/SW50 L&N&S Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) R38/SW50 L&N&S Products in bold are stock items, other items are produced to order.

21 MAI SDA self-drilling anchors Anchor plate Size Type Dimension MAI SDA R38 accessories RIA-Kits Type RIA-RotoJec "Body" N RIA-RotoJec "Shank int. R38 / int. R38" N RIA-RotoJec "Seals S605 75x90x13" N Coupling box Adapters Shank adapters Type Quick coupling box R25-R38 with middle stop L=200 mm N Quick coupling box R32-R38 with middle stop L=200 mm N Quick coupling box R38-R38 with middle stop L=200 mm N Quick coupling box R38-T45 with middle stop L=200 mm N Quick coupling NW25 1" IT "female" N Shank R25 male / SK22 N Shank R25 male / SK25 N Drill bit adapter R51 / R38 N Injection adapter R38 / 1" N Pull test equipment Type Load testing unit Max load 600 kn, stroke 76 mm, bore 53 mm IRIA-Kits and parts N COP Conversion kit Type Reference COP 1238 N Rock Drills AB Örebro COP 1440 N Rock Drills AB Örebro COP 1838 N Rock Drills AB Örebro BSH 110 Type Reference BSH 110 SDA N Rock Drills AB Örebro BSH 110 Bushing halves Type Reference R38 N Rock Drills AB Örebro Shank adapters Type Reference COP 1838-R38F N Secoroc AB Fagersta COP 1440-R38F N Secoroc AB Fagersta Integrated injection adapter Type Reference IRIA kit for COP 1238, 1838 and 1440 N Rock Drills AB Örebro IRIA seals kit, complete for COP 1238,1838 and 1440 Thickness Hole Ø R38 N 200x Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) R38 N 200x N Rock Drills AB Örebro IRIA Shank adapters Type Reference COP 1238-R38F N Secoroc AB Fagersta COP 1838-R38F N Secoroc AB Fagersta Products in bold are stock items, other items are produced to order. 21

22 MAI SDA self-drilling anchors Hammer Shank adapter Adapter coupling Anchor rod T51-R51 R51 Extension coupling R51-R51 Anchor rod R51 Bit example R51 COP / T51 MAI SDA R51 anchor rods Size Length (m) Outer Ø Inner Ø 1 Area 2 (mm 2 ) UL 3 (kn) YL 4 (kn) R51L R51 L R51 L R51 L R51 N R51 N R51 N R51 N Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) R51 L R51 L R51 L R51 N R51 N R51 N Average internal diameter / 2 Cross sectional area / 3 Ultimate load / 4 Yield load 51,0 mm 36,0 mm L version 51,0 mm 33,0 mm N version MAI SDA R51 extension couplings Size Type Length Outer Ø R51 L R51 N Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) R51 L R51 N MAI SDA R51 bits Size Type Outer Ø Drill bit R51 L&N XX Button bit R51 L&N ES-F Button bit R51 L&N ESS-F Button bit R51 L&N ES-D Button bit R51 L&N ESS-D Products in bold are stock items, other items are produced to order.

23 MAI SDA R51 nuts & plates Nut Size Type Length MAI SDA self-drilling anchors Key size R51 L&N , Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) R51 L&N , Anchor plate Size Type Dimension Thickness Hole Ø R51 L 200x R51 N 250x Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) R51 L 200x R51 N 250x MAI SDA R51 accessories RIA-Kits Type RIA-RotoJec "Body" L&N RIA-RotoJec "Shank int. R38 / int. R51" L&N RIA-RotoJec "Shank int. T45 / int. R51 L&N RIA-RotoJec "Shank int. H55 / int. R51 L&N RIA-RotoJec "Seals S x90x13 L&N Coupling box Adapters Shank adapters Type Coupling box R51-R38 with middle stop L=235 mm L&N Coupling box R51-T38 with middle stop L=235 mm L&N Coupling box R51-T45 with middle stop L=235 mm L&N Quick coupling NW25 1" IT "female" L&N Centralizer R51 / Ø 100 mm L&N Injection adapter R51 / 1" L&N Products in bold are stock items, other items are produced to order. 23

24 MAI SDA self-drilling anchors Hammers Shank adapters Adapter couplings Anchor rod T76 Extension coupling T76-T76 Anchor rod T76 Bit example T76 T51-T76 COP / T51 HL90-T76 MAI SDA T76 anchor rods Size Length (m) Outer Ø Inner Ø 1 Area 2 (mm 2 ) UL 3 (kn) YL 4 (kn) T76N T76N T76N T76N T76 S T76 S T76 S T76 S Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) T76 N T76 N T76 N T76 S T76 S T76 S ,0 mm 51,0 mm N version 76,0 mm 45,0 mm S version 1 Average internal diameter / 2 Cross sectional area / 3 Ultimate load / 4 Yield load MAI SDA T76 extension couplings Size Type Length Outer Ø T76 N&S Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) T76 N&S MAI SDA T76 bits Size Type Outer Ø Button T76 N&S EX Button T76 N&S XX Button T76 N&S XX Button T76 N&S XX Drill bit T76 N&S ESS-F Products in bold are stock items, other items are produced to order.

