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1、BS 7861-1:2007 Strata reinforcement support system components used in coal mines Part 1: Specification for rockbolting ICS 73.100.10 NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW BRITISH STANDARD Publishing and copyright information The BSI copyright notice displayed in this
2、 document indicates when the document was last issued. BSI 2007 ISBN 978 0 580 58550 0 The following BSI references relate to the work on this standard: Committee reference MRE/1 Draft for comment 07/30163374 DC Publication history First published October 1996 Second edition, October 2007 Amendments
3、 issued since publication Amd. no.DateText affected BS 7861-1:2007 BSI 2007i BS 7861-1:2007 Contents Foreword iii 1Scope 1 2Normative references 1 3Terms and definitions 2 4Steel rockbolts and components 4 5Glass fibre reinforced plastic (GRP) rockbolts and components for use in the sides 6 6Resins
4、and capsules 9 7System type tests Steel rockbolts 10 8System type tests GRP rockbolts 11 Annexes Annex A (normative) Tensile test on steel bar 12 Annex B (normative) Resistance to brittle fracture 12 Annex C (normative) Breakout facility torque test 14 Annex D (normative) Tensile test to establish f
5、lattening and pull through loads of steel domed washer plate assemblies 15 Annex E (normative) Alignment test 17 Annex F (normative) Fire resistance test on non-metallic components 18 Annex G (normative) Torsional strength test on GRP bar 20 Annex H (normative) Tensile strength test on GRP bar 21 An
6、nex I (normative) Minimum tensile strength of GRP rockbolt bar 23 Annex J (normative) Flexural strength tests on GRP rockbolt bar 25 Annex K (normative) Tensile test to establish GRP bolt assembly failure load 26 Annex L (normative) Determination of uniaxial compressive strength (UCS) of resin 28 An
7、nex M (normative) Determination of elastic modulus of resin 29 Annex N (normative) Determination of creep of resin 31 Annex O (normative) Tensile test on rockbolt threaded end 33 Annex P (normative) Shear test on rockbolt/resin system 34 Annex Q (normative) Determination of bond strength and system
8、stiffness 36 Bibliography 44 List of figures Figure 1 Example of a steel rockbolt assembly in situ 3 Figure B.1 Charpy impact specimen machining from bar details 13 Figure C.1 Arrangement for nut breakout torque test for GRP rockbolts 15 Figure D.1 Load test arrangement for tensile test flattening a
9、nd pull through loads of steel domed washer plate 16 Figure E.1 Alignment capacity of conical seat and domed washer plate assembly 17 Figure F.1 Draught-free cabinet for flame test 19 Figure G.1 Arrangement for torsional strength test on GRP bar 20 Figure H.1 Arrangement for tensile test on GRP bar
10、22 Figure I.1 Double embedment tensile test schematic diagram 24 Figure J.1 Arrangement for flexural strength test on GRP bar 25 BS 7861-1:2007 ii BSI 2007 Figure K.1 Load test arrangement for GRP components 27 Figure M.1 Arrangement for elastic modulus test and creep test: machine platen 31 Figure
11、O.1 Arrangement for tensile test on rockbolt threaded end 33 Figure P.1 Sectional diagram of shear frame 34 Figure Q.1 General arrangement of lathe-based pull test apparatus 37 Figure Q.2 General arrangement of hydraulic pull test apparatus 38 Figure Q.3 Hydraulic biaxial pressure cell 39 Figure Q.4
12、 Rock core performance envelope 43 List of tables Table 1 Colour coding of rockbolt length 5 Table 2 Resin setting times at 27 C 10 Table Q.1 Standard consumables and criteria for rock core performance testing 42 Summary of pages This document comprises a front cover, an inside front cover, pages i
13、to iii, a blank page, pages 1 to 43, an inside back cover and a back cover. BSI 2007iii BS 7861-1:2007 Foreword Publishing information This part of BS 7861 is published by BSI and came into effect on 31 October 2007. It was prepared by Subcommittee MRE/1/1/1, Roof supports and strata reinforcements,
14、 under the authority of Technical Committee MRE/1, Mining mechanical equipment and machinery. A list of organizations represented on this committee can be obtained on request to its secretary. Supersession This part of BS 7861 supersedes BS 7861-1:1996, which is withdrawn. Assessed capability. Users
15、 of this British Standard are advised to consider the desirability of quality system assessment and registration against the appropriate standard in the BS EN ISO 9000 series by an accredited third-party certification body. Product certification/inspection/testing Users of this British Standard are
16、advised to consider the desirability of third-party certification/inspection/testing of product conformity with this British Standard. Appropriate conformity attestation arrangements are described in BS EN ISO/IEC 17025. Users seeking assistance in identifying appropriate conformity assessment bodie
