Prof (Dr) A K Mishra

Indian School of Mines

Physical Properties
Shape & Size
The Roof bolt shall be of MS Steel or TMT Rebar having circular
cross-section with ribs on circumferential region.

The design, calculations, Yield Strength and Ultimate Tensile

Strength along with elongation at Yield and the factor of safety of
the roof bolt has to be defined clearly.

Length
Length of the Roof Bolt shall not be more the designed length + 5mm

Straightness
The roof Bolt shall be straight without any joint, welding, deviation or
deflection.

In case of deflection and deviation cannot avoided due to practical

reasons, it shall not be more than + 0.1 % per meter length of the bolt.

Rib
The Rib of the Roof Bolt shall be as per the design of the rib with an
objective to maximize the surface area without reducing the core
diameter of the roof bolt and having maximum grip with the grout.

the height of the rib shall be kept within the standard prescribed in IS
1786 2008 or BS 7861 (Part 1) 1996 or latest revision thereof.

Physico-mechanical Properties
Steel for the Roof Bolt
The roof bolt shall be of thermo-mechanically treated
(TMT) rebar manufactured from MS Grade Fe-500, Fe600 or above.

The minimum load bearing capacity (Anchorage Load) of

the roof bolt shall be 160 kN.
The Yield Stress, Tensile Strength and % elongation steel
Grade shall be maintained as per the IS 1786 and IS
13920.

Chemical Composition
Chemical composition of the steel for manufacturing of the roof bolts
varies according to the requirement of strength characteristics and
specific applications.
Certain chemical constituents of the steel which influence the required
properties of steel are
Sl. No.

Constutuent

Percentage by weight

Carbon

0.25 (Max)

Sulfur (S)

0.05 (Max)

Phosphorous(P)

0.05 (Max)

Manganese

1.5 (Max)

Other Alloying/micro
alloying elements

0.50 (Max)

Thread on the Roof Bolt

The thread on the roof bolt shall be M20 cold rolled thread
conforming to IS 4218 (part- 2 & 3) and no cut thread shall be used.
The minimum length of the thread shall be 150 + 5mm and the
tolerance class designation of 8g.

The thread shall conform to tolerance class of 7H.

As a routine test, one thread in every 50 produced shall be checked
using a go/no-go gauge.

Non-threaded end
The non threaded end of the rock bolt shall be formed by cropping or
sawing.

It shall be free from burrs and edges which protrude beyond the
profile of the rock bolt.
Nut
The Nut shall be of hexagonal shape of thickness not less than 30mm
conforming to IS 1363 (Part-3) and the thread shall conform to
tolerance class of 7H.

Pull Test
Thread and the Nut on the roof bolt shall be subjected to pull test
which should not slip at the yield strength/load of the roof bolt.
The anchorage strength of roof bolt is determined for generally
check, that the rock bolt can sustain the specified conditions in prespecified load conditions of rock strata.

As per DGMS, the anchorage and setting time relation is

Sl. No.

Setting Time

Anchorage (Te)

30 min

2 hrs

24 hrs

10

28 days

12

Bearing Plate
The Bearing Plate of the roof bolt shall be Dome Washer Plate of
dimension 150 x 150 x 8 (minimum) mm with compatible central
hole of required size and angled side to ccommodate the conical seat
and nut.
The minimum load at which the Domed Washer Plate will become flat
should be at least 14 Tonnes.

Conical Seat
Conical Seat shall be of forged steel of required dimension.
The Conical Seat shall not deform at 1.20 times the Yield stress of the
roof bolt.

Tensile Test of the Roof Bolt Assembly

The Roof Bolt Assembly shall be subjected to Tensile Test and should
not fail up to 16 Tonnes load.

Weatherability
The Roof Bolts and its components or parts shall be subjected to
Accelerated Weathering Test in mine water condition for 20 days.
No deterioration should occur on the Assembly.
Accelerated Weathering Test shall also be conducted in acidic water
condition for 20 days during which no deterioration should occur on
the Assembly.