25 MAI SDA T76 nuts & plates Nut Size Type Length Anchor plate Size Type Dimension MAI SDA self-drilling anchors Thickness Hole Ø T76 N&S 250x Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) Key size T76 N&S Corrosion protected (Galvanized in accordance with EN ISO 1461:1999) T76 N&S T76 N&S 250x MAI SDA T76 accessories RIA-Kits Type RIA-RotoJec "Body" N&S RIA-RotoJec "Shank int. H55 / int. T76 N&S RIA-RotoJec "Seals S x90x13 N&S Coupling box Adapters Shank adapters Type Coupling box H55-T76 with middle stop L=220 mm N&S Injection adapter T76 / 6 /4" N&S Products in bold are stock items, other items are produced to order. 25

26 MAI SDA accessories Centralizer A centralizer is available for specialist applications. For general use the centralizer is not required as it snags during rotation and interferes with grout circulation in the borehole. The use of a centralizer does not guarantee comprehensive grout cover along the length of the bar as it's is impossible to control the grout within the borehole. Coupling boxes Manufactured from thick-wall steel which is machined and case hardened. Coupling boxes are used at high wear locations, typically just below the hammer drive. A locking torque is normally applied to the coupling box at the permanent joint, to avoid release when additional anchor bars are added. Centralizer All the coupling boxes are supplied with a bridge to act as a centre stop. When a step down (reducer) drive arrangement is used i.e. R38 shank to drive to install R32 anchor bar, a locking torque should be applied at the R38 end to prevent the R32 bar climbing into the R38 chamber. Step up drive arrangements are not recommended as the additional torque overloads the smaller drive. Coupling boxes Shanks Rotary percussion is the preferred method of installation. Either hydraulic or air hammer is suitable. To transfer the rotation and percussion from the hammer to the bar's system there is a need for the special tool named shank adapter. Atlas Copco is providing a full range of different shank adapters for different hammers. A common shank adaptor 26

27 MAI SDA accessories Grout coupling After using standard flushing media - water or air, grouting has to be done. For connecting the grouting hose from the pump with the anchor bar, the grout coupling is used. The grout coupling will be removed and reused after the grouting process is done. Grout coupling MAI SDA mortar The MAI anchor mortar is mostly used for grouting of anchor bore holes or for consolidation grouting of fractured rock formation and loose unconsolidated ground. Depending on the work environment the MAI anchor mortar is available as standard or sulphate-resistant type cement. Processing MAI anchor mortar is mixed with clean water; approximately 5.0 l/bag are needed. For processing, standard mortar mixing pumps, especially the MAI pump m400 NT are suitable. Storage The MAI anchor mortar is delivered in bags of 25 kg each. The bags should be kept in dry conditions, a max. shelf life of 6 months can be expected. Safety As per international chemical substance law the MAI anchor mortar is not considered as a dangerous substance. Technical data MAI SDA anchor mortar MAI mortar, sulfat resistant MAI mortar, normal/standard data Max. grain size 0.3 mm Bulk weight ~ 1200 kg/m 3 Water consumption ~ 20% of dry mass Cube strength 1d 15 N/mm 2 Cube strength 3d 30 N/mm 2 Cube strength 7d 40 N/mm 2 Cube strength 28d 50 N/mm 2 Products in bold are stock items, other items are produced to order. 27

28 MAI grout pump MAI SDA grout pump m400 NT The MAI pump m400 NT is a proven high quality pump which is used successfully around the world in tunnel construction, civil engineering, mining and shoring of building excavations, slopes and hill sides. Areas of use The proven mixing and pumping technology is especially suitable for: Injection work Re-injection grouting Drill hole filling Back filling Anchor mortar Productivity characteristics Sturdy construction. Galvanized frame guarantees optimum corrosion protection and can withstand even the toughest treatment. Simple to dismantle and quick to clean and maintain. Technical data MAI pump m400 NT (standard) Other pump constructions available on request data Delivery rate l/h Delivery distance m max. Delivery pressure 40 bar, approx. Electricity supply 400 V, 50 Hz Amperage 12.1 A Main supply fuse 25 A Power requirement Min. 16 KVA Normal output 6.2 kw Dimensions Total length 1730 mm Total width 570 mm Length without motor and pump 1040 mm Total height 960 mm s Total weight 217 kg without dismantled parts 125 kg Accessories Spur-wheel gear motor Worm pump MP 3 "L" (Standard) High pr. mortar hose with quick-release coupl. - Vibrator - Automatic reverse drive - Automatic screen safety feature - Tools - Cleaning equipment - Water pump optional - Automatically polarity control 6 kw/200 rpm 600 l/h Dia. 25 mm 28 Products in bold are stock items, other items are produced to order.

29 Swellex rock bolts Since its introduction 25 years ago, the Swellex rock bolting system has gained wide recognition in mining and tunnelling works. It is a unique rock bolt, as it is made out of a welded tube folded on itself and sealed at one extremity. It is re-expanded using a high pressure water flow provided by a special pump and adapter. The bolt is expanded inside a borehole drilled into the excavation wall, why the installation process is easy and very similar as other rock bolts, making Swellex accessible to all operators. The speed and quality of installation and the extensive application range have solved support problems and increased profitability for contractors and mine operators all over the world. As mine and tunnel safety requirements have become more stringent, the prompt, reliable and versatile support available with Swellex rock bolts has made them the best for most problem solving, and one of the best for rock reinforcement in general. Through a process of continuous improvement, Atlas Copco has refined Swellex to offer the most versatile portfolio of rock bolts available on the market. Swellex rock bolts from Atlas Copco exist in two typical versions, one being the Swellex Premium line, a relatively stiff rock bolt for tunnelling and mining in moderate stress conditions, and the other one called the Swellex Manganese line, a highly deformable rock bolt for large rock deformation situations. Another improvement is the line of corrosion protected Swellex. From the well accepted rubber bitumen coating to the new Plasticoated Swellex for highly corrosive environments, Atlas Copco covers all demands for corrosion protection and long life rock bolts. And again, for special applications like hangers and deep reinforcement, Atlas Copco has perfected versions of Swellex to perform these tasks with the same easy system. With the Swellex Hanger Pm24H, the operator can install its service hanger in the same reinforcement operation as the primary support. The Connectable Pm24C is a modern replacement to medium length cable bolts, with high productivity, quality control and safety components. 29

