Straps

DYWIDAG-SYSTEMS INTERNATIONAL
DYWIDAG
DYWIDAG DSI product range
1.1 1.2 1.3 1.4 1.5 1.5.1 1.5.2 1.6 1.7 1.7.1 1.7.2 1.8 2.1 2.2 3.1 3.2 4.1 4.2 4.3 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 DYWIDAG THREADBAR Bolt Self-Drilling hollow-core Bolt Groutable DCP Bolt Fiberglass Bolt Expansion Shell Bolt Expansion Shells Expansion Shell Accessories Headed Resin Bolt Tension Rebar Bolt Tension Rebar Oz-Drive Nut Tension Rebar Pin Nut Set Tension Rebar Bolt Cable Bolts 0.6, 0.7 7-wire Cable Bolts 0.9" 19-wire (Hi-Ten) Friction Bolts 33, 39, 46mm mega Expandable Anchor Hanger Brackets Eyebolts Bar and Cable Trusses
Bar Bolts
Cable Bolts
01/04
Friction Bolts
Trusses & Utilities
Plates 6 Domed plates Plates Other Plates Plates Larger Plates Plates Butterfly plates W-Strap Plates & Mesh Mesh Strap Mesh Channel Welded Wire Mesh Chain Link Mesh Longwall Recovery Geogrid Mats DYWIDAG Bolts Spin adaptors Cable Bolts cable tensioner Cable Bolts cable spin adaptors Pull Testing Gear Cable Truss tensioner jack Friction Bolt installer Scaling Bars Spinners & Nutrunners General Tools & Hardware
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Tools
1 01/04
Bolt Summary Overview
Bolt type and size
Grade
[ksi]
Ultimate Load
[1000lbs]
Yield Load
[1000lbs]
Max Bar OD
[inches]
Features
1.1 DYWIDAG THREADBAR

#6 LH #7 LH #8 LH #9 LH #10 LH 5/8 RH 7/8 RH 1" RH 1.25" RH 75 75 75 75 75 160 160 150 150 44.0 60.00 79.0 100.0 127.0 43.8 78.4 127.5 187.5 33.0 45.0 59.3 75.0 95.3 36.7 64.1 102.8 151.2 0.860 0.990 1.120 1.260 1.430 0.693 0.906 1.200 1.410 LH means left-hand; RH means right hand thread
DYWIDAG bar has a rugged, self cleaning hot rolled thread along its entire length. Hardware develops the full section of the bar. Threadbar also shows high ductility as well as good corrosion resistance. Threadbar bolts are usually supplied with a domed anchor nut (mushroom nut) and a deformed plate. They can be used resin grouted or cement grouted, black, galvanized or epoxy coated.
2 . 1 Cable Bolt
0.5" x 7 0.6" x 7 0.62" x 7 0.7" x 7 0.9" x 19 270 270 270 270 41.3 58.6 62.7 76.2 124.0 37.1 52.6 53.2 68.6 108.0 0.520 0.620 0.640 0.720 0.900 Cable bolts can be supplied passive with a preseated head, or tensionable using the cable tensioner underground. Cable can be supplied black or galvanized; wedges develop the guaranteed Fu of the cable.
Wedge will hold 92,000 lbs.
1 . 2 Self-Drilling Hollow Core Bolt

R25N R32N R32S R38N R51N 65 70 70 70 70 45.0 62.9 80.9 112.4 168.6 33.7 51.7 62.9 89.9 0.857 1.117 1.117 1.378 1.851
The bolt has a hollow core to allow flushing and grouting the bolt. The bolt uses a disposable lost drill bit. After drilling with the bolt, the bolt is usually cement grouted into the hole. The bar has a standard rope thread to allow for couplers.
2 . 1 Fiberglass Bolt
15 to 20 to 30 to n/a n/a n/a 33.7 45.0 67.5 N/a N/a N/a 0.787 0.787 0.787
corrosion resistant, cuttable bolt, bolt is threaded over 6inch, nut thread develops 12kips
3 . 1 Friction Bolt
33mm 39mm 46mm n/a n/a n/a 22.5 26.0 37.1 18.0 20.0 27.0
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1.250 1.375 1.750
A ring or collar is welded to the outer end to hold a dome plate to the rock surface. Also known as 'split set' this bolt is hammered into hole, black or galvanized
2 01/04
Size
Grade [ksi]
Ultimate Load [1000lbs]
Yield max bolt Load diameter [1000lbs] [inch]
Features
1 . 5 Expansion Shell Bolt

5/8" 5/8" 3/4" 3/4" 55 75 55 75 19.2 22.6 28.4 33.4 12.4 17.0 18.4 25.1 0.625 0.625 0.750 0.750
Smooth bar, 6inch thread for expansion shell, headed end to be used with plate; not resin assisted
1 . 6 Headed Resin Bolt

#5 #6 #7 gr60 gr60 gr60 27.6 39.8 54.1 18.4 26.5 36.1 0.625 0.750 0.875 The deformations of reinforcing steel rebar allow high bond with the resin, passive bolt with a hotforged head to use with a plate
1. 7 Tension Rebar Bolt

