1、BS 7861-1:2007Strata reinforcement support system components used in coal mines Part 1: Specification for rockboltingICS 73.100.10NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAWBRITISH STANDARDPublishing and copyright informationThe BSI copyright notice displayed in this docum
2、ent indicates when the document was last issued. BSI 2007ISBN 978 0 580 58550 0The following BSI references relate to the work on this standard:Committee reference MRE/1Draft for comment 07/30163374 DCPublication historyFirst published October 1996Second edition, October 2007Amendments issued since
3、publicationAmd. no. Date Text affectedBS 7861-1:2007 BSI 2007 iBS 7861-1:2007ContentsForeword iii1 Scope 12 Normative references 13 Terms and definitions 24 Steel rockbolts and components 45 Glass fibre reinforced plastic (GRP) rockbolts and components for use in the sides 66 Resins and capsules 97
4、System type tests Steel rockbolts 108 System type tests GRP rockbolts 11AnnexesAnnex A (normative) Tensile test on steel bar 12Annex B (normative) Resistance to brittle fracture 12Annex C (normative) Breakout facility torque test 14Annex D (normative) Tensile test to establish flattening and pull th
5、rough loads of steel domed washer plate assemblies 15Annex E (normative) Alignment test 17Annex F (normative) Fire resistance test on non-metallic components 18Annex G (normative) Torsional strength test on GRP bar 20Annex H (normative) Tensile strength test on GRP bar 21Annex I (normative) Minimum
6、tensile strength of GRP rockbolt bar 23Annex J (normative) Flexural strength tests on GRP rockbolt bar 25Annex K (normative) Tensile test to establish GRP bolt assembly failure load 26Annex L (normative) Determination of uniaxial compressive strength (UCS) of resin 28Annex M (normative) Determinatio
7、n of elastic modulus of resin 29Annex N (normative) Determination of creep of resin 31Annex O (normative) Tensile test on rockbolt threaded end 33Annex P (normative) Shear test on rockbolt/resin system 34Annex Q (normative) Determination of bond strength and system stiffness 36Bibliography 44List of
8、 figuresFigure 1 Example of a steel rockbolt assembly in situ 3Figure B.1 Charpy impact specimen machining from bar details 13Figure C.1 Arrangement for nut breakout torque test for GRP rockbolts 15Figure D.1 Load test arrangement for tensile test flattening and pull through loads of steel domed was
9、her plate 16Figure E.1 Alignment capacity of conical seat and domed washer plate assembly 17Figure F.1 Draught-free cabinet for flame test 19Figure G.1 Arrangement for torsional strength test on GRP bar 20Figure H.1 Arrangement for tensile test on GRP bar 22Figure I.1 Double embedment tensile test s
10、chematic diagram 24Figure J.1 Arrangement for flexural strength test on GRP bar 25BS 7861-1:2007ii BSI 2007Figure K.1 Load test arrangement for GRP components 27Figure M.1 Arrangement for elastic modulus test and creep test: machine platen 31Figure O.1 Arrangement for tensile test on rockbolt thread
11、ed end 33Figure P.1 Sectional diagram of shear frame 34Figure Q.1 General arrangement of lathe-based pull test apparatus 37Figure Q.2 General arrangement of hydraulic pull test apparatus 38Figure Q.3 Hydraulic biaxial pressure cell 39Figure Q.4 Rock core performance envelope 43List of tablesTable 1
12、Colour coding of rockbolt length 5Table 2 Resin setting times at 27 C 10Table Q.1 Standard consumables and criteria for rock core performance testing 42Summary of pagesThis document comprises a front cover, an inside front cover, pages i to iii, a blank page, pages 1 to 43, an inside back cover and
13、a back cover. BSI 2007 iiiBS 7861-1:2007ForewordPublishing informationThis 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, under the authority of Technical Committee MRE/1, Mining mechani
14、cal equipment and machinery. A list of organizations represented on this committee can be obtained on request to its secretary.SupersessionThis part of BS 7861 supersedes BS 7861-1:1996, which is withdrawn.Assessed capability. Users of this British Standard are advised to consider the desirability o
15、f 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 advised to consider the desirability of third-party certification/ins
16、pection/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 bodies or schemes may ask BSI to forward their enquiries to the relevant a
17、ssociation.Presentational conventionsThe 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, explanation and general informative material is presented in smaller italic type,
18、and does not constitute a normative element.Contractual and legal considerationsThis publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application.Compliance with a British Standard cannot confer immunity from legal obligations.