30 Swellex rock bolts Swellex features The Swellex rock bolt is made out of a welded steel tube folded on itself and sealed at one extremity, while the other extremity is set with a special head bushing used for inflation and retaining of the face plates typically used in rock bolting. The expansion of the bolt, inside the drilled borehole, creates a friction and interlocking anchor, which provides instant reinforcement and support. Swellex rock bolts can be considered as a full column support as they provide reinforcement and support on the whole length of the borehole, whatever happens at the collar area. Due to its unique anchorage mechanism, the Swellex bolt can adapt to a wide variety of ground conditions and provide good to excellent anchorage capacity in most rock types. The steel profile can also adapt to shear movements, and in softer materials the Swellex bolt accommodates large shear displacements without failure. A Swellex rock bolt before inflation An inflated Swellex rock bolt adapted to the bore hole s irregularity The simplicity of the system can explain its performance. The operator simply drills a hole in the rock, inserts the bolt and then inflates it to a predetermined pressure using a dedicated inflation system. The pump stops when reaching the recommended inflation pressure that guarantees the quality of the installation. Friction and interlocking support of the whole length Swellex rock bolts can easily be pull tested. In fact, a Swellex rock bolt has the easiest pull test operation of any rock bolt type. As the anchorage principle of Swellex is a tight interlock with the asperities of the borehole surface, corrosion can develop if the environment is prone to corrosion processes. In order to provide a solution for long term reinforcement, and handle particularly aggressive situations, Atlas Copco provides two versions of protected Swellex bolts, the Bitumen coated Swellex and the Plastic coated Swellex. These two products extend the normal life of a Swellex by many years. Swellex net washer for screening Bridges gaps in the rock Allows major shear movements in medium to soft rocks Adapted to the bore hole s irregularity A 50 cm long inflated bolt can develop 100 kn friction 30

31 Swellex rock bolts Applications Swellex rock bolts are extremely versatile and can be used in a variety of excavation, from tunneling to mining. A very typical application in tunneling is to use Swellex as pattern bolts to support, reinforce or consolidate the periphery of an excavation. The density of bolting depends of the size of the excavation and the self-supporting qualities of the rock mass. In mining, common applications like roof and hanging wall bolting have adopted Swellex as a rapid and performing stabilisation device. Because Swellex is expanded inside a borehole smaller than the folded tube circumference, it is not sensitive to hole diameter, rock quality or water conditions and provides a good anchorage capacity in most tunneling and mining conditions. nn Tunnelling Mining Radial systematic bolting Radial systematic bolting Ha Ha g wall bolting g wall bolting Roof bolting Roof bolting 31

32 Swellex rock bolts Atlas Copco offers a versatile portfolio of rock bolts that provides reinforcement solutions for ground conditions varying from easy to very difficult. With three typical capacity ranges, at 120 kn, 160 kn and 240 kn, the Swellex rock bolts can be used in most reinforcement and support applications. They can also be used either in mines or in civil engineering applications and their specific mechanical properties will provide the needed safety and performance. Selection of a rock bolt is usually done during the design phase of an excavation, and is the prerogative of the design engineer as it involves geological and structural knowledge and engineering computation. However, the following sections can help understand the specific mechanical properties of the Swellex bolts and ease the selection process. Premium line The Premium line is a typical tunnelling bolt, with a high yield load and good deformability. It provides a competitive strength combined with the classic Swellex system performance. Pm rock bolts can also be used in mining when low to medium stress conditions require a stiff Swellex rock bolt with a high yield load. However, Pm line Swellex are deformable enough to provide a safe behaviour in rising stress conditions and can be used in most typical mining environments. Swellex Premium line rock bolts Manganese line The Manganese line was developed to suit large stress changes occuring in some mining and tunneling projects. Made from a very specific steel type, Mn rock bolts receive a heat treatment to improve their mechanical properties. Manganese line Swellex rock bolts have a unique yielding behaviour that can be matched only with the proper steel manufacturing. As a result, they provide a high ultimate load and a large deformation capability. Because of these outstanding mechanical properties and the quality assurance associated with the Swellex system, the Manganese line has been a mining success. Swellex Manganese line rock bolts 32

33 Swellex rock bolts Bitumen coated Bitumen coated Swellex is created by coating a Swellex bolt with a thick rubber bitumen paint, to provide medium term corrosion protection against most corrosive conditions. Plastic coated Plastic coated Swellex is providing its long term corrosion protection through a thick plastic coating that is impervious to water and current. The damage resistant coating is very effective in very corrosive environments and its resistance and effectiveness is proven over years of application in highly acidic conditions. Swellex Pm24C a connectable bolt Further to the typical pattern rock bolting application, the Swellex Pm24C offers the possibility of deeper reinforcement without grouting operation. The Swellex Pm24C is a connectable rock bolt, which consists of individual sections that are joined together via R thread connections. The required bolt length is achieved by adding one or more sections. Swellex Pm24C bolts are very competitive against short and medium length cable bolts. Swellex Pm24H a hanger The Swellex Pm24H is a new generation of hanger that provides a high anchorage capacity hanger with a flanged head with a female M36 thread. The rock bolt has a static axial load carrying capacity of 200 kn and is designed for hanging services. The final hanging capacity is determined by the eye bolt capacity. After the Pm24H bolt has been installed by using an inflation adapter, a forged eye bolt with M36 thread is screwed on. Utilities can then be suspended directly from the eye bolt. As the Pm24H is not designed for excentric loading, the design load should always be coaxial to the bolt profile, and the bolts installed as vertical as possible. The end sleeve should be inside the borehole in rock and shotcrete. Swellex Pm24H can be installed using standard Swellex installation equipment combined with a small inflation adapter. A plastic coated Swellex rock bolt A Swellex connectable rock bolt The Swellex hanger system 33