#5 #6 #7 0.68 0.81 gr60 gr60 gr60 gr75 gr75 20.3 30.1 41.6 33.4 46.2 13.6 20.0 27.7 25.1 34.7 0.625 0.750 0.875 0.750 0.875
The deformations of the reinforcing bar bond to the polyester resin. One end is threaded 612inch to allow for tensioning after the resin has set. The bolt capacity is determined by tensile thread area.
1 . 8 Set-Tension Rebar Bolt

#5 #6 #7 0.68 0.81 gr60 gr60 gr60 gr75 gr75 27.6 39.8 54.1 36.3 49.9 18.4 26.5 36.1 27.2 37.4 0.625 0.750 0.875 0.750 0.875
Threaded on one end 6inch for an expansion shell to mechanically assist initially. The deformations of the reinforcing bar bond to the chemical resin. The opposite end has a hot forged head.
3 . 2 mega Expandable Anchor

10 12 20 n/a n/a n/a 22.5 27.0 45.0 n/a n/a n/a 1.375 1.750 1.750
thin walled steel pipe that is expanded using water pressure, load transfer is via friction
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3 01/04
1.1
DYWIDAG THREADBAR
ASTM F432 gr75
#7 60 45 2 0.996 7/8 11%
gr4
Type #6 44 33 Weight [lbs/ft] 1.5 Max bar diameter [inch] 0.862 Nominal diameter [inch] Ultimate Elongation* 11%
Ultimate Load [1000lbs] Yield Load [1000lb] typical plate
* in 8inch guage length
#8 79 59.3 2.7 1.122 1 11%

gr6
#8 50T 100 70 2.7 1.268 1.13 11%
#9 100 75 3.4 1.268 1.13 11%
#10 127 95.3 4.3 1.433 1.25 11%
gr3
** larger sizes such as #14, #18 are also available
Complies to ASTM F-432 and A-615 Rugged, self-cleaning hot-rolled, left-hand threaded the entire length of the bar Unique threadform provides excellent resin mixing, superior bond strength and fast assembly. Hex nuts, semispherical anchor nuts and couplers develop the full strength of the bar. Also available: expansion shells and eye-nuts Excellent ductility High toughness:13 ft-lbs charpy V-notch at 77F according to ASTM A370 Also available: galvanized or epoxy coated Resin or cement groutable Point-anchor active or full-column passive Superior corrosion resistance: hot rolled rounded thread deformations eliminate local stress raisers. Also mill scale provides additional corrosion barrier
INSTALLATION The unique threadform allows to spin the bar using a special oval shaped spin adaptor. There are special installation nuts available for example a pin-nut that releases once the resin starts to set.
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4 01/04
1.1
DYWIDAG HARDWARE
Full Load Hardware ASTM F-432
Type #6
B06U28810
#7
B07U28810
#8
B08U28810
Cast Anchor nut

Hex x length
1.25 x 1.375
B06U27701
1.375 x 1.63
B07U27701
1.5 x 1.75
B08U27701
Cast Hex Nut

Hex x length
1.188 x 1.125
B06K31110
1.312 x 1.313
B07K31110
1.438 x 1.625
B08K31110
Cast Coupler
Dia x length
1.19 x 3.44
n/a n/a n/a B06K21710
1.44 x 4.19
B07U95010
1.63 x 4.75
B08U95010
Cast Eye Nut

inside eye dimension 2-to-1 safe working load [kips]
2 inch 30
B07K21710 or B07K23610 1-5/8 or 1-3/4
2.25 inch 40
B08K23710
Expansion Shell
preferred Hole diameter
1-5/8
Material is ductile iron ASTM A-521 grade 80-55-06
Torque Tension Relationship
16 14 12 tension [kips] 10 8 6 4 2 0 50 100 150 200 250 300 350 torque [ft-lbs]
dry lubricated
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5 01/04
1.1
DYWIDAG THREADBAR
high grade, right hand
5/8 160 43.8 36.7 0.97 0.693 7% 7/8 160 78.4 64.1 1.75 0.906 7% 1 150 127.5 102 3.01 1.2 7%
Type Grade [ksi] Ultimate Load [1000lbs] Yield Load [1000lbs] Weight [lbs/ft] Max bar diameter [inch] Ultimate Elongation
1- 150 187.5 150 4.39 1.46 7%
*gr160 is available upon request. Elongation is measured in 10 dia. guage length per ASTM A722
Complies to ASTM A722 Rugged, self-cleaning hot-rolled, right-hand threaded the entire length of the bar Unique threadform provides excellent resin mixing, superior bond strength and fast assembly. Anchor nuts and couplers develop the full strength of the bar. Excellent ductility High toughness: 6.5 ft-lbs charpy V-notch at
77F according to ASTM A370
Also available: galvanized or epoxy coated Resin or cement groutable Point-anchor active or full-column passive Matched bearing plates Superior corrosion resistance: hot rolled rounded thread deformations eliminate local stress raisers.
INSTALLATION The unique threadform allows to spin the bar using a special oval shaped spin adaptor. There are special installation nuts available for example a pin-nut that releases once the resin starts to set.
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6 01/04
1. 2
SELF DRILLING BOLT

