DSI Cable Bolts

Cable Bolts
Table of Contents Section

Mechanical Rock Bolts, Extension Bolts & Stelpipe Bolts 1
Rebar Rock Bolts 2
Cable Bolts 3
Friction Stabilizers & Expandable Bolts 4
Threadbar 5
Trusses & Slings 6
Specialty Bolts 7
Fiberglass Bolts 8
Resins & Cement Cartridges 9
Mesh, Straps & Plate Washers 10
Eyebolts, Scaling Bars & Utility Hangers 11
Tools & Hardware, Drilling Consumables 12
Lattice Girders, Steel Arches & Props 13
High Performance Grouts & Application Equipment 14
Drilling Fluids 15
Miscellaneous 16
www.dsiunderground.com
DYWIDAG-SYSTEMS INTERNATIONAL
August 2012 www.dsiunderground.com
Section3-Page1
Minicage Cable Bolts (Plain & Bulb)
0.5", 0.6" and 0.7"
Plain Cable Bolt
Bulbed Cable Bolt
Dimensions
Physical Properties
Construction Details
Section3-Page2
Installation Accessories
Cable Bolts
End Holding Device - conventional style
to hold cable bolt prior to grouting
2 straps
3
/4" x 2
3
/4" (19 mm x 70 mm)
suitable for 2" (51 mm) to 2.5" (64 mm) hole
can be ordered separately and site installed
if factory ordered, straps removed for shipping
not available for double cable bolts
End Holding Device - sh hook style
hooks swaged on with steel tubing
hooks can be bent out to accommodate
any hole size
for single or double cable bolts
tting holds double cables together
0.5", 0.6" & 0.7" Machined Cable Grip - to fasten plates
rated for full load of cable bolt
1
1
/4" (32 mm) for 0.5" cable bolts
1
1
/2" (38 mm) for 0.6" cable bolts
c/w 2 part gripper wedges
available galvanized
optional plastic cap to secure wedges
during shipping
0.6" & 0.7" Cast Domed Cable Grip
- to fasten plates
2" (51 mm) domed face
c/w 2 part gripper wedges
wedges available with or without
groove & retaining spring
available galvanized
optional plastic cap to secure wedges
during shipping
Section3-Page3
Passive Spinnable Cable Bolt - for resin installation
0.6" & 0.7" cable available
resin anchored
bulbs provide resin mixing and anchoring
accepts 1
1
/8" square or hex male spinner
available plain or galvanized
cable available in any length
factory assembled
Strand Lok
available with minimum 4 ton or 12 ton terminal
easy installation, no cement to mix
dissipates impact shock
maintains bond between cable and resin grout
enhanced one pass support
bulge diameter and spacing variable
ideal for conned spaces
superior shear strength for one pass support
higher ultimate tensile
installed with high strength low viscosity strand-loc resin
resin compressive strength exceeding 100 MPA
Youngs modulus 11-13 GPA
custom cartridge diameter and length
Installation Procedure
drill a 1" hole to a depth which will allow the bolt to bottom out when fully inserted
insert the Strand-Lok resin cartridges
manually push the Strand Bolt into the resin to within 2' or 3' of full penetration
Spin the Strand Bolt through the resin to complete the insertion and then continue spinning
for an additional 10 seconds at full insertion
on tensioned installations allow sufcient time for the resin to gel and gain strength before torquing
Notes
the 12 ton terminal is designed for where collar support is needed
a recessed terminal has been designed to be used in close quarters where the
protruding termnal would be an obstruction
a coupled extension drill steel has been designed to keep the "extension" drill
hole size at 1"
Installation Accessories continued
Section3-Page4
0.6" & 0.7" Dogbone Cable Coupler
used to join cables for slings or trusses
used to wrap failing pillars
requires 2 sets of wedges (included)
Grout and Breather Tubing
" ID x
7
/8" OD black poly tubing (400' roll)
" ID x
7
/8" OD high density grout tubing (400' roll)
" ID x
5
/8" OD regular poly tubing (400' roll)

3
/8" ID x " OD high density poly tubing (500' roll)
black poly tubing rated for 100 psi
yellow high density tubing rated for 200 psi
Installation Accessories continued
Section3-Page5
Cable Bolt
0.6" or 0.7" Passive and Tensionable
270 ksi, low relaxation cable per ASTM A416.
