Morgantown, WV: West Virginia University, July - Aug. 2013.

32nd International Conference on Ground Control in Mining

A Comprehensive Analysis of Cable Bolt AnchorageCharacteristics
Dakota D. Faulkner, Research
Faulkner,D.
& DevelopementEngineer
Thomas M. Cook, Research
Cook,T.
& DevelopementEngineer
John C. Stankus,
Stankus,J.
President ofKMS
Keystone Mining Services,LLC
Jennmar Corporation,Inc
Pittsburgh,PA

ABSTRACT
Cable bolts anchored with traditional two component polyester
resin cartridges have successfully supported difficult roof
conditions in underground mines. Resin cartridges provide a costeffective cable bolt anchoring system with consistent anchorage
performance characteristics when properly installed. The most
commonly used cable bolts in the U.S. mining industry are 270
ksi (1,862 MPa), 0.7 and 0.6 inch (18 and 15 mm), seven-strand
smooth cable with resin mixing bulbs (also known as bird cages),
and 40- and 30-ton nominal capacity, respectively. However, there
are other types of cable bolt anchoring systems aside from bird
cages. Recently, many questions have been raised regarding the
anchorage characteristics of various types of cable bolts. Keystone
Mining Services, LLC (KMS), the affiliated engineering company
of Jennmar Corporation, conducted a variety of controlled tests
developed to closely model actual underground installations. These
tests compared the performance of three commonly used cable bolt
varieties, including plain, bird caged and indented seven-strand
cable. Details of the laboratory testing and comparative analysis of
the results areprovided.

Anchorage capacity per linear length ofencapsulation;

Angle boltcapacity;
Effects of reverse spinning on installation;and
Effects of long-termcreep.
TESTSAMPLES
All tests were conducted using 270 ksi (1,862 MPa), 0.6 in (15
mm) diameter, left-hand lay cable in plain, bird caged and indented
styles. Samples of these cables are shown in Figure 1. The plain
and bird caged samples used the Jennmar Cable Bolt Safe-TCap while the indented samples used a steel end button. The end
configurations were cut off of all samples and therefore did not
affect the length of encapsulation or the capacity of the anchorage
for each sample. The lay of the cable can be determined by the
direction in which the outer strands of the cable are wrapped
around the center king wire. For left-hand lay cable, the outer
strands wrap in a counter-clockwise direction, down the length of
the cable away from the viewer. The most widely used cable type
in the U.S. is left-hand laycable.

INTRODUCTION
Traditional cable bolts anchored with two component polyester
resin cartridges are a proven and cost-effective cable bolt anchoring
system with consistent performance characteristics when properly
installed. Non-tensioned and tensioned cable bolts are now used for
both primary and supplemental bolting. Cable bolts are typically
installed in either a 1 in (25.4 mm) or 1-3/8 in (35 mm) diameter
drill hole with 4 - 5 equivalent feet (1.2 - 1.5 m) of two-component
polyester resin (Faulkner, 2012). With the introduction of various
new cable supports to the U.S. mining market, tests were conducted
to compare the performance characteristics of each support. These
tests were highly controlled to limit any unforeseen variables
from affecting the results. These tests were developed to simulate
actual installations in an underground mine using two-component
polyester resincartridges.
These tests compare the three commonly used cable bolt
varieties including plain, bird caged, and indented seven-strand
cable, and will compare the following performance characteristics
for each respectivecable:

20

Figure 1. Test Samples, top to bottom: indented cable, plain

cable with a single bird cage and plaincable.

Morgantown, WV: West Virginia University, July - Aug. 2013.

32nd International Conference on Ground Control in Mining

ANCHORAGECAPACITY
The anchorage capacity of grouted cable bolts was determined
by performing tensile tests on cable samples with various lengths
of resin encapsulation. These tests were conducted to determine the
minimum amount of resin anchorage needed to reach the ultimate
strength of each respective cable type. A standard two-component,
60-second J-LOK resin cartridge was used as the anchorage
component. Standard operating procedures were followed to install
the cables and resin to simulate actual field installations. A slow gel
time was used to limit factors that may affect the final results, as a
faster acting gel time may haveincurred.
In order to limit the variables affecting the cable anchorage tests,
1 in (25 mm) ID by 1.75 in (45 mm) OD steel pipe was used as
the anchoring device and to simulate the drill hole. The steel pipe
was internally threaded to a 27 mm x 3 metric thread in accordance
with ASTM F432 A3.1.2 for Chemical Grouting Materials (ASTM
International, 2010). The 3/8 inch (10 mm) steel wall thickness
provided the necessary strength and confinement needed to
guarantee that the resin and cable bolt interface would fail before
the drill hole and resin interface, and provide adequate strength
during the tensile tests (Hyett, Bawden, & Reichert, 1992). Failure
of a grouted anchorage by load transfer failure will occur by one
of four methods: failure at the cable-to-grout interface; failure at
the grout-to-rock interface; failure through the grout column; or by
failure through the rock around the borehole wall (Thomas,2012).