32mm hollow-core bar
R32N 2.28 lbs/ft 1.14inch 396mm2 63 52 52ft R32S 2.75 lbs/ft 1.14inch 488mm2 81 63 65ft
Type Weight Bar OD Cross Sectional Area Ultimate Load [1000 lbs] Yield Load [1000 lbs] Max drilling depth
Other sizes available are 25, 38, 51, 76mm
The DYWIDAG hollow core anchor is a fully threaded hollow bar that initially serves as a drill rod, utilizing a lost bit. For use in unconsolidated ground or other difficult ground conditions Excellent for spiling (fore-poling) Bolt is drilled in and grout is pumped through the center hole with pumpable resin or cement grouts The couplers are designed to exceed the ultimate load of the bar by 20%. The couplers are designed to minimize the loss of drill energy. Several drill bits are available. Most widely used is the EXX Tungsten carbide chisel bit for handling UCT* up to 12.5N/mm2 (RQD 100%) and up to 50 N/mm2 (RQD 75%) Standard length is 3m (9ft-10). Longer lengths are available: 4m, 6m
INSTALLATION Detailed installation instructions are available.

* UCT is unconfined compressive strength
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7 01/04
1. 3
DCP BOLT
Double Corrosion Protection by Grouting

The DCP bolt combines ease of installation with durable long-term corrosion protection.
Patent application filed
The square drive nut sits on domed washer. The nut has grouting channels. The domed washer transitions to a steel trumpet that provides a sealing fit with a deformed plastic sleeve. The deformations of the plastic sleeve center the bar inside, allow grout to flow inside and outside the sleeve. The deformations are designed to transfer the load from the inner to the outer grout. The sleeve is a protective barrier against corrosive elements. The bolt is installed using an expansion shell for immediate support.
INSTALLATION The grout nozzle is easily attached over the end of the bar and sealed against the drive nut. Grout is injected through the nut for encasing the bar is completely in grout even at the critical inside of the nut for maximum corrosion protection. The nut comes with a one-way valve to eliminate any grout bleed-off.
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8 01/04
1. 4
FIBERGLASS BOLT
GRP (glass reinforced polymer) bolts
Standard
Ultimate Load Nut/Thread tensile Load Single Shear Load Nut beak-out torque Weight Nominal bolt diameter Nominal Cross Section lengths 3 Specific gravity [g/cm ] Resin color 33,700 lbs 11,000 lbs 10,000 lbs 28ft-lbs to 30 ft-lbs 0.433 lbs/ft 20mm = 0.787 inch 2 2 310mm = 0.48 inch 4 - 10ft 1.7 1.8 White (w/ filler)
Threaded Bolt
higher grades up to 67,500 lbs ultimate are available
The 20mm fiberglass bolt is a pull formed (matched die) fiberglass construction, ribbed over its full length to provide maximum load transfer. Robust threads 150mm long (6inch) Fiber reinforced plastic nuts and bearing plates Corrosion resistant, cuttable Nuts and threads develop 12,000 lbs Also available: Thrustdowel with integral head and 18,000 lbs anchor head capacity Ultimate strain is 1.8% without yield point.
Swivel Plate Thrust Dowel
All 20mm fiberglass bolts are designed as chemical anchors and fully encapsulated. The non-filled resin bolts (green) are suitable for more aggressive environments and are to be used with cement grouts. Preferred hole diameter is 26-27mm (1 inch). For larger holes, we recommend a 22mm dia. fiberglass dowel which is available upon request in the above grades. Circular bearing plate and Swivel plate is available.
INSTALLATION After inserting the resin cartridges, the bolt is spun and pushed through the resin cartridges. Observe the resin manufacturers recommended mixing and hold time. DO NOT OVERMIX.
Product code(s) Thrust dowel 3ft Plate 5 dia 20mm bolt FT20090015 F22L2155 AROA0500
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9 01/04
1. 5
EXPANSION SHELL BOLT

Conventional Roof Bolt
Type 5/8 gr75 Ultimate Load 22,600 lbs Yield Load 17,000 lbs 3/4" gr75 33,400 lbs 25,100 lbs
gr2 w/ 1
7/8 gr75 46,200 lbs 34,700 lbs

gr3 w/ 1 /8
1
typical plate w/ hole*
gr2 w/
13
/16
* hole size for underground assembly; pre-assembled bolts require larger hole plates to clear shell.
This conventional roof bolt is made from smooth bar. The hot-forged head has a 1-1/8 square shape for standard bolting sockets. The opposite end of the bolt has a rolled-on thread (usually 6inch) for an expansion shell. Several types of expansion shells are available for different conditions For long-term service life, the bolts may be cement grouted.
INSTALLATION The conventional bolt is usually not resin-assisted and develops its anchorage immediately after setting the expansion shell. See special notes on expansion shells. The length of the bore hole must be longer than the bolt by approximately 2inch. The expansion shell, separately supplied, is screwed onto the bolt so that the bolt thread extends slightly beyond the expansion shell plug. After inserting the bolt into the hole, the bolt head is rotated to set the shell and to tension the bar.
Turn to 1.5.1 for selection of available expansion shells
Product code(s) SH63048LH06 SH75048LH06 01/04 SH88048LH06 5/8 x4ft w/ 6 LH thread 3/4 x4ft w/ 6 LH thread 7/8 x4ft w/ 6 LH thread
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10
1. 5.1
EXPANSION SHELLS
Mechanical Anchors
30,000 D1L 5/8 22,500 1.375
3 3.125
Type F2B UNC thread 5/8