Corrosion Resistance Test

The Roof Bolt Assembly shall also be subjected to Field Exposure
and Corrosion Resistivity Test as per IS- 5555: 1970
It is to test the resistance to corrosion of the steel of the roof bolt and
its parts.

SAMPLING & TESTING

To check the composition and required parameters during
manufacture, random sampling be done @ of 2 roof bolts per 1000
pieces of roof bolts and its accessories.

Shall be signed by the persons carrying out the test and shall be
countersigned by the quality
control officer posted at the
manufacturing unit(s).

 The user shall carry out Physical examination tests as far as

possible but shall conduct Tensile Test of the Assembly for every
batch of Roof Bolts & its Accessories.

In case the Roof Bolts or any of its accessories fail to pass the
required tests at the users end, that batch or lot of the manufacture
shall not be used in the mine and intimation thereof shall be sent to
the manufacturer.
The Chief Inspector of Mines or an Inspector of Mines may

Inspect and check

Examine the manufacturing facilities at any time
Get samples tested during the course of inspection
Send such samples for testing at any national test houses/laboratories at the cost
of the manufacturer
May inspect, check and examine the roof bolts and its accessories at any time in
the mine or the area of the mines and get samples tested

 All the Owner, Agent and Manager including the

manufacturers and suppliers shall be required to
comply with this standard and any deviation or defects
found in the product supplied or used in the mine, shall
be bought to the notice of this Directorate.
Manufacturers and the Users including the Test Houses,
who are engaged for testing of such material, are
therefore requested to ensure the above mentioned
Standard and Parameters before supplying and using at
the mine.

Standards for use of Resin capsule as grouting material

Shape & Size
The measured gel time and setting time of the resin capsule shall conform to
the
Gel Type

Setting Time

Fast Set

23 sec to 54 sec

Slow Set

134 sec to 202 sec

Reaction Temperature and Thermal Stability

The reaction temperature and thermal stability of resin capsule shall
conform to
Reaction Temp (oC)

Not more than 80

Thermal Stability
At 5 oC for one hr
At 45 oC for one hr

The sample shall satisfy gel

time and setting time
mentioned above

Physico-Mechanical Properties
The physico-mechanical properties of the resin capsule after setting
shall conform to
Sl. No.

Properties

Remarks

Compressive strength: (for slow-set type)

30 min
30MPa (min)
24 hrs
80MPa (min)

Bond Strength Test:

30 min
24 hrs

10 Tonnes
15 Tonnes

Shear Test

19 MPa (min)

Shrinkage Test: (for slow-set type)

24 hrs
7 days

0.01% (max)
0.01% (max)

Flammability Test

The product should

be of very low
flammability

Rock Bolt Installation

More versatile
Costly

Limited
Inexpensive

Roof Bolting
Support Principles
Support Parameters
Shotcrete

Bolting Principles
What is the Bolt System Designed to do?

Beam building
Suspension
Keying
Surface control - natural arch

Beam Building

Support Principles

Laminated
Weak
Strata
Strata

Individual laminations
bound together to form a
single beam

Suspension
Competent
Strata

Weak
Strata

Support Principles

Anchorage
Zone
Suspended layer

Keying
Fractured
Rock
Weak
Strata

Support Principles

Surface Control
Support Principles

Highly jointed, altered or

weathered rock

Critical Parameters
Bolt Type
Strength
Grade
Diameter
Length
Density (spacing)
Plate

Types of Bolts
Friction Anchored
Mechanical
Fully Grouted
Tensioned Rebar
Combination/Point Anchored
Mechanically Anchored/Resin
Assisted

Support Characteristics
Anchorage
Clamping
Vertical Stiffness
Horizontal Stiffness

Friction Anchored Support

Splitsets or Swellex Bolts
Split sets provide minimal support (~1
ton per foot of anchorage) when
utilized in a suspension application.