After the samples were installed and allowed to cure for a

minimum of 48 hours, ultimate tensile tests were conducted as
shown in Figure 3. Even though 60-second J-LOK resin can obtain
the maximum capacity of the cable support within minutes after
installation, 48 hours was used as a way to limit variables affecting
the test results. The cable samples measured 36 in (91 cm) in length
plus the encapsulation length for each respective cable type. A
standard cable bolt housing with a two-piece wedge assembly and
1-1/8 inch square drive nut was set on the opposite end. A 0.6 in
(15 mm) diameter 270 ksi (1,862 MPa) cable is required to have
a minimum ultimate tensile strength of 58,600 lbf (261 KN) as
per ASTM F 432-10. This specification requires that all cable
bolt assemblies must obtain 90% of the minimum ultimate tensile
strength, which is 52,740 lbf (235 KN). The specification for a
Jennmar produced cable bolt assembly is 95% of the minimum
ultimate tensile strength, or 55,670 lbf (247 KN) as per in-house
quality control procedures. The 95% minimum ultimate tensile
strength was adopted to create a higher standard as compared to
industry minimum standards. During the tensile tests, the samples
were loaded at a consistent rate until a cable strand failure occurred
or a load transfer failure occurred between the cable and resin
anchorage interface. The average anchorage capacity results for
each linear length of encapsulation are shown in Figure 4 and Table
1. Four samples were tested for each individual category to develop
the average anchoragecapacity.

The samples were prepared at the Jennmar Research and

Development Laboratory facility with a Jennmar test lab bolter
developed by Fletcher. The bolter is shown in Figure 2. The
Jennmar bolter is custom designed to control and record a wide
range of parameters. Either clockwise (forward spin) or counterclockwise (reverse spin) rotation was used to mix the resin. The
clockwise and counter-clockwise tests were conducted as some
ground support manufacturers and products recommend counterclockwise mixing of the resin during installation. No published
tests were found comparing the two installation methods so a
comparison was necessary. The generally accepted method in the
U.S. is clockwise rotation for left-hand laycable.

Figure 2. Insertion of a cable sample into a 48 bore tube with a

Jennmar test labbolter.

21

Figure 3. Tensile test of plain cable sample with 12 of

resinencapsulation.

Morgantown, WV: West Virginia University, July - Aug. 2013.

32nd International Conference on Ground Control in Mining

Equation 2. Safety Factor for Resin Encapsulation when a strand
failureoccurs.
Equation 2 utilizes data obtained from Equation 1 to determine
the SFre. The variables in this equation are asfollows.
c - The encapsulation length of thesample.
p - The encapsulation length when the SFre is equal toone.

Figure 4. Average anchorage capacity per linear length of

capsulation (n=4).
As detailed in Table 1, a cable bolt with one birdcage installed
with clockwise rotation and 6 in (15 cm) of resin encapsulation
exceeds the ASTM minimum break strength of a cable bolt by 4%.
For a plain cable installed with clockwise rotation a minimum of 48
in (1.22 m) of encapsulation was required and the indented cables
installed with clockwise rotation required 36 in (0.91 m) of resin
encapsulation to exceed the minimum breaking strength specified
by ASTM. For counter-clockwise installations, the single birdcage,
plain and indented cable samples each required 36 in (0.91 m), 48
in (1.22 m), and 48 in (1.22 m) of resin encapsulation respectively
to exceed the minimumcapacity.
SAFETY FACTOR FOR RESINENCAPSULATION
The objective of the safety factor for resin encapsulation (SFre) is
to categorize the anchorage capacity and assign a safety factor for
each individual arrangement. The SFre does not rate the cable, but
rates the total amount of anchorage capacity available. The SFre
is based on the obtained load or potentially attainable load, and is
compared against the minimum design load of the cable which is
58,600 lbf (261KN).
To determine the SFre two equations are required. Equation 1
is used when a load transfer failure (slippage) occurs between
the resin and cable bolt anchorage. Equation 2 is used when a
strand failure occurs which will take into account the additional
encapsulation length of the resin anchorage after the ultimate
capacity has beenreached.

SFre

Obtained Load
Designed Load

(1)

Equation 1. Safety Factor for Resin Encapsulation when a load

transfer failureoccurs.