34 Swellex installation methods Manual installation 1. Drill the hole. 2. Insert the bolt. 3. Connect and start the pump to expand the bolt. 4. Installation completed. Mechanized installation Rock bolting for mining and tunnelling has reached a phase of performance never attained in the past. While spot bolting is still used to stabilize individual blocks in roofs and walls of excavations, the trend is to use rock bolting as a systematic mean to provide a global reinforcement mechanism that will allow longer and safer use of underground excavations. Along these changes, mechanization of rock bolting has become a preferred way for many tunnel and mining operators. Not only does a mechanized installation provide a higher productivity, it also helps to maintain a safer working environment. However, since the demand for manually installed rock bolts is still high, support systems must be flexible and allow manual as well as mechanized installation operations. Fully mechanized installation of Swellex with a Boltec drill rig Over the last decade, it has been recognized that the installation operation is a critical step in assuring the effectiveness of a rock support system. If not properly installed, the best rock bolt will behave poorly and provide a false sense of security that is detrimental to the reinforcement purpose. Better bolting operation and quality control of the raw materials is now a basic component of a good reinforcement system. 34

35 Swellex installation methods Manual installation of Swellex Connectables 1. Drill the hole 2. Install bolt 1 and add bolt 2 3. Add bolt 3 with face plate 4. Connect the inflation chuck and install all the bolts 5. Inflate the bolts 6. Installation completed Manual installation of Swellex Hangers 1. Drill the hole 2. Mount the inflation adapter 3. Connect the chuck to the bolt 4. Inflate the bolt 5. Dismount the adapter 6. Mount the eyebolt 35

36 Swellex rock bolts Quick reference Swellex Premium line Type of steel * Typical values ** A5. According to SS-EN where applicable. Bolt type Pm12 Pm16 Pm24 Pm24C Pm24H S275JR / S355MC Minimum breaking load kn Minimum yield load kn Minimum elongation ** % Inflation pressure Bar Profile diameter mm Original tube, diameter mm Material thickness mm Upper bushing, diameter mm Inflation bushing, diameter 30.0/ / / / mm Optimal hole diameters* mm Range hole diameters mm Connection diameter including welds mm Recommended collar diameter mm Bitumen coated option Yes Yes Yes Yes Yes Plastic coated option Yes Yes Yes Yes Yes Unit Swellex Manganese line Type of steel Bolt type Mn12 Mn16 Mn24 S355JR Minimum breaking load kn Minimum yield load kn Minimum elongation ** % Inflation pressure Bar Profile diameter mm Original tube, diameter mm Material thickness mm Upper bushing, diameter mm Inflation bushing, diameter 30.0/ / /48.0 mm Optimal hole diameters* mm Range hole diameters mm Recommended collar diameter mm Bitumen coated option Yes Yes Yes Plastic coated option * Typical values ** A5. According to SS-EN where applicable. Unit 36

37 Swellex rock bolts Swellex Premium line Swellex rock bolts for applications where higher yield and breaking strength are required. Swellex Premium line is engineered to provide safety and productivity in areas where stiff rock bolting is expected to work within its elastic range and to minimize the deformation in and around the excavation. Improved yield and breaking load values extend the use of well-known Swellex concept into applications where the design requires higher work load from a bolt. A special steel composition coupled with the inherent Swellex advantages offer perfect installation, immediate support on the entire length and an ideal bolt for demanding excavations. 37

38 Swellex rock bolts Swellex Pm12 General information Minimum breaking load 110 kn Minimum elongation* 10% Minimum yield load Inflation pressure For further information, see also Technical data page 36 * A5. According to SS-EN where applicable. 100 kn 300 bar Size Length (m) incl. colour plugs SWX Pm On request SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm On request SWX Pm SWX Pm On request SWX Pm SWX Pm On request SWX Pm On request SWX Pm SWX Pm SWX Pm SWX Pm On request SWX Pm On request Bitumen coated SWX Pm On request SWX Pm On request SWX Pm On request SWX Pm On request SWX Pm On request SWX Pm On request SWX Pm On request SWX Pm On request Plastic coated SWX Pm On request SWX Pm On request SWX Pm On request SWX Pm On request SWX Pm On request SWX Pm12 3,6 7.5 On request For suitable face plates, see page Products in bold are stock items, other items are produced to order.

39 Swellex rock bolts Swellex Pm16 General information Minimum breaking load 160 kn Minimum elongation* 10% Minimum yield load Inflation pressure For further information, see also Technical data page 36 * A5. According to SS-EN where applicable. 130 kn 300 bar Size Length (m) SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm Bitumen coated SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm Plastic coated SWX Pm For suitable face plates, see page 48 Products in bold are stock items, other items are produced to order. 39

40 Swellex rock bolts Swellex Pm24 General information Minimum breaking load 240 kn Minimum elongation* 10% Minimum yield load Inflation pressure For further information, see also Technical data page 36 * A5. According to SS-EN where applicable. 200 kn 300 bar Size Length (m) SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm Bitumen coated SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm SWX Pm Plastic coated SWX Pm SWX Pm SWX Pm SWX Pm For suitable face plates, see page Products in bold are stock items, other items are produced to order.

