Stiff Split Set Stabilisers

• Can hold approximately 3-4 times per metre, the rock mass of a normal Friction Bolt
• One pass bolting solution
• Compatible with Jumbo installing mesh
• Offers a genuine alternative to a resin bolt
• Easier to install than a resin bolt

Split Set Mining Systems mission was to develop a system to install pre-grouted Friction Bolts using the existing equipment and methodology of regular Friction Bolts. Without compromising ease of installation, compatibility with mesh and shotcrete, overall productivity and increasing the level of safety provided.

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How it works; The thick grout is pre-placed into the bolt via the use of a wet cement sausage, inserted into the bolt before the installation of the bole in the hole.  The bolt is then installed &#;as normal&#;.

Performance can be greatly improved by grouting the inside of the bolt using a thick strong grout. This occurs because Split Sets conform to the shape of the borehole in which they are installed and the grout once set locks the shape dimensions of the Split Set in the Hole.  A typical 45mm borehole varies 1mm along its length.

In order to remove the grouted bolt from the hole either the grout, the steel, the rock or some combination of theses three needs to fail.

The construction and mining industries continually evolve, introducing new technologies and methods to enhance safety, efficiency, and cost-effectiveness. One such innovation is the split set rock bolt, a revolutionary type of anchor that offers full anchorage and active reinforcement for surrounding rock. This article delves into the split set rock bolt, exploring its construction, application characteristics, and benefits in the current state of the industry.

Introduction to Split Set Rock Bolts

Split set rock bolts are high-strength steel pipes with a longitudinal slit, designed to be installed in boreholes slightly smaller than the pipe diameter. When inserted, these bolts apply radial pressure to the borehole walls, creating friction that prevents the surrounding rock from sliding. The anchor tray adds supporting force, placing the surrounding rock in a three-dimensional stress state. Even under conditions of blasting vibrations, the anchoring force of the split set rock bolt increases, maintaining its support resistance despite significant rock displacement.

Construction and Mechanics of Split Set Rock Bolts

Split set rock bolts are characterized by their unique design and high-strength construction:

• Material: Made from high-strength steel, the split set rock bolt is resilient and capable of withstanding substantial stress and pressure.
• Design: The longitudinal slit allows the bolt to expand and apply consistent radial pressure along the entire length of the borehole, ensuring comprehensive reinforcement.
• Installation: The bolts are installed in boreholes slightly smaller than their diameter, creating an immediate frictional force that stabilizes the surrounding rock.

Application Characteristics of Split Set Rock Bolts

The split set rock bolt offers several distinct advantages, making it a preferred choice in modern construction and mining operations:

1. Superior Support Effect

The support principle of split set rock bolts aligns with modern rock mechanics and surrounding rock control theory, offering &#;active&#; support. Once installed, these bolts reinforce the rock from within, forming a unified rock-support structure. This configuration mobilizes and utilizes the inherent stability of the surrounding rock, effectively controlling deformation and enhancing tunnel stability.

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• Enhanced Stability: The active support system improves the overall stability of tunnels, preventing collapse and reducing maintenance requirements.
• Quick Reinforcement: The immediate frictional force applied by the split set rock bolt quickly forms a supportive structure, minimizing the time needed to stabilize the rock.

2. Reduced Labor Intensity and Increased Efficiency

Compared to traditional shed support systems, split set rock bolts require fewer materials and are lighter in weight. This reduction in material usage decreases transportation volume and labor intensity, significantly improving excavation efficiency.

• Efficient Excavation: The lighter and fewer support materials streamline the excavation process, allowing for quicker and more efficient progress.
• Simplified Support Removal: The elimination of steel shed support withdrawal reduces labor efforts and enhances safety for workers.

3. Economic Benefits

The economic advantages of split set rock bolts are substantial. By reducing the need for support materials and minimizing direct support costs, these bolts offer a cost-effective solution for tunnel construction and mining operations.

• Cost Savings: Reduced material input and lower direct support costs translate into significant savings.
• Optimized Tunnel Section: Since the anchor support does not occupy the effective section of the tunnel, the designed section can be reduced, further saving materials and costs.

Ensuring Quality and Performance

To maximize the benefits of split set rock bolts, it is crucial to ensure their quality. Key quality indicators include:

• Surface Condition: A qualified split set rock bolt should have a flat surface without serious strain or rust.
• Weld Integrity: The welds should be free from cracks, pores, or slag inclusions, and there should be no burn-through of the pipe wall.
• Tray Movement: The tray must move freely along the rod body.
• Retaining Ring and Pipe Seam: The retaining ring interface and the pipe seam opening should ideally be offset by 170 to 190 degrees.

Industry Applications of Split Set Rock Bolts

Split set rock bolts are widely used in various sectors, including mining, tunneling, and civil engineering. Their applications range from reinforcing mine roofs to stabilizing tunnel walls and supporting large underground excavations.

Mining

In mining operations, split set rock bolts play a crucial role in roof support. They provide immediate reinforcement upon installation, preventing roof falls and ensuring the safety of miners. Their ability to maintain support resistance even during significant rock displacement makes them particularly valuable in dynamic mining environments.

• Roof Support: Split set rock bolts are essential for preventing roof falls and ensuring miner safety.
• Dynamic Environments: The bolts&#; resilience to significant rock displacement makes them ideal for use in dynamic mining conditions.

Tunneling

Tunnels, whether for transportation or utilities, require robust support systems to maintain stability and safety. Split set rock bolts offer an efficient and cost-effective solution for tunnel reinforcement, particularly in challenging geological conditions.

• Transportation Tunnels: These bolts ensure the stability of transportation tunnels, reducing maintenance needs and enhancing safety.
• Utility Tunnels: Split set rock bolts provide reliable support for utility tunnels, preventing collapse and ensuring uninterrupted service.

Civil Engineering

In civil engineering projects, such as underground storage facilities and subway systems, split set rock bolts offer essential support. Their ability to stabilize large excavations and maintain support resistance over time makes them a valuable tool in the construction and maintenance of underground structures.

• Underground Storage: Split set rock bolts stabilize large underground storage facilities, ensuring structural integrity.
• Subway Systems: These bolts support the construction and maintenance of subway systems, enhancing safety and reliability.

Conclusion

Split set rock bolts represent a significant advancement in the field of rock reinforcement, offering superior support, reduced labor intensity, and substantial economic benefits. Their application in mining, tunneling, and civil engineering projects has revolutionized the way these industries approach rock stabilization. By ensuring the quality and proper installation of split set rock bolts, we can fully harness their potential to enhance safety, efficiency, and cost-effectiveness in various construction and mining operations. As the industry continues to innovate, the future of split set rock bolts looks promising, with ongoing advancements set to further improve their performance and application versatility.