Non-seizure load Drill hole size
Shell length Wedge length
30,000
F9F 30,000 1.75

3.25 2.25
7/8 40,000
17,000 1.375
2.875 1.375
Expansion Shell Mechanical Anchors use proven components with a long history of use. The non-seizure load is the maximum design load beyond which the threads start to seize. Mechanical Anchors rely on competent rock strata in the anchor zone. The suitability of the rock anchor zone and specific mine roof support anchor to be used is best determined by actual in-situ underground testing. The above expansion shell anchors are to be set dry (without resin) or with cement grouting. Please call DSI Technical Support for resin installed expansion shell bolts. All anchors comply to ASTM F432.
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11 01/04
1. 5. 2
EXPANSION SHELL BOLT

Accessories
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12 01/04
1. 6
HEADED RESIN BOLT

#6 gr60 39,800 lbs 26,500 lbs
1 gr2 w/ 1
Type #5 gr60 Ultimate Load 27,600 lbs Yield Load 18,400 lbs
Preferred Hole typical plate w/ hole 1 gr2w/ 1
#7 gr60 54,100 lbs 36,100 lbs

1-1/8, 1-3/8 gr3 w/ 1 /8
1
#8 gr60 71,100 lbs 47,400 lbs

1-3/8 gr4 w/ 1 /8
3
This roof bolt is made from reinforcing grade bar with a hot forged head to fit standard bolting sockets. Good bond with grout for excellent load transfer hot forged head (1-1/8 square) Passive full-column resin grout Matched bearing plates
INSTALLATION For larger hole sizes it is recommended to add a pig-tail resin mixer to the end of the bolt.
Product code(s) RH06048 RH07048 RH08048 #6 bolt 4ft long #7 bolt 4ft long #8 bolt 4ft long
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13 01/04
1. 7
TENSION REBAR BOLT

#6 60 30.1 20.0
gr2
Type #5 Grade 60 Ultimate Load [1000lbs] 20.3 Yield Load [1000lbs] 13.6
Typical plate gr2
#7 60 41.6 27.7
gr3
0.68 75 33.4 25.1

gr3
0.81 75 46.2 34.7

gr4
This roof bolt is made from reinforcing steel bar. One end is roll-threaded to accept a nut. The nut is torqued to tension the bolt after the epoxy resin has set. Either six, eight or twelve inches of threads Different types of break-away nuts are available Point-anchor or fully grouted Tensionable Load carrying capacity (above) is determined by the threaded area Matched bearing plates
INSTALLATION For larger hole sizes it is recommended to add a pig-tail resin mixer to the end of the bolt.
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14 01/04
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15 01/04
1. 7
TENSION REBAR BOLT

Accessories
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16 01/04
1. 7 .1
OZ DRIVE NUT
DSI continues to develop torque resistant nuts which provide greater benefits over and above the hot forged mixing square enabling the use of a single spanner operation in installation of chemical rock bolts. A metal disk is inserted into end of the nut and held in place with deformed tabs. These tabs break loose providing a torque release mechanism. BREAKOUT TORQUE RANGE COLOR Stamp *) White (W) Orange (O) Red (R) Yellow (Y) Blue (B) Purple (P)
Typical torque required to break loose the disk and thus allow the nut to be tightened. This torque is the maximum mixing torque.
140 + ft-lbs 100 - 140 ft-lbs 75 115 ft-lbs 60 - 80 ft-lbs 35 - 50 ft-lbs 25 - 35 ft-lbs
190 + Nm 135 190 Nm 100 155 Nm 80 - 110 Nm 50 - 70 Nm 40 - 50 Nm
*) Appropriate color symbols stamped into each disk to indicate torque range, i.e. R= Red; B= Blue, etc.
DSI OZ Nuts offer the following advantages: o o o o Up to 30% greater pre-tension for a given ft/lb. of torque. No residual drag after torque break-out. Will not seize on bolt threads. Less strain on operators using hand-held roof bolters due to a smooth break mode
OZ Nuts are supplied with the following threads: UNC: 3/4-10; 7/8-9; 1-8 UNC LH or RH DYWIDAG THREADBAR: # 6, #7, #8 OZ Nuts are normally supplied attached to the appropriate bolts, but may be supplied bagged in 100 piece bags. Patent protected.
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17 01/04
1. 8
SET-TENSION REBAR BOLT