Obtained Load (( c p ) * l )
SFre
Designed Load

(2)

22

l - The load capacity per inch of encapsulation calculated

from a 12 cablesample.

Analyzing the safety factor chart (Figure 5), one birdcage rotated
in the clockwise direction achieved the highest range of safety
factors. As little as 12 (305 mm) of resin encapsulation obtained
a safety factor of 1 and a SFre of 1.69 was obtained with 48 in
(1,220 mm) of encapsulation, which is the highest safety factor
for any system tested. For the plain and indented cable samples
with either clockwise or counter-clockwise rotation required a
minimum of 48 (1,220 mm) of resin encapsulation to achieve a
safety factor above 1. In underground systems, three birdcages
are standard with 48 in (1,220 mm) of encapsulation. The safety
factor for this system was taken as the single birdcage multiplied
by three which equates to a 5.07 safety factor. In the previous
section, the difference of clockwise and counter clockwise rotation
was discussed. The safety factor chart correlates to those findings
that counter-clockwise rotation produces inconsistencies, thus
achieving a lower safety factor of 3.76 with 48 in (1,220 mm)
ofencapsulation.
ANGLE BOLTCAPACITY
The objective of the angle bolt capacity test was to simulate
cable bolts installed at an angle over the rib, such as in a cable
truss as shown in Figure 6 or as a stand-alone angled bolt. The test
fixture shown in Figure 7 is capable of aligning the bearing plate of
the cable at either a 30- or 45-degree angle offset from the cables
linear axis by interchangeable faceplates.
Six samples each of standard plain and indented cable were
tested. The plain cable with birdcages was not tested because
the birdcage does not affect the angle bolt capacity as no resin is
involved. The interchangeable face plates utilize T-5 channel and
T-3 channel plates to simulate how the system would be installed
underground, such as with a B-Rigid truss system. Tension was
steadily applied to the cable samples by a hydraulic ram and the
peak load was recorded once the first failure occurred in the strand.
The two types of cables were both tested at 30 and 45 degrees and
the results are shown in Table 2. The capacities of the plain cable at
30 and 45 degrees and indented cable at 30 degrees achieved loads
above the ASTM minimum standard for cable bolt assemblies. The
indented cable at 45 degrees only reached 45,500 lbs (202 kN), or
only 78% of the ASTM minimumstandard.
Effects of Counter-ClockwiseRotation
As stated previously, the samples were installed with J-LOK
resin and mixed with either clockwise or counter-clockwise
rotation. The difference in the two directions is that when mixing
the resin in the clockwise direction, the resin will be augered to the

Morgantown, WV: West Virginia University, July - Aug. 2013.

32nd International Conference on Ground Control in Mining

Table 1. Anchorage Capacity per Linear Length of Encapsulation (n=4).
Anchorage Capacity per Linear Length of Encapsulation
Sample
Type

Rotation
Direction

Plain Cable

Clockwise

CounterClockwise

Indented Cable

Clockwise

CounterClockwise

One Birdcage

Clockwise

CounterClockwise

Average Peak Capacity,

Tons

Percentage of ASTM
Minimum Break Strength1

12

6.4

22%

24

17.5

60%

36

23.5

80%

48

30.3

103%

Encapsulation Length

12

7.1

24%

24

12.6

43%

36

25.3

86%

48

29

99%

12

9.8

34%

24

19.5

66%

36

28.9

99%

48

30.4

104%

12

3.5

12%

24

25.9

89%

36

25.4

87%

48

30

103%

27.6

94%

12

29.2

100%

24

30.3

103%

36

30.3

103%

48

30.3

103%

9.8

34%

12

22.9

78%

24

26.2

89%

36

30.3

103%

48

30.3

103%

ASTM minimum break strength of a 0.6 in(15mm) cable is 29.3 tons, per ASTM F432-10.
back of the drill hole due to the lay of the cable. Essentially, the
resin is compressed and compacted into a tighter annulus. When
mixing the resin in the counter-clockwise direction, the resin has
the potential to be augered to the open end of the drill hole which
has a tendency to create voids within the resin anchorage as shown
with the indented cable sample in Figure 8. These voids can reduce
the linear length of encapsulation and anchorage capacity. Figure
9 shows a sectioned bore tube sample of a single birdcage with
clockwise rotation that was sectioned at thebirdcage.
A comprehensive comparison between clockwise and counterclockwise rotation is detailed in Table 3. The peak capacity and
displacement at peak capacity differences were determined by
Equations (3) and(4).
(

Figure 5. Encapsulation SafetyFactor.