19、In particular, attention is drawn to the following statutory regulations.The Health and Safety at Work etc. Act 1974 1The Chemicals (Hazard Information and Packaging for Supply) Regulations 2002 2The Control of Substances Hazardous to Health Regulations 1995 3iv BSI 2007 This page deliberately left
20、blankBS 7861-1:2007 BSI 2007 1BS 7861-1:20071 ScopeThis Part of BS 7861 specifies dimensional, material and performance requirements for rockbolting support system components used in coal mines. Components included are steel rockbolts, glass reinforced plastics (GRP) rockbolts, resins, nuts, conical
21、 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 referencesThe following referenced documents are indispensable for the application of this document. For dated references, onl
22、y 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: Method for preparation of test specimensBS 6319-2:1983, Testing of resin compositions fo
23、r use in construction Part 2: Method for measurement of compressive strengthBS EN 837-1, 1998, Pressure gauges Part 1: Bourdon tube pressure gauges Dimensions, metrology, requirements and testingBS EN 10002-1:2001, Metallic materials Tensile testing Part 1: Method of test at ambient temperatureBS EN
24、 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 requirementsBS EN ISO 527-1, Plastics Determination of tensile properties Part 1: General principlesBS
25、EN ISO 1461, Hot dip galvanized coatings on fabricated iron and steel articles Specifications and test methodsBS EN ISO 4034, Hexagon nuts Product grade C BS EN ISO 6789, Assembly tools for screws and nuts Hand torque tools Requirements and test methods for design conformance testing, quality confor
26、mance testing and recalibration procedureBS EN ISO 7500-1:2004, Metallic materials Verification of static uniaxial testing machines Part 1: Tension/compression testing machines Verification and calibration of the force-measuring systemBS EN ISO 9513:2002, Metallic materials Calibration of extensomet
27、ers used in uniaxial testingBS 7861-1:20072 BSI 20073 Terms and definitionsFor the purposes of this Part of BS 7861, the following terms and definitions apply.3.1 bond strengthload in a rockbolt/resin/rock system at which the system stiffness falls below 20 kN/mm, when measured by pull testing, for
28、a given bond length3.2 breakout facilityfacility 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 allows the nut to be spun up the thread to tighten on the domed washer plate when a predetermined tor
29、que value is reached3.3 brittle fracturefailure of a steel rockbolt without plastic deformation3.4 conical seataccessory which, when used in conjunction with a rockbolt, nut and domed washer plate, accommodates a degree of misalignment between the rockbolt and the strata surface3.5 domed washer plat
30、eaccessory 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 hole3.6 equivalent diameterdiameter of an equivalent circular bar calculated from the weight and density
31、of a 150 mm long sample of actual barNOTE For steel rockbolts that are to be galvanized, the equivalent diameter is determined from a sample of un-galvanized bar.3.7 flexural strengthmaximum flexural stress occurring at the surfaces of the test specimen during a bending test, based on the maximum lo
32、ad sustained during the test and assuming that the neutral axis is through the middle of the section3.8 gel timeperiod during which a resin can be mixed with no appreciable change in viscosity, i.e. before it begins to turn from fluid to solid state3.9 hand held machinedrilling machine where the dri
33、ll thrust is provided solely by human power3.10 resinencapsulating material used to achieve a bond between rockbolt and strata3.11 rockboltbar inserted into the roof or side of a roadway, used with fully encapsulating resin as part of a rockbolting support system BSI 2007 3BS 7861-1:20073.12 rockbol
34、t assemblyrockbolt complete with appropriate end fittings NOTE An example of a steel rockbolt assembly is given in Figure 1.3.13 rockbolting support systemrockbolt assemblies installed systematically to provide principal roof and/or side support for mine roadways3.14 setting timeperiod following the