Friction anchored bolts

SPLIT TUBE

EXPANDING TUBE

Mechanisms of friction anchor bolts

LOW ANCHORAGE
DEVELOPED ALONG
BOLT LENGTH

NO CLAMP
LOADS

LITTLE OR NO SHEAR
RESISTANCE ALONG
SLIPS AND JOINTS
UNLESS INTERSECTED
BY BOLT

LOW PLATE LOADS

Split Sets
Inexpensive
Easy to Install
No resin cartridges
Can be installed in soft or shifting ground

SPLITSET

RADIAL FORCE

SWELLEX

DYWIDAG BOLT

Friction Anchor Bolts

Critical Parameters
Bolt Type
Strength
Grade
Diameter

Length
Density (spacing)

Plate

EXPANSION SHELL
ANCHOR BOLT

PARTS OF A BOLT
SHELL
STANDARD ( HARD ROOF )
BAIL
( SOFT ROOF )
PLUG
SPREADS SHELL
SUPPORT NUT (PAL NUT or JAM NUT)
HOLDS SHELL IN PLACE - THEN BREAKS
AWAY
WASHER
ACTS AS LUBRICATION BETWEEN PLATE AND
BOLT HEAD

WHAT DOES GRADE OF

A BOLT MEAN ?
GRADE 75 MEANS THE BOLT HAS
A TENSILE STRENGTH 75,000 PSI
-TENSION BOLTS

GRADE 60 MEANS THE BOLT HAS

A TENSILE STRENGTH 60,000 PSI
-NONTENSION BOLTS

WHAT DOES THE TERM

#5 REBAR MEAN ?
THE DIAMETER OF BOLT ARE
STAMPED IN 1/8 INCH INCREMENTS
SO A #5 HAS A DIAMETER OF 5/8
INCH
A CIRCLE AROUND THE NUMBER
MEANS IT IS A DEFORMED BAR

5/8 INCH REBAR =

ROOF BOLT HEAD

MARKING

5/8 INCH
DIAMETER

Grade 55

ROOF BOLT MARKINGS

GRADE
40
55
60
75
100

DIAMETER
DESIGNATION
3/4 INCH UP
NONE
5/8 INCH UP
5/8 INCH UP
5/8 INCH UP
X
5/8 INCH UP

Plugs

Bail

Shell Leaves
Support Nut

Bolts

BAIL

STANDARD

STANDARD 4 LEAF TYPE

EXPANSION SHELL

THREE PRONG EXPANSION

SHELL

TWO LEAF BAIL TYPE

EXPANSION SHELL

JAM NUT
TO STRONG

JAM NUT
TOO STRONG
( DOES NOT
BREAK AWAY
AND DEFORMS
THE SHELL )

DEFORMED SHELL

JAM
NUT
TOO
WEAK

JAM NUT
TOO WEAK
( BREAKS AWAY
TOO SOON
AND DOES NOT
EXPAND SHELL )

WHAT IS THE RELATIONSHIP

BETWEEN THE WASHER AND
THE TENSION IN THE BOLT ?
THE K FACTOR IS THE RELATIONSHIP
BETWEEN THE WASHER & TENSION IN
BOLT
NO WASHER
K = 40
HARDENED WASHER
K = 50
ANTIFRICTION WASHER K = 75 > 125
HARD PLASTIC

K FACTOR cont.
TENSION IN BOLT = K x TORQUE
FOR A BOLT USING A HARDEN
WASHER AND HAS A TORQUE OF
150 FT- LBS
TENSION IN BOLT = 50 x 150
TENSION IN BOLT = 7500 LBS

MECHANISMS OF MECHANICAL BOLTS

MODERATE TO HIGH
ANCHORAGE
DEPENDING ON THE
STRATA
MODERATE
CLAMP
LOADS

CLAMP LOADS DEVELOP

SOME SHEAR RESISTANCE
ALONG BEDDING PLANES,
SLIPS AND JOINTS

MODERATE PLATE LOADS

MECHANISMS OF FULLY GROUTED BOLTS

HIGH ANCHORAGE
DEVELOPED ALONG
BOLT LENGTH
HIGH SHEAR RESITANCE
ALONG RESIN/ROCK
INTERFACE
NO CLAMP
LOADS

LITTLE OR NO SHEAR
RESISTANCE ALONG
SLIPS AND JOINTS
UNLESS INTERSECTED
BY BOLT

LOW PLATE LOADS

RESIN ANCHOR
TORQUE TENSION BOLT
IN THE FIRST
TYPE OF
INSTALLATION,
TWO FOOT OF
FAST SETTING
RESIN IS USED,
AND THE REST
OF THE HOLE IS
LEFT OPEN