#6 60 39.8 26.5
gr2
Type #5 Grade 60 Ultimate Load [1000lbs] 27.6 Yield Load [1000lbs] 18.4
Typical plate gr2
#7 60 54.1 36.1
gr3
0.68 75 36.3 27.2

gr3
0.81 75 49.9 37.4

gr4
* hole size for underground assembly; pre-assembled bolts require larger hole plates to clear shell.
This roof bolt is made from reinforcing steel bar. One end is roll-threaded 6inch long to accept an expansion shell. Hot forged head to accommodate bearing plate Threaded for expansion shell, designed to be pushed through grout cartridges. Installed with or without grout Point anchored or fully-resin grouted Tensionable Matched bearing plates Does not loosen during blasting or ground vibrations
This design enables to instantaneously set the bolt by expanding the shell. No hold time needs to be observed for curing the grout. After the resin has set, the hot-rolled deformations of the bar provide a longterm, bond anchorage over the entire bolt length.
INSTALLATION Insert the resin cartridge, then insert the bolt (without spinning) to within 1/16 or 1/8 of the roof line. Rotate the bolt to expand the shell until the head is tight against the plate. Use a preset torque to avoid over-torqueing the shell. The rotation to expand the shell is mixing the resin which then starts to set after the shell has been set.
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18 01/04
2 .1
CABLE BOLT
0.6 gr270 0.74 lbs/ft 1" to 1.375" 140mm2 58.6 46 3.5%
gr6 w/ 1-3/8 hole
0.6" or 0.7" Passive and Tensionable

Cable Diameter Weight Bore Hole Diameter Cross Sectional Area Ultimate Load [1000lbs] Yield Load [1000lbs] Min. Elongation in 2ft
Typical plate
0.7 gr270 1.11 lbs/ft 1" to 1.375" 196mm2 76.2 68.6 3.5%
Grade 6
Also available are 0.5, 0.62 and 0.9 upon request.
270 ksi, low relaxation cable per ASTM A416. Supplied in any length, black or galvanized cable. Point anchored active bolt, tensioned after installation utilizing the hydraulic tensioning jack. Point-anchored passive bolt with pre-seated head. Wedge barrel shaped to accept 1-1/8 hex or square male spinner.
tensionable
passive
Several options for anchoring in the resin are available: The bulbed cable bolt is designed for point-anchoring in resin. It may also be fully grouted with slow speed resin, or cement grouts. Bulbing is an effective means to center the bolt in the drill hole, to mix the resin and to develop bond for anchoring the bolt. The Bond head is an additional bulb that can be formed on the end of the cable bolt. Bulbs are provided to fit hole sizes: 1 hole: 1-3/8 hole: 1-3/4 hole: strip cage plunge bulb bond head
Plunge bulb for 1-3/8 hole Bond Head at end to fit specific Hole diameter
Product code(s)
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19 01/04
CB16PTP
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20 01/04
2 .1
CABLE BOLT
Accessories
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21 01/04
2 .1
CABLE BOLT
Installation Accessories
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22 01/04
2 .1
The Wedge Anchorage of the cable bolt
The anchorage of most cable bolts consists of a wedge barrel and a 2- or 3-part wedge. The wedge segments grip the cable by means of tooth shaped threads which are forced into the surface of the cable wires.
The clamping force W is highly dependent on the friction between wedge and wedge hole. For normal friction conditions, the clamping force W is more than 4 times the cable pulling force V and it adjusts with the pulling force V.
Warning: If friction increases (due to corrosion), a larger F will reduce the clamping force. As V increases all other forces can only increase if the wedge can seat deeper into the barrel. If the wedge is restrained to do so (i.e. by corrosion or dirt-accumulation), the clamping force can not increase with the pulling force causing slippage when the load on the cable bolt gradually increases during service life. To avoid slippages during use, it is important that the cable bolt is fully stressed at time of installation to a force equal to 0.5 Fu.
When a wedge is properly seated, radial cracks may develop indicating adequate seating. The wedge can be supplied with a rubber O-ring or a metal spring ring holding the wedge segments together.
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23 01/04
2.2
HI-TEN STRAND BOLT