41 Swellex rock bolts Swellex Pm24C a connectable bolt Size Length (m) Assembled Overall "NR" (Connectable) SWX Pm24C Blind SWX Pm24C Injection SWX Pm24C Intermediate SWX Pm24C Blind SWX Pm24C Injection SWX Pm24C Intermediate SWX Pm24C Blind bushing SWX Pm24C Injection hole SWX Pm24C Intermediate SWX Pm24C Blind SWX Pm24C Injection SWX Pm24C Intermediate SWX Pm24C Blind SWX Pm24C Injection SWX Pm24C Intermediate SWX Pm24C Blind SWX Pm24C Injection SWX Pm24C Intermediate "NR" Plastic coated (Connectable) SWX Pm24C Blind SWX Pm24C Injection SWX Pm24C Intermediate SWX Pm24C Blind SWX Pm24C Injection SWX Pm24C Intermediate SWX Pm24C Blind bushing SWX Pm24C Injection hole SWX Pm24C Intermediate SWX Pm24C Blind SWX Pm24C Injection SWX Pm24C Intermediate SWX Pm24C Blind bushing SWX Pm24C Injection hole SWX Pm24C Intermediate SWX Pm24C Blind SWX Pm24C Injection SWX Pm24C Intermediate For suitable face plates, see page 48 Products in bold are stock items, other items are produced to order. 41

42 Swellex rock bolts Swellex Pm24H a hanger Size Length (m) M36 "NG" (Hanger) SWX Pm24H M36 thread SWX Pm24H M36 thread SWX Pm24H M36 thread SWX Pm24H M36 thread SWX Pm24H M36 thread Products in bold are stock items, other items are produced to order.

43 Swellex rock bolts Swellex Manganese line Rockbolts for applications where high energy absorbency in tensile and shear loading is required. Swellex Manganese line is engineered to provide safety and productivity in areas where improved elongation capability at maximum load capacity are required. Made from a very specific type of steel the Swellex Mn rock bolts also receive a heat treatment to improve their mechanical properties. Swellex Manganese line rock bolts are a high quality product with extraordinary work absorbency. 43

44 Swellex rock bolts Swellex Mn12 General information Minimum breaking load* Minimum yield load 110 kn 90 kn Minimum elongation* 20% Inflation pressure For further information, see also Technical data page 36 * A5. According to SS-EN where applicable. 300 bar Size Length (m) incl. colour plugs SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn On request SWX Mn On request Bitumen coated SWX Mn On request SWX Mn On request SWX Mn On request SWX Mn On request SWX Mn On request For suitable face plates, see page Products in bold are stock items, other items are produced to order.

45 Swellex rock bolts Swellex Mn16 General information Minimum breaking load Minimum yield load 160 kn 120 kn Minimum elongation* 20% Inflation pressure For further information, see also Technical data page 36 * A5. According to SS-EN where applicable. 300 bar Size Length (m) SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn Bitumen coated SWX Mn On request For suitable face plates, see page 48 Products in bold are stock items, other items are produced to order. 45

46 Swellex rock bolts Swellex Mn24 General information Minimum breaking load Minimum yield load 200 kn 180 kn Minimum elongation* 20% Inflation pressure For further information, see also Technical data page 36 * A5. According to SS-EN where applicable. 300 bar Size Length (m) SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn Bitumen coated SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn SWX Mn For suitable face plates, see page Products in bold are stock items, other items are produced to order.

47 Swellex rock bolts Swellex face plates Face plates are used to create a local surface support around the borehole collar area. With point load anchor bolts, the plate is used to transfer the displacement of the rock mass into the rock bolt, without it no load transfer can take place. Full column support like grouted bolts and friction bolts need a face plate to maintain rock mass loading on the area of the collar only as most of the loading occurs along the bolt body. Face plates are used to maintain local roof stability, to prevent keyblock movement, and retain surface support like mesh. The Swellex face plates are manufactured from high quality steels, and meet or exceed the properties stated in the individual specifications. All face plates are designed, manufactured and tested according to ASTM F standards.the face plate s capacities are designed to meet the customers requirements. Hard rock conditions In hard rock, where the anchorage capacity is often exceeding 200 kn per metre of anchorage length, the load that is transferred on to the face plate is rarely more than 50 kn, as friction on the profile takes over most of the loading from the rock mass. Swellex face plates Soft ground conditions In softer ground conditions and broken rock masses, the load transferred onto the plate is much higher as the rock mass close to the borehole collar tends to yield more freely and exert a direct loading over the plates. Accordingly, the high strength face plates are designed for high convergence conditions and potentially dynamic conditions. In low stress or loading conditions, regular strength face plates can be used efficiently and safely as proven by years of usage in the tunneling and mining industries. Hanging feature Most face plates types can be specified with a hole or notch to be used to hang light and non-vibrating or oscillating services. The suffix L is then added to the plate description to indicate the presence of such a hole or notch. This added feature does not reduce strength specifications, but it should not be attempted to hang heavy or vibrating services as the long term capacity of the rock bolt could be dramatically reduced. Face plates with lance Face plates with a bent corner 47

