How megabolts installed as

primary support assist in

safely improving
development rates

ACARP Roadway Development Operators Workshops - October 2011

 Introduction

Three types of megabolts installed from

continuous miner

● Post grouted megastrands – MW9

● Resin anchored, torque-tensioned megaflex bolts - TTX
● Resin anchored, post groutable fibreglass rib bolts

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 MW9 Megabolt

● Most commonly
installed megabolt is
the barrel & wedge
version – MW9
● Fully bulbed using
spiral rib wire for max
load transfer
● Up to 11 m long cables
installed from miner in
LW installation roads

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MW9 – Nth Goonyella face road

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 MW9 advantages

● 42 mm hole – no reaming
● Single 1,000 mm resin capsule
with resin retainer
● Resin pushed up hole with bolt
– no conduit
● Collar fittings attached after
bolt installed
● No bearing plate or bolt head to
catch on walkway

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 MW9 advantages

● Tension within 5 mins of

installation
● Tension using system
hydraulics or intensifier
● 9 to 20 t pre-tension can be
achieved depending whether
system hydraulics or
intensifier used
● No air needed on miner
● Provides immediate point
anchor support of 57 t

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 Important considerations

● Bolt is point anchored until

grouted
● Anchor length designed to
take capacity of bolt – depends
on rock type at anchor horizon
● Pull tests must be done to
determine if anchor can take
full capacity of bolt
● This ungrouted bolt is loaded
to 45-50 tonnes

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 MW9 grouting

● Top down grouted using grout

lance – quickest grouting
method
● Grouting done within
designated time or distance
advanced – depends on
conditions
● Heavy conditions may require
grouting within 24 hrs
● Good conditions (intersections)
can be left for more than a week

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 MW9 grouting

● Grout generally reaches

sufficient strength (30 to 40
MPa) within 24 hrs
● Readily & easily audited
● Regular auditing has greatly
improved quality of
installation
● Grouting non-compliance now
less than 5%
● Good installation reduces
likelihood of remedial roof
support
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 MW9 developments

Mechanised insertion
● Lobster from Conway
Engineering
● Being used at Angus
Place
● Favourable reports so
far

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 MW9 developments

Resin grouting using Minova

Carbothix
● Immediate roof support
● Remote pumping
● Quicker grouting

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 Megaflex TTX

● Torque-tensioned
● TT bolt becoming more in
demand
● 56 t and 48 t versions
● 56 t generally requires 28
mm hole
● 48 t a 27 mm hole

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 TTX – advantages

● No exposure to high
pressure tensioner
hydraulics
● Reduced injuries from
handling tensioners
● Quicker installation than
hydraulically tensioned
cables
● Combo dolly

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 Combo dolly – no changing dollies

Mixing Tightening
Inner socket engages hex drive Outer socket engages nut

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 TTX – advantages

● Roller race between nut &

washer reduces friction
● Race is shrouded to keep
bearing free of dirt or mud
● 7 t bolt tension from 320
Nm drill torque
● Minimal protrusion from
roof – important in low
seams
● Removing hex drive
reduces protrusion further
– as little as 115 mm
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 TTX – advantages

● Wires are anchored in the bolt

head using button heads forged
on end of each wire – maintains
max collar strength
● B&W anchor typically reduces
cable collar capacity by approx
10%

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 TTX – advantages

● Increased load transfer from

spiral wire
● Groutable version being
developed – will require 42
mm dia. hole

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 Limitations of torque-tensioned cables

● Reduced bolt pre-tension compared to hydraulic

tensioning
● Possible use of torque multipliers
‐ Slows down installation
‐ Failure of torque multiplier can delay production
‐ Possible safety issues
● May need modifications to head-plate of drill mast to
accommodate bolt and/or dolly
● Full resin encapsulation difficult for cables > 4 m
● Load transfer lower than for bulbed cables
● If bulbed then larger hole dia. & bigger resin capsule

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 Groutable FG rib bolt

● 42 t capacity
● Cuttable
● 42-45 mm drill hole
● Point anchored initially
● Breakout nut
● High torsion strength –
stalls rib bolting rigs
● 17 t collar capacity
● Shear strength of 14 t
● SG of 1.9 to 2.1 – separates
in washery

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 Groutable FG rib dowel - advantages

● Immediate rib support

● Hollow centre - post groutable
with thixotropic grout
● Full encapsulation vital in
heavy rib conditions
● Easily audited
● No secondary rib support
required – maximises
development rates

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