0.9 inch 124,000 lbs 108,000 lbs 3-4% 1.9 lbs/ft
HI-TEN stands for HIGH PRE-TENSION Diameter Ultimate Load Yield Load Uniform elongation Weight
The HI-TEN cable bolt has a semispherical barrel with a wedge and will carry loads between 46 and 50 Tons. Dywidag HI-TEN cable bolts are designed for long rock bolts and are capable of being post-tensioned after installation to loads up to 28 tons using the DSI hydraulic tensioning unit. A square end allows the bolt to be rotated to mix resin grout. The HI-TEN cable bolt is designed to be point -anchor grouted and pre-loaded. It may also be fully grouted with slow speed resin grouts, or cementitous grouts. An excellent choice to supplement existing strata reinforcement. Compatible domed plates are available from DSI. Patent Pending
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25 01/04
3 .1
FRICTION BOLT
33mm
1.3 inch 1.03 lbs/ft 1.1875 -1.25 2 204mm 2 0.32 inch 22,500 lbs 18,000 lbs
gr2 w/ 1.5 hole
Type
Diameter Weight Bore Hole Dia. Cross Sectional Area Ultimate Load Yield Load Recommended bit Typical plate
39mm
1.54 inch 1.19 lbs/ft 1.375 - 1.5 2 225mm 2 0.35 inch 26,000 lbs 20,000 lbs 1.375 1.5
gr2 w/ 1-5/8 hole
46mm
1.85 inch 1.87 lbs/ft 1.69 1.79 2 355mm 2 0.55 inch 27,000 lbs 37,000 lbs 43-45 mm
gr3 w/ 2 hole
3ft
4ft
To indicate length friction bolts can be color coded or the ring slot can be indexed as shown.
6ft 9ft
Friction Bolts can be load tested by fitting a special ring to the bolt prior to installation. The test is carried out using a center hole hydraulic jack.
Suitable for installation with hand-held rock drills (stopers) and other rotary-percussive drills. Standard deformed plates (ASTM-F432) are supplied with the bolts. Hot dip galvanizing is available to provide corrosion protection.
INSTALLATION The hole length shall be longer than the bolt by 6inch to allow for any rock fretting during installation. The bolt is inserted into the hole. The driving dolly is fitted into the rock drills chuck and then the bolt (with accessories) is placed onto the dolly. Using full percussion and thrust the bolt is driven into the hole until the domed plate is firmly against the rock surface. Care shall be taken to ensure the rock drills feed/thrust is collinear with the hole axis otherwise the bolt may be bent or buckle during installation.
Product code(s) 33mmx18: 39mm: x6ft 46mm x 8ft: 39mm x 4ft + plate FB33045 FB39180 FB46240 FB39122D1541
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26 01/04
3.2
MEGA
11 tons 22,500 lbs 25% 35-38mm 3-26ft 1.29 lbs/ft 4350 psi
grade 2
EXPANDABLE FRICTION ANCHOR
Type Ultimate Load Ultimate Elongation Optimal Borehole dia. Delivery Lengths Weight Installation Pressure Typical plate
13.5 tons 27,000 lbs 25% 45-51mm 3-26ft 1.72 lbs/ft 3625 psi
grade 2
22.5 tons 45,000 lbs 25% 45-51mm 3-26ft 2.54 lbs/ft 4350 psi
grade 4
Thin walled, folded steel pipe is seated at the end installed in hole and expanded with water pressure. Matched bearing plates The anchorage is effective over the entire anchor length. MEGA anchors are not susceptible to blasting shock waves. The anchors work by friction without bonding agent. MEGA anchors can accommodate a high borehole diameter tolerance.
MEGA
INSTALLATION Anchor plates available are: longhole: 6x6 x0.157 or 0.25, roundhole 6x6x0.315 or 8x8x 0.39 Pneumatic or electric high-pressure water pumps are required to set the MEGA anchors.
Order information Imported product Lead time 8-10 weeks Electric or pneumatic pump also available
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27 01/04
4.1a
KEYHOLE BRACKETS
Service Line Keyhole Brackets are used in conjunction with service line slots pre-punched in W-Strap vees.
The Keyhole Brackets are used for suspension of light mine services using chain. A safety factor of 6:1 has been applied to the failure load on the design. Loads are valid for static loads only with no allowance being made for shock load or vibration. Corrosion protection may be provided by hot dip galvanizing.
NOTES For details of Keyhole Brackets, load limitations and other factors please contact DSI Ground Support Systems.
Product code(s) MH8030 6x4x5/16 L x 4
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28 01/04
4.1b
KEYHOLE BRACKETS
UTILITY HANGERS
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29 01/04
4.2a
EYE BOLTS
16mm Eye Bolts are available for hanging light service lines in mining applications. Available with a rolled thread M16 x 150mm to accept 16mm expansion shell mechanical anchors. Note: the slotted option as per 24mm Eye Bolts is not available for 16mm Inside diameter of the eye is 75mm Nominal bolt length is measured from under eye to end of bolt. Feed material around eye is lapped back for a minimum of 50mm along bolt shank before being fillet welded on both sides. Manufactured from round bar feed AS1442/U1040 material May be supplied hot dip galvanized.
PACKAGING Bundles of 10 units or larger quantities on pallets.
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30 01/04
4.2b
EYE BOLTS
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31 01/04
4.3 a
SanJuan EZ TRUSS
ASTM F432 gr6
The DYWIDAG SanJuan EZ Truss combines ease of installation with superior support performance. It can be installed safely from the bolter without exposure to unsupported roof at anytime.
Patent application pending in USA
INSTALLATION
The truss shoe and the inclined bolt can be installed first and separately from the truss. Then a dead ended pre-seated wedge-barrel is swung into the truss shoe. It self-centers inside the truss shoe. This can be done using the cable as an extension without leaving the protection of the bolter. Then both cables are fed through the cable truss coupler in the middle. Wedges are installed into barrels against the cable truss coupler and stressing may commence using a hydraulic tensioning unit. The truss shoe is designed to accommodate #7 or #8 bar and angles between 45 and 60 degrees to the horizontal.
Product code(s) Truss Shoe CTS06 Truss Set 0.6 cable and #7 DYWIDAG bar w/ shoe and coupler EZ TRUSS
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32 01/04
4.3 b
TRUSSES AND SLINGS