Supplied in any length, black or galvanized cable.
Point anchored active bolt, tensioned after
installation utilizing the hydraulic tensioning jack.
Point-anchored passive bolt with pre-seated
head. Wedge barrel shaped to accept 1
1
/8" hex or
square male spinner.
Several options for anchoring in the resin are
available: The bulbed cable bolt is designed
for point-anchoring in resin. It may also be fully
grouted with slow speed resin, or cement grouts.
Bulbing is an effective means to center the bolt
in the drill hole, to mix the resin and to develop
bond for anchoring the bolt.
The Bond head is an additional bulb that can be
formed on the end of the cable bolt.
Bulbs are provided to t hole sizes:
1" hole: strip cage
1
3
/8" hole: plunge bulb
1" hole: bond head
Ultra low passive heads can be provided for low
clearance situations.
Section3-Page6
CBJ-1 Cable Bolt Tensioning Jack
For installation of bearing plates
Specications
for 0.6" (15.2 mm) or 0.7" (17.8 mm) cable bolts
maximum load 25 ton @ 10,000 psi (225 kN @ 70 MPa)
stroke = 3" (75 mm)
double acting hollow core ram
aluminum construction - weighs only 10 lbs (4.5 kg)
requires double acting hydraulic pump or hand pump
L = 11.75" (300 mm)
D = 4" (102 mm)
Parts
Seal Kit includes:
1 - 2.25" AN wiper
1 - 2.25" x 2.75" x 3.75" rod seal
1 - 1.25" x 1.75" x 0.250" rod seal
1 - 2.31" O-ring
1 - 2.875" T-seal
1) Regularly ensure autogripper is
screwed hand tight into the hollow
core ram.
2) Ensure the cable strand is free
from mud and dust. Also regularly
clean the autogripper wedges.
Section3-Page7
Torque Tension Relationship for CB1-1
Cable Jack with 3.4:1 Intensier
Specications
for 0.6" (15.2 mm) or 0.7" (17.8 mm) cable bolts
stroke = 3" (75 mm)
double acting hollow core ram
aluminum construction - weighs only 10 lbs (4.5 kg)
requires double acting hydraulic pump or hand pump
L = 11.75" (300 mm)
D = 4" (102 mm)
0.6" Cable Tensioner with 3.4:1 Intensier Pressuer Vs Load (LBF)
2000 Psi Maximim Working Pressure
Note
cylinder area = 5.01 in
2000 psi is the maximum pressure allowed for use with 0.6" cable
L
o
a
d

(
L
B
F
j
Pressure (Psij
0 250 500 750 1000 1250 1500 1750
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
2000
Section3-Page8
Operating Procedure
For intensied cable truss tensioner
of the dogbone/wedge barrel.
A minimum of one inch of cable tail should
protrude from the end of the autogripper
assembly. (If the cable does not protrude
from the back of the tensioner the minimum
one inch length the jaws will not grip the cable
properly. There is signicant risk that the cable
will strip the wedge teeth).
Pressurize the cylinder to the desired load
(2,000 psi/17 ton maximum for the 0.6 x 30
ton cable see appendix 1 for a pressure
versus load plot). If the cylinder runs out of
travel before the load is reached, release the
pressure and slide the cylinder on further and
repeat the tensioning process.
The following wear components are available
for purchase from your local DSI supplier
(appendix 2):
Autogripper assembly
Autogripper wedges
O-Ring kit
Banana Nose
Ensure that all hydraulic ttings are tightened
before operation, and that the unit is in good
working order. Check the following:
There are no major dents in the housing.
That the autogripper assembly (gold in color)
is fully tightened against the face
of the piston.
That the autogripper wedges are in good
condition and are not chipped, dented or
missing teeth.
That there are no major leaks in the system.
Monitor during use the following
The autogripper remains screwed in tight
against the face of the piston
The gripper wedges do not become too dirty
That the wedge teeth do not wear too badly.
The autogripper wedges are designed for
reuse, but eventually need replacing.
Before placing the tensioner onto the cable,
ensure the cable has minimal dirt and or dust on
its surface. This dirt and dust will make it harder
for the wedges to grip the cable.