23

Peak CapacityCounter Clockwise Peak CapacityClockwise

) * 100 %
Peak Capacity Clockwise

 (3)

Morgantown, WV: West Virginia University, July - Aug. 2013.

32nd International Conference on Ground Control in Mining

(

Displacement at Peak CapacityCounter Clockwise Displacement at Peak CapacityClockwise

Displacement at Peak Capacity Clockwise

)*100%

(4)

Table 2. Average test results for each offset angle. (n=6).

Off-Axis Capacity Results
Test
Cable

Plain
Indented

Offset
Angle,
degrees

Average Peak
Load, lbs (kN)

Percentage
of ASTM
Minimum
Break
Strength2

45

55,000 (245)

94%

30

60,500 (270)

103%

45

45,500 (202)

78%

30

59,500 (264)

102%

ASTM minimum break strength of a 0.6 in (15 mm) cable is

29.3 tons, per ASTM F432-10.

Figure 6. B-Rigid truss system detailing angled cablebolts.

Figure 8. Void detected in sectioned bore tube sample of indented

cable with counter clockwiserotation.
Table 3 shows that for the indented and plain cable samples
with an encapsulation length of 12 in 36 in (15.2 cm - 91
cm), the capacity results proved to be inconsistent and for
48 of encapsulation the capacities were about equal. For the
birdcaged cables with shorter encapsulation lengths of 6 in - 24
in (15.2 cm - 61 cm) and counter-clockwise rotation, the peak
capacity was reduced by 14 to 64 percent. For the samples with
36 in and 48 in (91 cm and 122 cm) of encapsulation, the peak
anchorage capacities were greater than the ultimate strength of the
cablesamples.

Figure 7. The Off-Axis test fixture allows cable to be aligned at

30 or 45 degrees as load isapplied.

24

When comparing the average displacement at peak capacity

results, it should be noted that only the samples that exceeded the
minimum designed capacity of the cable, 58,600 lbf (261 KN),
were considered. If none of the samples in the test set reached this
requirement, comparisons are not possible. After examining the
results, the counter-clockwise samples with encapsulation lengths
of 24 in and 36 in (15.2 cm and 91.4 cm) tended to require more
displacement than the clockwise rotated samples. With 48 in (122
cm) of resin encapsulation, the opposite was noted. The clockwise

Morgantown, WV: West Virginia University, July - Aug. 2013.

32nd International Conference on Ground Control in Mining

EFFECTS OF LONG-TERMCREEP
The creep test was designed to maintain a constant load as
a function of time on underground support systems with the
ability to adjust the load, as seen in Figure 10. Standard pull
tests conducted in a lab or in the field utilize a high-capacity
tensile testing machine or portable pull test equipment. Both
methods apply the desired load within seconds or minutes without
determining the supports ability to handle long term loads.
The creep test provides a key advantage by allowing a load to
be applied to a sample for weeks or months at a time. This load
can be steadily increased or decreased in accordance to the test
procedure. This advantage allows observations of how holding the
system at critical loads over time affects the overall performance of
thesystem.
During the tests, load was applied by a building method,
which means load was steadily increased over an extended period
of time. The first level was 20,000 lb (89 kN), then 30,000 lb (133
kN), increasing to 34,000 lb (151 kN), 40,000 lb (178 kN), and
ending at 50,000 lb (222 kN). Each load level was held for three
to five days after no increases in deflection was detected, totaling a
25-day test period for eachsample.

Figure 9. Sectioned bore tube sample of single birdcage sample

with clockwise rotation (sample was cut at the birdcage).

Three samples were subjected to the creep test. The samples

consisted of indented cable with no birdcages, plain cable with
one birdcage, and plain cable with three birdcages, all of which
were encapsulated in 40 in (1.0 m) of J-LOK resin with standard

Table 3. Comparison between clockwise and counter-clockwiserotation.

Comparison of Clockwise to Counter-Clockwise Rotation
Average Displacement @ Peak Capacity, Inches

One Birdcage

Indented
Cable

Plain Cable

Sample
Type

Encapsulation
Length, Inches

Peak Capacity
Difference, %

12

11%

24

-28%

36

8%

2.06

2.36

15%

48

-4%

2.16

1.47

-32%

12

-64%

24

33%

36

-12%

2.23

2.20

-1%

48

-1%

2.2

1.73

-21%

Clockwise
Rotation

CounterClockwise
Rotation

Displacement
Difference, %
-

-64%

1.83

12

-22%

1.83

24

-14%

1.82

3.30

81%

36

0%

1.8

2.30

28%

48

0%

1.53

1.40

-8%

rotated samples required more displacement at peak capacity than

the cables that were installed with counter-clockwise rotation. This
condition may be a result of the counter-clockwise rotation causing
an auguring effect which can pump the resin to the open end of the
drillhole.