Bar Sling
Full Load Truss coupler Torque wrench to tension truss at coupler
Patented in US and Canada
Cable Truss
Full load dog-bone cable coupler Hydraulic jack to tension Ring-eye plate or wood at bends to transfer corner forces
Patented in US and Canada
Product code(s) CTC06 cable truss coupler (dogbone) B08K32910 #7or #8 cast truss coupler B09U32010 #8 or #9 cast truss coupler
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33 01/04
5.1
6X6 DEFORMED PLATE

rated per ASTM F-432
Hole Diameter [inch] 0.8125, 0.9375,1.000, 1.125, 1.250, 1.500, 1.625, 1.600 1.000, 1.125 1.125, 1.250, 1.375, 1.500 1.250, 1.375 Net weight [lbs] 1.45 2 3.18 3.8
Grade 2 3 4 6
Deformed plates are proof tested according to ASTM F-432 on a continuing basis using an in-house testing machine. The deflection under load is recorded. Identification stamp G1-#2: G1 identifies the DSI plant in Salt Lake City. The #2 identifies a grade 2 plate. Eccentric loop to allow the attachment of light service lines. User friendly rounded corners. Designed to fit into the butterfly plate. The combination of deformed plate and butterfly is called a dragonfly plate. Corrosion protection may be provided by hot-dip galvanizing the finished plate or by using pregalvanized material. Embossed plates for low-profile requirements are available upon request
PACKAGING Domed Plates are tied with wire clips and palletized.
Product code(s) 6x6 gr2 hole 13/16 6x6 gr3 hole 1 6x6 gr4 hole 1-1/8 6x6 gr6 hole 1-1/4 D060614513 D060619516 D060631218 D060637520
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34 01/04
5.2
BEARING PLATES
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35 01/04
5.3
BEARING PLATES
larger plates and flat plates
Thickness available up to 1-1/8 flat up to 1 flat Grade 6 deformed up to 7/8 flat Max hole size 1-3/8 1.5 1-3/8 1-9/16 Max weight 10.9 lbs 17.4 lbs 24 lbs
Bearing size 6 x 6 8 x 8 8 x 8 10 x 10
Plates made from ASTM A36 or A572 gr50 steel. The above maximum thicknesses are available in ASTM A36 steel. Plates are available black or galvanized or epoxy-coated. Welded on studs are also available upon request. Net weight: 0.28 lbs/inch3
Product code(s) 8x8 gr6 domed hole 1-3/8 8x8 flat hole 1.5 D8838138 F8838150
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36 01/04
5.4
BUTTERFLY PLATE
Thickness Hole Diameter 1.9mm 50mm = 2inch 1.9mm 50mm = 2inch Net weight black 2.87 lbs 3.73 lbs Net weight galv. 2.95 lbs 3.83 lbs
Length x Width 300 x 278mm 12 x 11inch 400 x 278mm 15.75 x 11inch
The butterfly plate is a light-weight plate with a large surface area. It is used as an intermediate plate to increase the surface coverage of a bolt. DSI Butterfly plates feature both longitudinal and transverse V-shaped deformations for added strength and greater ability to conform to irregularities in the rock surface. The deformed design renders a greater strength, placing the perimeter of the Butterfly Plate in tension. User friendly rounded corners. Can be used with both flat and domed plates (up to 150mm, 6inch square) Butterfly plates are can be placed directly to the rock surface or used with Welded Steel Mesh. Butterfly plates are supplied with slots for supporting of light service lines. Corrosion protection may be provided by hot-dip galvanizing the finished plate or by using pre-galvanized material.
PACKAGING Butterfly Plates are tied with wire clips and palletized.
Product code(s) 12x12 black 12x12 galv. 12x16 black 12x16 galv.
Page
BUTT300S USA BUTT300GS USA BUTT400SWA BUTT400GS
37 01/04
5.5 Steel Mat, Bacon-Strip, Monster Mat Type Material thickness Typical Width Delivery lengths Mats per bundle Roof Mat 16 or 14ga 9-10 inch wide 9-20 ft 25 Monster Mat 12 ga 14inch 9-20 ft 10
W-STRAP
Steel Mat is commonly used when additional support is required in conjunction with rock bolts. These steel straps are pulled against the rock surface by the bolts and tend to conform to major irregularities in the rock and rounded tunnel shapes. Steel Mats provide a large surface confinement to loose rock. Standard hole pattern is multi holes 1ft on center, starting 6inch from the end, 1.75 hole diameter; oblong holes as well as special, hole distances and diameters can be supplied upon request. Service line slots can also be provided upon request.
INSTALLATION Typically the Roof Mat bears against the rock surface. A roof bolt plate is placed against the Mat and a roof bolt is installed. Depending on the roof conditions, a steel mesh can be placed behind the Roof Mat for additional surface control.
Product code(s) RM1207216B RM1207216G RM1210816B RM1210816G