48 Swellex rock bolts Swellex Pm12, Mn12 face plates Regular strength Name General Suitable conditions Data s Std SWX plate VR12 / VR12L D12/D12L NR12 Traditional spherical domed plates Domed plates Low profile plate with a ridge Low profile domed plates Normal ground conditions with low to medium stress level & small convergence Normal ground conditions with medium stress levels & small convergence. Normal duty applications. Normal ground conditions with low stress levels & small convergence. Mining & tunnelling applications. Normal ground conditions with low to medium stress levels & small convergence. Steel: Domex 600 / Plate size: 151x151 mm Hole size: 29x39 mm ± 5 mm Min. mtrl. thickness: 3,8 mm Min. breaking load: 89 kn ASTM grade 2 Steel: HSLA Gr 75 ksi / Plate size: 151x151 mm Hole size: 30,2 mm ± 0,3mm Min. mtrl. thickness: 3,8 mm Min. breaking load: 110 kn ASTM grade 2 Steel: HSLA Gr 75 ksi / Plate size: 151x151 mm Hole size: 30,2 mm ± 0,3mm Min. mtrl. thickness: 3,8 mm Min. breaking load: 100 kn ASTM grade 2 Steel: S355JR / Plate size: 151x151 mm Hole size: 30,2 mm ± 0,3mm Min. mtrl. thickness: 4,0 mm Min. breaking load: 70 kn Standard Bent corner Lance - Standard Bent corner - Lance Standard Bent corner - Lance Standard Bent corner - Lance - F12 Flat plate Mining and tunnelling applications and relatively even rock surfaces High strength VS12 Domed plates Normal ground conditions with high stress levels & important convergence. NS12 Low profile domed plates Mining & tunnelling applications. Normal ground conditions with high stress levels & important convergence. Steel: S355JR / Plate size: 151x151 mm Hole size: 30,2 mm ± 0,3mm Min. mtrl. thickness: 4,0 mm Min. breaking load: 70 kn Steel: HSLA Gr 75 ksi / Plate size: 151x151 mm Hole size: 30,2 mm±0,3mm Min. mtrl. thickness: 4,8 mm Min. breaking load: 142 kn ASTM grade 3 Steel: S355JR / Plate size: 151x151 mm Hole size: 40 mm±0,3mm Min. mtrl. thickness: 5,0 mm Min. breaking load: 100 kn ASTM grade 2 Standard Bent corner - Lance Standard Bent corner - Lance Standard Bent corner - Lance - Swellex Pm16, Pm24, Mn16, Mn24 face plates Regular strength Name General Suitable conditions Data Mn face plate Traditional spherical dome plates Normal ground conditions with low to mediuim stress levels & small convergence Steel: Doomex 600 / Plate size: 151x151 mm Hole size: 39x44 mm ± 0,5 mm Min. mtrl. thickness: 3,8 mm Min. breaking load: 89 kn ASTM grade 2 Standard Bent corner - Lance - NR24 Domed face plates Normal ground conditions with low to medium stress levels & small convergence. VR24 / VR24L Domed face plates High strength VS24 / VS24L Domed face plates developed for the North American market Normal duty applications. Normal ground conditions with low stress levels & small convergence. All ground conditions and especially for high stress & convergence. Steel: S355JR / Plate size: 151x151 mm Hole size: 40 mm ± 0,3mm Min. mtrl. thickness: 4,0 mm Min. breaking load: 100 kn ASTM grade 2 Steel: HSLA Gr 80 ksi / Plate size: 151x151 mm HHole size: 40 mm ± 0,3mm Min. mtrl. thickness: 4,1 mm Min. breaking load: 90kN ASTM grade 2 Steel: HSLA Gr 75 ksi / Plate size: 151x151 mm Hole size: 40 mm ± 0,3mm Min. mtrl. thickness: 5,4 mm Min. breaking load ASTM: 144 kn Min. breaking load, bushing: 200 kn ASTM grade 3 Standard Bent corner - Lance - Standard Bent corner - Lance Standard Bent corner - Lance Products in bold are stock items, other items are produced to order.

49 Swellex installation pumps The installation system for Swellex rock bolts consists of a high pressure water pump coupled with an inflation chuck that is pushed over the bolt s head bushing to conduct the water flow from the pump to the inside of the bolt. The water pumps used for this operation are high pressure pumps that can rapidly and safely deliver the 300 bars constant pressure specified for a perfect installation. The inflation chuck is a safe and simple system that grips and injects the water inside the bolt. Once the inflation is completed, the pressure is released manually, or automatically, like with the electric and hydraulic versions of the pump. Inflation chuck How to choose the right Swellex pump When choosing between a pneumatic, electric or hydraulic pump, the user should know the availability of water, air and electricity in the locations where the pumps will be used. Comparison of the various input requirements with the available services is necessary in order to make an educated choice on the best type of pump to use. Installation with a hydraulic rig tends to favor the hydraulic pumps but the electric and pneumatic pumps can still be an option as they can be easily installed on most rigs and more rudimentary bolting equipment. Flexibility requirements can also affect the choice of the pump as the operator may need a pump that can be used in various environments that do not always have all the same service availability. Inflation time [Sec.] PSP E1 H1/HC ,5 2, Bolt length [m] Comparison of performance between different Swellex pumps for Pm/Mn24 Finally, hydraulic and electric Swellex pumps have the lowest maintenance costs of the three types available at Atlas Copco. The diagram provided to the right can help to evaluate the pump that best suits the performance requirements of the bolting operations, in term of inflation time. 49