17、s or schemes may ask BSI to forward their enquiries to the relevant association. Presentational conventions The provisions of this standard are presented in roman (i.e. upright) type. Its requirements are expressed in sentences in which the principal auxiliary verb is “shall”. Commentary, explanatio
18、n and general informative material is presented in smaller italic type, and does not constitute a normative element. Contractual and legal considerations This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. Compli
19、ance with a British Standard cannot confer immunity from legal obligations. In particular, attention is drawn to the following statutory regulations. The Health and Safety at Work etc. Act 1974 1 The Chemicals (Hazard Information and Packaging for Supply) Regulations 2002 2 The Control of Substances
20、 Hazardous to Health Regulations 1995 3 iv BSI 2007This page deliberately left blank BS 7861-1:2007 BSI 20071 BS 7861-1:2007 1 Scope This Part of BS 7861 specifies dimensional, material and performance requirements for rockbolting support system components used in coal mines. Components included are
21、 steel rockbolts, glass reinforced plastics (GRP) rockbolts, resins, nuts, conical seats and domed washer plates. This British Standard does not cover the assembly or installation of these components to form a rockbolting support system on site. 2 Normative references The following referenced docume
22、nts are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. BS 6319-1:1983, Testing of resin compositions for use in construction Part 1: Me
23、thod for preparation of test specimens BS 6319-2:1983, Testing of resin compositions for use in construction Part 2: Method for measurement of compressive strength BS EN 837-1, 1998, Pressure gauges Part 1: Bourdon tube pressure gauges Dimensions, metrology, requirements and testing BS EN 10002-1:20
24、01, Metallic materials Tensile testing Part 1: Method of test at ambient temperature BS EN 10045-1:1990, Charpy impact test on metallic materials Part 1: Test method (V- and U-notches) BS EN 13463-1, Non-electrical equipment for potentially explosive atmospheres Part 1: Basic method and requirements
25、 BS EN ISO 527-1, Plastics Determination of tensile properties Part 1: General principles BS EN ISO 1461, Hot dip galvanized coatings on fabricated iron and steel articles Specifications and test methods BS EN ISO 4034, Hexagon nuts Product grade C BS EN ISO 6789, Assembly tools for screws and nuts
26、Hand torque tools Requirements and test methods for design conformance testing, quality conformance testing and recalibration procedure BS EN ISO 7500-1:2004, Metallic materials Verification of static uniaxial testing machines Part 1: Tension/compression testing machines Verification and calibration
27、 of the force-measuring system BS EN ISO 9513:2002, Metallic materials Calibration of extensometers used in uniaxial testing BS 7861-1:2007 2 BSI 2007 3 Terms and definitions For the purposes of this Part of BS 7861, the following terms and definitions apply. 3.1bond strength load in a rockbolt/resi
28、n/rock system at which the system stiffness falls below 20 kN/mm, when measured by pull testing, for a given bond length 3.2breakout facility facility whereby the nut is held in position on the thread of the rockbolt, enabling mixing of the resin to take place during rockbolt installation, but which
29、 allows the nut to be spun up the thread to tighten on the domed washer plate when a predetermined torque value is reached 3.3brittle fracture failure of a steel rockbolt without plastic deformation 3.4conical seat accessory which, when used in conjunction with a rockbolt, nut and domed washer plate
30、, accommodates a degree of misalignment between the rockbolt and the strata surface 3.5domed washer plate accessory which, when used in conjunction with a rockbolt, nut and conical seat, facilitates load distribution, ensures correct alignment and reduces weathering around the mouth of the rockbolt
31、hole 3.6equivalent diameter diameter of an equivalent circular bar calculated from the weight and density of a 150 mm long sample of actual bar NOTEFor steel rockbolts that are to be galvanized, the equivalent diameter is determined from a sample of un-galvanized bar. 3.7flexural strength maximum fl
32、exural stress occurring at the surfaces of the test specimen during a bending test, based on the maximum load sustained during the test and assuming that the neutral axis is through the middle of the section 3.8gel time period during which a resin can be mixed with no appreciable change in viscosity
33、, i.e. before it begins to turn from fluid to solid state 3.9hand held machine drilling machine where the drill thrust is provided solely by human power 3.10resin encapsulating material used to achieve a bond between rockbolt and strata 3.11rockbolt bar inserted into the roof or side of a roadway, u