25

clockwise rotation. The sample with three birdcages was tested

because it is a standard system used in underground mines. The
cables were installed in a 1 in (25.4 mm) ID steel pipe that was
rifled to simulate a drill holeunderground.
Displacement readings were continuously measured at two
locations to monitor movement in the cables. The first location was

Morgantown, WV: West Virginia University, July - Aug. 2013.

32nd International Conference on Ground Control in Mining

Figure 11. Creep test samples before testing. Left to right: plain
cable with one birdcage and indentedcable.

Figure 12. Creep test samples after testing. Left to right:

Indented plain cable with one birdcage, and plain cable with
threebirdcages.

Figure 13. Creep test - end displacement of cable samples as a

function of time andload.

Figure 10. Long term creeptester.

the end displacement of the cable (top of the borehole), which
monitored the pull from the resin (Figures 11 and 12). The
second location determines the housing and wedge assembly
movement of the cables by measuring the base of the cable to a
specific stationarypoint.
The final results indicated that three birdcages in 40 in (1.0m) of
resin produced an end displacement of just 0.004 in (0.10 mm), one
birdcage produced an end displacement of 0.190 in (4.80 mm), and
the indented cable produced 0.80 in (20.3 mm) at 50,000 lb (222

26

kN). On Day 2 of the 50,000 lb (222 kN) load level, the indented
cable pulled 0.750 in (19 mm) from the resin (Figure 12). This
excessive movement indicates that creep occurred in the support
and the creep test had to be stopped on day 23 for this sample. The
sample with three birdcages, which is a standard cable anchorage,
incured minimal movement from within the resin, producing a
lower cable deflection. Future testing is planned to determine the
affects of creep on indented cables encapsulated with 48 in and 60
in (1.20 m and 1.52 m) ofresin.

Morgantown, WV: West Virginia University, July - Aug. 2013.

32nd International Conference on Ground Control in Mining

SUMMARY ANDCONCLUSIONS
It was determined that traditional cable bolts incorporated
with birdcages are a proven system with consistent anchorage
performance characteristics when properly installed. As little as
6 in (15.2 cm) of resin encapsulation is needed to break the cable
with a single birdcage. The indented and plain cable samples
required 36 in of encapsulation to break the cable. The method
of counter-clockwise rotation of a cable bolt on installation
substantially reduced the anchorage capacity of each respective
system when compared to clockwise rotation. These reductions
are confirmed by the anchorage capacity per linear length of
encapsulation test results. Therefore, it is recommend that counter
clockwise rotation should not be used due to its reduced anchorage
capacity. The angle bolt capacity test determined that a plain cable
is more effective than the indented style cable. With an angle of
30 degrees, the capacities were relatively equal. However, with
an angle of 45 degrees, the plain cable obtained a 20% higher
capacity than the indented cable. The long-term creep tests again
showed that the samples with birdcages are more effective than the
indented cables. Future testing is planned to increase the sample set
of the creep test results and to develop a more definitiveconclusion.
ASTM F432-10 currently requires short encapsulation tests for
thread-deformed, reinforcing bar; however, no such specification
exists for cable supports. After the analysis and comparison of
these results, the industry should consider the development of a
specification for encapsulation tests of grouted cable bolts. With the
influx of various cable supports to the mining industry and the
results of the tests shown here, a specification would permit the
end user to know the actual capacity associated with each type of
cable bolt being installed into their mines. The developed strength
index would compare each type of cable support by a consistent and
ASTM certified testprocedure.
REFERENCES
ASTM International. (2010). Standard Specification for Roof and
Rock Bolts and Accessories. In ASTM F 432-10 (pp. 1 - 18).
WestConshohocken.
Faulkner, D. D. (2012, August 3). The Developement and
Application of Polyurethane Injectable Cable Bolts. Retrieved
April 15, 2013, from 31st International Conferences of Ground
Control in Mining: http://icgcm.conferenceacademy.com/
custom/icgcm/Home.aspx
Hyett, A. J., Bawden, W. F., & Reichert, R. D. (1992). The Effect
of Rock Mass Confinement. International Journal of Rock
Mechanics and Mining Sciences (pp. 503-524). Great Britain:
Pergamon PressLtd.
Thomas, R. (2012, August 3). Load Transfer Properties of PostGroutable Cable Bolts Used in the Australian Coal Industy.
Retrieved 4 15, 2013, from 31st International Conference on
Ground Control in Mining: http://icgcm.conferenceacademy.
com/ebook/view.aspx?PaperID=1011

27