50 Swellex installation pumps Swellex pump PSP 240/300 The pneumatic Swellex pump PSP 300 is a wellproven high pressure water pump for Swellex rock bolt installations. It has an integrated pump unit, which is a pressure booster consisting of a double acting air cylinder connected to a water pump by means of a common piston rod. It requires an inlet air pressure of 5 bar to inflate bolts up to 300 bar. The expansion time for a 4.0 m long Standard Swellex rockbolt is about 70 seconds. Productivity characteristics Sturdy, yet light construction. Suitable for work in hard and demanding under ground conditions. High availability / reliability. Areas of use This simple and yet high performance pump is especially suited for: Bolting where electricity is not widely available Manual installation of Swellex rock bolt with various equipments Relatively low bolts consumption Technical data Accessories Product number PSP 300 Std. (No inst. arm incl.) PSP 300 (Inst. arm, 1.6 m incl.) Manometer and Chuck Pm/Mn12 PSP 300 (Inst. arm, 1.6 m incl.) Manometer and Swellex Chuck for Pm/Mn16, Pm/Mn24 incl. data Max. working pressure for water Max. working pressure for air Air consumtion at 5 bar, average Max. inlet water pressure bar 5 bar 53 l/s 3 bar Chucks Swellex chuck Pm/Mn Swellex chuck Pm/Mn 16 & Installation arms with chucks L=1,6 m for Pm/Mn L=1,6 m for Pm/Mn 16 & L=1,6 m with manometer for Pm/Mn 12 L=1,6 m with manometer for Pm/Mn 16 & Connections air Claw coupling (1/2") Connections water Hose coupling (1/2") Noice level at op. ear, 4 m away Vibrations in the installation arm Depth x width x height Weigth installation arm with valve and chuck Below 96 db (A) Not measureable 280 x 850 x 320 mm 6.5 kg 50 Products in bold are stock items, other items are produced to order.

51 Swellex installation pumps Swellex pump H1 and HC1 The hydraulic Swellex pump H1 is designed to be used with hydraulic bolting rigs. The H1 is robust and reliable. It can be used with a manual installation arm or it can be integrated with the rig's installation system. Swellex H1 hydraulic pumps are only available in stainless steel version to resist corrosion, provide a long life expectancy and low operating costs. The HC1 version has been designed to assure the quality of installation by controlling the inflation until the required pressure is reached. It then maintains this pressure for a set period of time so the bolt is fully expanded around the irregularities inside the borhole and the best anchorage capacity and a perfect installation is granted. When Swellex HC1 is used with a drill rig equipped with the CANBUS control system, an optional function is available for recording number of bolts installed and inflation pressure. Areas of use Swellex hydraulic pumps are preferred when high bolting performance is required. To be used with hydraulic rigs. With the HC1, the inflation process is fully con trolled by the pump system and is not affected by human factors. Productivity characteristics To be used with hydraulic rigs. Short inflation time. Simple and robust. Quality of installation is assured with the HC1. Technical data Accessories H1 HC1 Product number kg 38 kg Max. inlet water pressure Max. otlet water pressure 20 bar 320 bar Max. water temperature 70 ºC Max. water consumtion Hydraulic pressure Hydraulic flow Vibrations in the instal. arm 17 litres/min bar 40 litres/min. Not measureable Electric voltage - 22V max. 28V DC Power consumption Max. 2A CE marked yes yes Dimensions (L x W x H) installation arm with valve and chuck 550 x 280 x 270 mm 6.5 kg Chucks Manual installation chuck for Pm/Mn Swellex chuck Pm/Mn 16 & Installation arms with chucks for manual installation L=1.6 m for Pm/Mn L=1.6 m for Pm/Mn 16 & L=1.6 m with manometer for Pm/Mn 12 L=1.6 m with manometer for Pm/Mn 16 & 24 L=1.6 m HC1 arm for Pm/Mn 12 L=1.6 m HC1 arm for Pm/Mn 16 & 24 Upgrade kit for conventional Swellex arm Hydraulic Hose/cable set 5 m for HC Products in bold are stock items, other items are produced to order. 51

52 Swellex installation pumps Swellex E1 The electric Swellex pump E1 is a fast and quiet, high pressure water pump. It has an electrically driven Triplex plunger pump for up to 320 bar installation pressure. The main advantage is that the flow delivered by the pump is independent of the water pressure and thus speeding up the bolt expansion process. The expansion time for a 6.0 m long Mn24 or Pm24 rockbolt is less than 60 seconds. The pump is equipped with electric main switch, a pressure sensor on the incoming water side and an outlet pressure sensor with signal light. The outlet pressure from the pump can easily be adjusted via a pressure switch. The pump can also be used as a high pressure washing unit when used with Atlas Copco dedicated washing nozzle. Productivity characteristics Can be used with any types of rigs or equipment where electricity is available. Can be ordered with required current and voltage requirements. Robust with short inflation time. Areas of use Swellex Electric pump E1 is the favourable tool when high performance bolting is required with various types of rigs and equipment. Can be used with hydraulic rigs or others. Can be used for manual or mechanized bolting. The pump is equipped with a time control system so the inflation process is unlikely to be affected by human factors. Technical data Accessories Product number E1 400 VY Europe E1 200/220 VD Japan E1 440 VY, CE-60Hz Japan E1 480 VY, CSA 60 Hz E1 525 VD, CE 50 Hz South Africa E1 575 VD, CSA 60 Hz Ext. hose for arm, 5 m long data Max. working pressure for water 320 bar Suppy water pressure 2-20 bar Chucks Manual installation chuck for Pm/Mn 12 Manual installation chuck for Pm/Mn 16 & Installation arms with chucks for manual installation L=1.6 m for Pm/Mn L=1.6 m for Pm/Mn 16 & L=1.6 m with manometer for Pm/Mn 12 L=1.6 m with manometer for Pm/Mn 16 & Max. supply water temperature 40 ºC Flow rate 12 litres/minute at 50 Hz Connections water Claw coupling (1/2") Noice level at op. ear, 4 m away Vibrations in the installation arm Depth x width x height Weigth installation arm with valve and chuck Below 60 db (A) Not measureable 450 x 775 x 450 mm 6.5 kg 52 Products in bold are stock items, other items are produced to order.