34、sed with fully encapsulating resin as part of a rockbolting support system BSI 20073 BS 7861-1:2007 3.12rockbolt assembly rockbolt complete with appropriate end fittings NOTE An example of a steel rockbolt assembly is given in Figure 1. 3.13rockbolting support system rockbolt assemblies installed sy
35、stematically to provide principal roof and/or side support for mine roadways 3.14setting time period following the gel time required for the resin to attain enough strength to resist the pull exerted on the rockbolt when the nut is tightened 3.15system stiffness stiffness of the rockbolt/resin/rock
36、system for a given bond length in load per unit displacement (kN/mm), when measured by pull testing Figure 1Example of a steel rockbolt assembly in situ Key 1 Rockbolt 2 Resin 3 Conical seat 4 Domed washer plate 5 Nut 1 2 3 4 5 BS 7861-1:2007 4 BSI 2007 4 Steel rockbolts and components 4.1Rockbolt 4
37、.1.1Rockbolt bar 4.1.1.1Composition The bar of a rockbolt shall be made from steel with a homogenous structure having a chemical composition of carbon 0.3% max., manganese 1.6% max., sulfur 0.05% max. and phosphorus 0.05% max. 4.1.1.2Profile The bar of a rockbolt shall be of rolled circular section
38、and may be ribbed or threaded. 4.1.1.3Diameter The minimum equivalent diameter of the bar of a rockbolt shall be not less than 21.5 mm. The minimum measurement across the minor axis of the bar shall be not less than 20 mm. 4.1.1.4Straightness Straightness shall be within 0.4% of the length of the ro
39、ckbolt bar. 4.1.1.5Tensile properties When tested in accordance with Annex A: a)the minimum yield strength shall be 640 N/mm2; b)the tensile strength shall be at least 20% greater than the yield strength on each tensile test; c)the elongation after fracture (A) shall be a minimum of 18% and the elon
40、gation at maximum force (Agt) shall be a minimum of 8%. 4.1.1.6Resistance to brittle fracture NOTEThe bar of a rockbolt should be tough enough to resist brittle fracture at the lowest expected operating temperature. When tested in accordance with Annex B: a)no more than two of the individual values
41、shall be lower than 27 J; b)no more than one individual value shall be lower than 19 J; c)the average value of all tests shall be no lower than 27 J. 4.1.2Manufacture 4.1.2.1Proximal end The minimum length of the thread at the proximal end of the rockbolt shall be 150 mm. The thread shall be compati
42、ble with the nut. 4.1.2.2Distal end The distal end of the rockbolt shall be capable of passing through a 450 mm long cylinder gauge with a diameter not more than 1.5 mm greater than the maximum diameter of the rockbolt bar. BSI 20075 BS 7861-1:2007 4.1.2.3Length The tolerance on the manufactured len
43、gth of the rockbolt shall be 5 mm. Colour coding on the proximal end in accordance with Table 1 shall identify rockbolt length. Rockbolt lengths other than those listed in Table 1 shall be identified by colour(s) other than those listed in Table 1. 4.1.2.4Corrosion protection Where corrosion protect
44、ion is required rockbolts shall be hot dipped galvanized in accordance with BS EN ISO 1461 with a minimum coating thickness of 85 4m. Rockbolts shall not be passivated after galvanizing as this can affect the resin bond strength. 4.1.3Supplier identification Either the nut or conical seat supplied w
45、ith the rockbolt shall be marked with the identity of the supplier. 4.2Nut 4.2.1General The nut shall be manufactured from black hexagon steel grade 8 conforming to BS EN ISO 4034, except that its thickness shall be not less than 26 mm. The nut shall be compatible with the bar thread and conform to
46、7.1. The nut shall have a breakout facility, unless it is intended for installation in the side with a hand held machine; in which case a breakout facility is optional. 4.2.2Nut breakout type test When tested in accordance with C.1, the nut breakout facility shall operate at torques in the following
47、 ranges: a)high torque range 100 Nm to 185 Nm; b)low torque range 35 Nm to 80 Nm. Table 1Colour coding of rockbolt length Nominal rockbolt length m Colour code 3.0Brown 2.4Red 2.1Green 1.8Yellow 1.5White 1.2Blue BS 7861-1:2007 6 BSI 2007 4.3Domed washer plate/conical seat 4.3.1Material The domed was
48、her plate and conical seat shall be manufactured from steel. 4.3.2Form The form of the domed washer plate and conical seat shall be as shown in Figure 1 and be compatible with other components of the rock bolt assembly. 4.3.3Supplier identification Each domed washer plate shall be marked with a uniq
49、ue supplier identification mark. 4.3.4Performance requirements 4.3.4.1Assembly load When tested in accordance with Annex D, the steel domed washer plate shall: a)flatten under a load of 50% to 70% of the nominal breaking load of the bar, based on the equivalent diameter and a stress of 770 N/mm2; b)allow pull-through of the rockbolt, nut and conical seat assembly under a load (the maximum tensile load or pull-through load) o