Slide assembly onto the tail of the cable until the
tensioner nose is fully seated against the wedges
Section3-Page9
Cable Tensioner Mark2
For tensioning cables and installing plates
Specications
A light weight and unique way for pre-loading
cable bolts, the DSI Cable Tensioner Mark2 grips
the end of the cable bolt and tensions it, leaving
only a short tail protruding from the bearing plate
(approx. 6"). The Cable Tensioner is a single
hydraulic ram driven by an air/hydraulic pump or by
machine hydraulics.
The jack weighs 25 lbs. The entire kit (jack
and pump) weighs 51lbs.
Two grip handles allow for operation by
one person.
Unit locks on the cable, until lanyard is pulled
to release spring loaded grippers.
Can be congured for all cable bolts, from 0.6"
to 0.7" and the DSI 0.9" HITEN cable bolt.
Capacity: 48,500 lbs
Bleed off: 15% i.e. cable lock-off load is 85%
of pulling force due to seating loss.
(for a typical 12' bolt)
Operation
Install the plate and wedge barrel with wedge on
the end of the cable bolt.
Push the Cable Tensioner on. It will self-lock onto
the cable.
Tension bolt to the desired load per hydraulic gage
included with the unit.
After stressing, the Cable Tensioner is easily
removed by pulling on the lanyard to release the
internal grippers.
Section3-Page10
Installation Guidelines
28mm hole diameters are preferred.
Hole depth is critical. Hole depth should
be approximately 155mm shorter than
the bolt length.
This allows for sufcient tail to t accessories,
roof plate, collar/wedges & Tensioner Unit.
After insertion of the chemical anchors the
bolt is rotated through the anchors while
pushing the bolt, fully, to the back of the hole.
It is important to follow the chemical
manufacturers recommended mixing and
hold times as printed on the chemical
anchor cartons. DO NOT OVER MIX.
The tensioner unit is connected to the HI-
TEN Strand Bolt and tension applied.
For further details refer to DSIs Tensioner
Unit user instruction guide.
Standard Lengths & Packaging
Standard HI-TEN Strand Bolts lengths
range from 4100 to 8100mm.
Collar/wedge assemblies are
supplied separately to the bolt.
Non-standard requirements are
available by negotiation.
HI-TEN Strand Bolt
General Features
The DSI HI-TEN Strand Bolt is a cable
designed to be installed as a long rock bolt
which is capable of being post-tensioned
at the face, or out-bye, to loads of up to
27 tonnes using the DSI Tensioner Unit.
The HI-TEN Strand Bolt is manufactured
from 21 wire strand having a 12mm square,
for mixing chemical anchors, welded to one
end of the strand.
The HI-TEN Strand Bolt has a special collar
and segmented wedge, which can sustain
collar loads of between 57 and 60 tons.
The HI-TEN Strand Bolt is designed for high
pre-tensioning using a point anchor system.
If full encapsulation is required, extra
slow speed chemical anchors of 20
minutes set time are available.
The HI-TEN Strand Bolt can also be
effectively used with cementitious grouts.
The HI-TEN Strand Bolt concept allows a
longer than seam height bolt to be installed
at up to 30 from the vertical at the face,
or out-bye, to supplement existing strata
reinforcement. Compatible domed plates
are available to be used with the
HI-TEN Strand Bolt.
The HI-TEN Strand Bolt system
is patent pending.
Section3-Page11
The Wedge Anchorage of the Cable Bolt
The anchorage of most cable bolts consists of a
wedge barrel and a 2- or 3-part wedge. The wedge
segments grip the cable by means of tooth shaped
threads which are forced into the surface of the
cable wires.
Warning: If friction increases (due to corrosion),
a larger F will reduce the clamping force. As V
increases all other forces can only increase if the
wedge can seat deeper into the barrel. If the wedge
is restrained to do so (i.e. by corrosion or dirt-
accumulation), the clamping force can not increase
with the pulling force causing slippage when the
load on the cable bolt gradually increases during
service life.
To avoid slippages during use, it is important that
the cable bolt is fully stressed at time of installation
to a force equal to 0.5 Fu. (i.e. 50% of the capacity
of the cable)
The clamping force W is highly dependent on
the friction between wedge and wedge hole. For
normal friction conditions, the clamping force W is
more than 4 times the cable pulling force V and it
adjusts with the pulling force V.
When a wedge is properly seated, radial cracks
may develop indicating adequate seating.
The wedge can be supplied with a rubber
O-ring or a metal spring ring holding the wedge
segments together.