RESIN ANCHOR
TORQUE TENSION BOLT
SECOND TYPE, ONE
TO TWO FOOT OF
FAST SETTING
RESIN IS PUT IN
THE BACK OF THE
HOLE, WHILE SLOW
SETTING RESIN IS
PUT IN THE
BOTTOM OF THE
HOLE

Aluminum Plug

Threaded
Deformed
Bar

Cast Dome

Shear Pin

TENSION NUTS

Tension Nut

MECHANISMS OF TENSIONED REBAR BOLTS

EXTREMELY HIGH
ANCHORAGE REGARDLESS OF STRATA

VERY HIGH
CLAMP LOADS

HIGH SHEAR RESISTANCE

ALONG RESIN/ROCK
INTERFACE
CLAMP LOAD DEVELOPS
VERY HIGH SHEAR
RESISTANCE ALONG
SLIPS AND JOINTS

VERY HIGH PLATE LOADS

Compression Tube

Deformed Bar

Mechanical Bolt

RESIN POINT ANCHOR

WITH REBAR SUPPLEMENT

RESIN POINT ANCHOR

WITH STEEL PIPE SUPPLEMENT

RESIN POINT ANCHOR

WITH

SHEAR PIN & COMPRESSION RING

MECHANISMS OF POINT RESIN ANCHORED BOLTS

HIGH ANCHORAGE
EVEN IN SOFT ROCK

HIGH
CLAMP
LOADS

CLAMP LOADS
DEVELOP
MODERATE SHEAR
RESISTANCE ALONG
BEDDING
PLANES,SLIPS AND
JOINTS

HIGH PLATE LOADS

Threaded
Deformed
Bar

Grout
Column
Tensioning
Coupler
Shear
Pin

Bearing Plate

WHAT IS A SHEAR PIN ?

MECHANISMS OF COMBINATION BOLTS

EXTREMELY HIGH
ANCHORAGE
REGARDLESS
OF STRATA

VERY HIGH
CLAMP LOADS

GROUTED LENGTH
REINFORCES THE STRATA
LIKE A FULLY GROUTED BOLT

CLAMP LOADS DEVELOPS

HIGH SHEAR RESISTANCE
ALONG BEDDING PLANES,
SLIPS AND JOINTS

VERY HIGH PLATE LOADS

Support Characteristics
Bolt Type

Anchorage

Clamping

Vertical
Stiffness

Horizontal
Stiffness

Mechanical

Moderate

Moderate

Low

Low

Fully
Grouted

Very
High

Low

High

Medium/
High

Point
Anchor

High

High

Very
High
Very
High

Very
High
Very
High

Low/
Medium
Medium/
High
Very
High

Low

Low

Low

Combination

Tensioned
Rebar
Frictional
Anchors

Medium

High
Very
High
Low

Full Contact Supports

Anchorage

Length

* Resin Anchored
* Friction Anchored

(Split Sets, Swellex, Friction Loc)

Friction Anchor

Resin Anchor

1 Ton Per Foot

10 Tons+ Per Foot

Anchorage Variable
Along Bolt Length

FULL CONTACT
SUPPORT

Anchorage
Constant
Along The Bolt
Length

POINT ANCHORED
SUPPORT

Anchorage
1 Ton/Ft.
(10 Tons)

Anchorage
10 Tons

10

FRICTION ANCHORED
SUPPORT
(SPLIT SET)

POINT ANCHORED
SUPPORT
(MECHANICAL BOLT)

Anchorage
1 Ton/Ft
(8 Tons)

FRICTION ANCHORED
SUPPORT

10

Anchorage
10 Tons

POINT ANCHORED
SUPPORT

Anchorage
1 Ton/Ft
(1 Ton)

FRICTION ANCHORED
SUPPORT

Anchorage
10 Tons
10

POINT ANCHORED
SUPPORT