53 Quality assurance Atlas Copco Swellex products are all manufactured according to strict ISO rules. Stringent incoming quality control assures high quality materials are used. Extensive quality testing is performed to assure that the products are adequate for the Atlas Copco brand. The quality assurance consists of: Letter of compliance Quality control stamps Pressure gauges Pull testers Steel sleeves Letter of compliance The letter of compliance is Atlas Copco's guaranty to the customer that the quality and performance of the products meet the required standards and specifications. If required by a customer, the letter of compliance can be issued for a particular order but Atlas Copco also provides a standing letter of compliance that states that all our products meet the specifications they are built for. It is a promise that Atlas Copco delivers what it claims. And it is the final step of the quality assurance process, as it seals the whole QA process into one final certifying document. Letter of compliance No. Buyer: Date: Order: Shipment number: Swellex Pm12 rockbolts Swellex Pm12 rockbolts are manufactured with a specially developed steel within the S355MC specifications according EN Swellex Pm12 rockbolts meet or exceed the breaking load, yield load and elongation specifications stated below. The production quality is continuously monitored and evaluated. Each bolt is marked with an individual batch number. The documentation system makes it possible to trace the bolt all the way back to the steel mill. Swellex rockbolts are designed, manufactured and tested to meet ASTM F 432 Standard. Swellex rockbolt production is ISO 9001 certified. Specification - Swellex Pm12 Technical data General data Type of steel... S355MC Profile diameter.. 27 mm Minimum breaking load.120 kn* Material thickness..2 mm Minimum elongation A % Original tube diameter.41 mm Minimum yield load kn Upper bushing. 28 mm Installation pressure MPa Recommended bore hole diameter mm * According to EN ATLAS COPCO MAI GmbH Werkstrasse 17 A-9710 Feistritz/Drau Letter of complicance Quality control stamps The alphanumerical code stamped on the bushing of every Swellex rock bolt manufactured by Atlas Copco allows the product to be quality controlled from the steel mill up to the manufacturing day. Quality pressure assurance gauge The pressure gauge for quality assurance is a simple tool designed to be used by the operator to verify the pressure delivered by the pump. It is to be used at the beginning of the shift or at any time when there is a doubt regarding the inflation pressure delivered to the Swellex. Quality control stamp on each head Gauge Pressure gauge for Pm12, Mn12 QA pressure gauge Ø 30 mm Pressure gauge for Pm16, Pm24, Mn16, Mn24 QA pressure gauge Ø 40 mm Products in bold are stock items, other items are produced to order. 53

54 Quality assurance Pull tester Hydraulically operated test equipment with digitally displayed test results. Atlas Copco Swellex products are the easiest to test for installation quality and random quality testing thanks to the original adapter that allows to pull-test any Swellex bolt at anytime, without special set up during the bolt installation. Accordingly, new and old Swellex bolts can be tested with the same ease. Atlas Copco provides a complete pull tester set for the customer's convenience. The Swellex pull-tester is designed to meet the highest demands on accuracy and portability that professional users in the mining and tunnelling industry put on a measuring instrument of this type. With Swellex pull-tester you can test any installed Swellex bolt. The adapter sleeve grips around the head of the bolt when you set up the equipment and you do not have to prepare a bolt for pulltesting prior to installation. This means that you can easily pull test bolts installed a long time ago. You can pull-test bolts with or without face plates. Pull test equipment Pull tester Pull tester complete Mechanical parts for pull tester Pull tester hose, 700 bar, 6m Steel sleeves When performing non destructive sliding tests to estimate the specific anchorage capacity of Swellex bolts in a given rock type or rock mass conditions, it is customary to use steel sleeves passed over the profile to reduce the effective anchored length, thus enabling to slip out the bolt without failure. Atlas Copco can also provide those sleeves for the customer convenience. Steel sleeves are an important tool when performing anchorage capacity pull tests. These tests are done to verify that the rock bolt can provide the necessary retaining force to hold the rock in place. Swellex Pm12 bolts Sleeve, length 300 mm Steel sleeves provided for performing anchorage capacity estimation Swellex Mn12 bolts Sleeve, length 300 mm Swellex Pm16, Pm24, Mn16, Mn24 bolts Sleeve, length 300 mm Products in bold are stock items, other items are produced to order.

55 Swellex accessories Mesh washers The Swellex Mesh Washers are used for installation of wire mesh on already installed Swellex rock bolts. This special friction washer is pushed over the inflation bushing head and can carry over 10 kn. Care must be taken that the washer is pushed straight over the bushing head and that the teeth of the hole are not broken or bent during the process. Swellex mesh washers Adapted to Outer Ø Capacity (kn) Product number Mesh washer installation Circular mesh washer Swellex Pm12 Swellex Mn Adapted to Dimensions Capacity (kn) Product number Square Mesh Washer Square Mesh Washer Square Mesh Washer Swellex Pm12 Swellex Mn12 Swellex Pm16 Swellex Mn16 Swellex Pm24 Swellex Mn x x x Mesh washers Colour plugs Color plugs are designed to help differentiate the length of Swellex bolts once the bolts are installed in the excavation. When more than one length of Swellex bolts are used in the same excavation, colour plugs are an easy and efficient way to perform quality control on the reinforcement system as they allow rapid identification of the bolt. Colour plugs Indicated bolt length (m) Colour plug, orange Colour plug, natural Colour plug, blue Colour plug, green Swellex colour plugs Colour plug, red Colour plug, white Colour plug, yellow

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