A RGE NT I NA
A US T RA L I A
A US T RI A
BE L GI UM
BOS NI A A ND HE RZ E GOV I NA
BRA Z I L
CA NA DA
CHI L E
CHI NA
COL OMBI A
COS T A RI CA
CROA T I A
CZ E CH RE P UBL I C
DE NMA RK
E GY P T
E S T ONI A
F I NL A ND
F RA NCE
GE RMA NY
GRE E CE
GUA T E MA L A
HONDURA S
HONG KONG
I NDONE S I A
I T A L Y
J A P A N
KORE A
L E BA NON
L UX E MBOURG
MA L A Y S I A
ME X I CO
NE T HE RL A NDS
NORWA Y
OMA N
P A NA MA
P A RA GUA Y
P E RU
P OL A ND
P ORT UGA L
QA T A R
RUS S I A
S A UDI A RA BI A
S I NGA P ORE
S OUT H A F RI CA
S P A I N
S WE DE N
S WI T Z E RL A ND
T A I WA N
T HA I L A ND
T URKE Y
UNI T E D A RA B E MI RA T E S
UNI T E D KI NGDOM
URUGUA Y
US A
V E NE Z UE L A
USA
DSI Underground Systems, Inc.
9786 S Prosperity Road
West Jordan, UT 84081, USA
Phone: +1-801 973-7169
Fax: +1-801 973-7172
447 DuPont Rd.
Martinsburg, WV 25404, USA
Phone: +1-800 332-3308
Fax: +1-304 274-4194
700 Technology Drive
South Charleston, WV 25309, USA
Phone: +1-800 547-4751
Fax: +1-304 553-0924
1959 Old White Plains Road
Mortons Gap, KY 42440, USA
Phone: +1-800 547-4751
Fax: +1-270 258-9204
9344 Sunrise Road
Cambridge, Ohio 43725, USA
Phone: +1-800 457-7633
Fax: +1-740 432-2827
26161 Old Trail Road
Abingdon VA 24210-7631, USA
Phone: +1-276 623-2784
Fax: +1-276 623-8273
1774 Mellwood Ave
Louisville KY 40206-1756, USA
Phone: +1-502 473-1010
Fax: +1-502 473-0707
1032 East Chestnut Street
Louisville KY 40204-1019, USA
Phone: +1-502 583-1001
Fax: +1-502 583-7865
Canada
DSI Canada Ltd.
3919 Millar Avenue
Saskatoon SK S7P 0C1, Canada
Phone: +1-306 244-6244
Fax: +1-306 931-3481
Please Note:
This brochure serves basic information
purposes only. Technical data and information
provided herein shall be considered
non-binding and may be subject to change
without notice. We do not assume any liability
for losses or damages attributed to the use
of this technical data and any improper
use of our products. Should you require
further information on particular products,
please do not hesitate to contact us. www. dsi underground. com
DSI Canada Ltd.
199 Mumford Road
Unit C&D
Lively ON P3Y 1L2, Canada
Phone: +1-705 692-6100
Fax: +1-705 692-0441
DSI Canada Ltd.
853 Boulevard Rideau
Rouyn-Noranda, QC J9Y 0G3, Canada
Phone: +1-819 762-0901
Fax: +1-819 797-1367
Mexico
DS International S.A. de C.V.
Carretera a Base Area Militar No. 1002
Bodegas 13, 14 & 15
Parque Industrial FERRAN
San Juan de Ocotn, Zapopan, Jalisco
Mxico CP 45010
Phone: +52-33-3366-57-94
Fax: +52-33-3366-58-03
Brazil
DSI Fosminas
Rua Um, 276
Distrito Industrial da bela Fama
Nova Lima/MG, Brazil
Phone: +55-31-35 42 02 00
Fax: +55-31-35 42 08 10
Chile
DSI Chile Industrial Ltda.
Las Encinas #1387
Valle Grande
Lampa, Santiago de Chile, Chile
Phone: +56-2-596 96 20
Fax: +56-2-596 96 69
Colombia
DSI Colombia S.A.S
Carrera 43A No. 8 sur 15 Oficina 403
Edificio Torre Oviedo
Medelln, Colombia
Phone: +57-4-403 12 00
Fax: +57-4-403 12 01
Peru
DSI Peru S.A.C.
Calle Rodolfo Beltran No. 947
Lima 1, Per
Phone: +51-1-431 3157
Fax: +51-1-638 3201

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