Testing and Monitoring of Rockbolts

1.General
The Contractor shall perform a number of approved pullout tests on the rockbolts prior to and during
tunnel excavation. For this purpose the Contractor shall furnish at least two sets of testing equipment
including but not limited to hydraulic jacks, fixing device, hydraulic pump with manometer,
extensometer, and all necessary accessories. The testing equipment shall be capable of stressing the
largest diameter rockbolt to the yield stress of the bolt. The ram stroke shall be sufficient to
accommodate a bolt movement of at least 75 mm during tensioning of grouted bolts and 200mm for
Swellex bolts.

2. Pre-production testing
(i) For resin grouted rockbolts and Swellex bolts, a series of tests shall be undertaken prior to their use
in the tunnel. Not less than ten (10) rockbolts of each type of rockbolt shall be tested to assess the
installation performance and capacity of the specified rock bolts. Pre-production testing shall be
undertaken in three successive stages as follows:

(a) Stage I - Installation test

For resin grouted rockbolts, one (1) bolt shall be installed into a tightly secured steel pipe with an end
cap. The internal diameter of the pipe shall be similar to that of the proposed hole diameter. The bolt
shall be spun into the proposed resin grout mix and held in position until the resin has set. Prior to the
setting of the resin a face plate and bolt shall be attached and tightened to hold the bolt in place. Once
the resin has set, the pipe and bolt shall be cut through to reveal a cross section of the assembly. The
bolt shall be cut to show a minimum of three locations through the anchor zone. For acceptance of this
trial the sections through the assembly must prove that the resin has been well mixed, has set hard, and
is free of entrained air and that the bar is encapsulated in resin throughout its perimeter in the anchor
zone. This test is not required for Swellex bolts.

(b) Stage 2 - Load testing

A minimum of three (3) bolts shall be installed in sub-horizontally drilled holes in representative rock
mass conditions. For resin grouted bolts, each bolt shall be secured in place with only resin
encapsulation of the anchorage zone, i.e. shall be debonded over its free length. Following setting of
the resin, the bolt shall be tensioned using a hydraulic jack to failure or to 90% of the ultimate load of
the bolt. Accurate measurements of end deflection of the bolt shall be recorded during testing. The
results of this testing shall be assessed and used to nominate the actual length of anchorage zone to be
used for production bolt installations. For Swellex bolts, each bolt shall be secured in place in
accordance with the manufacturer's recommended procedure. Swellex rock bolts shall be tensioned
using a hydraulic jack to failure or to 90% of the ultimate load of the bolt. Accurate measurement of
end deflection of the bolt shall be recorded during testing.

(c) Stage 3 - Overhead load testing

A minimum of three (3) bolts shall be installed into holes drilled vertically overhead. For resin grouted
bars, the amount of resin grout used shall be determined from the load testing undertaken in Stage 2
testing. These bolts should only be installed with resin in the anchorage zone, i.e. shall be debonded
over their free length. The bolts shall be tested as per the testing procedure adopted for Stage 2 testing.
The results of this testing shall confIrm the fIndings of Stage 2 testing in order for the bolts to be
accepted for use within the Works. For Swellex rock bolts, Stage 2 testing shall be repeated for the
vertically overhead position.
(ii) Records shall be submitted to the Engineer of the pull out tests in the form of a report indicating
details of:
- type and length of bolts used;
- type and make of resin cartridges (where applicable);
- bond lengths achieved (where applicable);
- bolt locations;
- date and time of installation,
- date and time of testing;
- ambient air temperature;
- load/displacement in the form of graphs;
- bolt projections;
- installations procedures; and
- problems encountered.

(iii)Any test results considered unsatisfactory by the Engineer shall be repeated, as instructed.
Installation procedures may need to be amended as required in the light of the trial results so as to
achieve the requirements of the Specification.
(iv) Anchoring of the rockbolts shall be monitored by pull-out testing on 2% of all rockbolts installed
or as otherwise approved by the Engineer, applying a test load of 80% of the yield force of the steel bar.
An alternative method of testing may be proposed. The testing method and program must be submitted
and approved by the Engineer prior to any such testing.

3 Production testing
(i) Production testing of rockbolts shall be undertaken by pull-out testing on a minimum of2% of all
rockbolts installed or as otherwise approved by the Engineer, applying a test load of 80% of the yield
strength of the rockbolt. These tests shall be undertaken on rockbolts installed at a variety of orientations
and locations along the tunnel alignment, and in a variety of geological conditions.

(ii) Should any rockbolt fail at a load less than 80% of the yield strength, the test shall be repeated on
adjacent rockbolts until a test is completed successfully and the Engineer is satisfied that the failed
rockbolt is not symptomatic of a wider problem. The Contractor and the Engineer shall attempt to
establish the reason for any failed rockbolts and if necessary, the method of rockbolt installation shall
be modified accordingly. The Engineer may instruct that any failed rockbolts are replaced at the
Contractor's own cost.