35、 gel time required for the resin to attain enough strength to resist the pull exerted on the rockbolt when the nut is tightened3.15 system stiffnessstiffness of the rockbolt/resin/rock system for a given bond length in load per unit displacement (kN/mm), when measured by pull testingFigure 1 Example
36、 of a steel rockbolt assembly in situKey1 Rockbolt2 Resin3 Conical seat4 Domed washer plate5 Nut12345BS 7861-1:20074 BSI 20074 Steel rockbolts and components4.1 Rockbolt4.1.1 Rockbolt bar4.1.1.1 CompositionThe bar of a rockbolt shall be made from steel with a homogenous structure having a chemical c
37、omposition of carbon 0.3% max., manganese 1.6% max., sulfur 0.05% max. and phosphorus 0.05% max.4.1.1.2 ProfileThe bar of a rockbolt shall be of rolled circular section and may be ribbed or threaded.4.1.1.3 DiameterThe minimum equivalent diameter of the bar of a rockbolt shall be not less than 21.5
38、mm. The minimum measurement across the minor axis of the bar shall be not less than 20 mm.4.1.1.4 StraightnessStraightness shall be within 0.4% of the length of the rockbolt bar.4.1.1.5 Tensile properties When tested in accordance with Annex A: a) the minimum yield strength shall be 640 N/mm2;b) the
39、 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 elongation at maximum force (Agt) shall be a minimum of 8%.4.1.1.6 Resistance to brittle fracture NOTE The bar of a rockbolt should be t
40、ough 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 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
41、 lower than 27 J.4.1.2 Manufacture4.1.2.1 Proximal endThe minimum length of the thread at the proximal end of the rockbolt shall be 150 mm. The thread shall be compatible with the nut.4.1.2.2 Distal endThe distal end of the rockbolt shall be capable of passing through a 450 mm long cylinder gauge wi
42、th a diameter not more than 1.5 mm greater than the maximum diameter of the rockbolt bar. BSI 2007 5BS 7861-1:20074.1.2.3 LengthThe tolerance on the manufactured length of the rockbolt shall be 5 mm.Colour coding on the proximal end in accordance with Table 1 shall identify rockbolt length. Rockbolt
43、 lengths other than those listed in Table 1 shall be identified by colour(s) other than those listed in Table 1.4.1.2.4 Corrosion protectionWhere corrosion protection is required rockbolts shall be hot dipped galvanized in accordance with BS EN ISO 1461 with a minimum coating thickness of 85 4m. Roc
44、kbolts shall not be passivated after galvanizing as this can affect the resin bond strength.4.1.3 Supplier identificationEither the nut or conical seat supplied with the rockbolt shall be marked with the identity of the supplier.4.2 Nut4.2.1 GeneralThe nut shall be manufactured from black hexagon st
45、eel 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 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 br
46、eakout facility is optional.4.2.2 Nut breakout type testWhen tested in accordance with C.1, the nut breakout facility shall operate at torques in the following ranges:a) high torque range 100 Nm to 185 Nm;b) low torque range 35 Nm to 80 Nm.Table 1 Colour coding of rockbolt lengthNominal rockbolt len
47、gthmColour code3.0 Brown2.4 Red2.1 Green1.8 Yellow1.5 White1.2 BlueBS 7861-1:20076 BSI 20074.3 Domed washer plate/conical seat4.3.1 MaterialThe domed washer plate and conical seat shall be manufactured from steel.4.3.2 FormThe form of the domed washer plate and conical seat shall be as shown in Figu
48、re 1 and be compatible with other components of the rock bolt assembly.4.3.3 Supplier identificationEach domed washer plate shall be marked with a unique supplier identification mark.4.3.4 Performance requirements4.3.4.1 Assembly load When tested in accordance with Annex D, the steel domed washer pl
49、ate 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) of 70% to 95% of the breaking load of the bar, based on the equivalent diameter and a stress of 770 N/mm2.NOTE Failure of the domed washer pla