Page
11.75x72 16ga black 11.75x72 16ga galv 11.75x108 16ga black 11.75x108 16ga galv
38 01/04
5.6 a
MESH STRAP
Deformed mesh strap
20inch x 15ft 36 lbs 3 x 2 inch 5mm @ 75mm 4 x 8mm and Longitudinal wire 6 x 5mm
Other sizes are available upon request.
Dimensions Weight Grid Transverse wire
Allows to set and add bolts where needed. Combines light weight with strength
The design also allows for bolts to be placed anywhere along the roof strap or module.
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39 01/04
5.6 b
MESH STRAP
Deformed mesh strap
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40 01/04
5.7
MESH CHANNEL
Deformed Mesh
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41 01/04
5.8
WELDED WIRE MESH

4x8, 6x9, 6x10 ft 6x16, 6x17 ft 3x3 or 4x2 or 4x4 inch 10 gage to 2.5 gage W1.4 to W5 0.135 inch to 0.25 inch
Typical sheet size Aperture size Wire gage Wire size Wire diameter
Typical gages and conversion:
Gage 6 6.5 7 7.5 8 9 nom dia. 0.192 0.185 0.178 0.171 0.162 0.1483
lbs/ft 0.099 0.091 0.085 0.078 0.070 0.059
Wire size W 2.9 W 2.7 W 2.5 W 2.3 W 2.1 W 1.7
Welded Wire Mesh is supplied in a variety of configurations. Sheet sizes as well as wire gage and spacing is mine specific to fit the underground condition. The spacings are variable in both directions (longitudinal wire and cross wire). To minimize injury risk during handling, the mesh sheets are flush-cut all around (0to overhang). Wire and weld are produced and tested according to ASTM A82 and A185. Wire Mesh is typically supplied in stacks of 25 or 50 sheets. It can be advantageous to design spacings so that plates can be placed onto the grid. Other mesh layouts consider reinforcing spacings or locator spacings so that the sheet is stronger around its edges and to match the rock bolt pattern.
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42 01/04
5.9a
CHAIN LINK WIRE MESH

Typical roll sizes 4ft to 9ft wide; 25-50ft long Diamond size 2, 2.25, 2.375 Wire gage 9 gage to 11 gage Black or galvanized Wire diameter 0.148 inch to 0.25 inch
Economical Versatile Shotcretable
Typical gages and conversion:

Gage 9 10 11 nom dia. 0.1483 0.135 0.120 lbs/ft 0.059 0.0492 0.0384 Weights in lbs/ sqft 2 2.25 2.375 diamond diamond diamond 0.7 0.646 0.61 0.6 0.543 0.51 0.46 0.377 0.356
Chain link screening offers an economical and durable solution for roof support or rib support. Chain link mesh is often used to engage more surface area for each roof bolt. Also, chain link has proven to be well suitable for shotcrete applications. Chain Link Wire Mesh is supplied in a variety of configurations. Sheet and roll sizes as well as wire gage and diamond opening is mine specific to fit the underground condition.
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43 01/04
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44 01/04
5.9b
WIRE MESH
Page
45 01/04
5 . 10
LONGWALL RECOVERY
Polyester or SUPRGRID
tensile strength (ASTM-D4595) MD XMD MD XMD Ultimate 1 at 2% strain ) ultimate lbs/ft kN/m Elongation 280 280 35 35 11x11% 650 650 1,600 650 1,600 1,100 1,600 1,600 80 80 200 80 200 140 200 200 100 80 100 100 100 200 11x11% 11x11% 11x11% 11x11% 3x11% 3x11% 3x11% 3% aperture size weight
2 2
DSI Grades
All Polyester 35/35 80/80 200/80 200/140 200/200 SUPRGRID ) 100/80 100/100 + 10 100/200 wire rope 6x19
3 2
inch 1.77 1.38 1.38 1.38 1.38 1.38 1.53 1.38
mm 45 35 35 35 35 35 39 35
oz/yd 8 19 23 32 38 12 14 27
g/m 271 644 780
1085 1288 407 475 915
3,400 ) 3,400
650 800
3,400 1,600 13,000 lbs
0.46 lbs/ft
MD = Machine Direction, XMD = Cross Machine Direction 1 ) 2% strain is equivalent to 10 convergence given 10ft unsupported span during shield recovery. 2 ) SUPRGRID with XMD in Polyester 3 ) Reinforcing bands add ultimate 10,000 lbs on 18 centers
DYWIDAG GridMesh is comprised of high tenacity yarns, woven into a stable interlocking grid structure and then fire-retardant coated with PVC for protection during installation. GridMesh is used for longwall recovery mats as well as rib control. Longwall recovery mats are fabricated and assembled to mine-specifications. Light weight - reduces cost and handling time for longwall moves compared to traditional chain link. No sharp edges, reducing injury hazard associated with chain link. Conforms easily to the roof or ribs due to the multifilament yarn design. Stronger than other polymer grids: Since the longitudinal and transverse members are crossed and independent, there is less ripping out at the intersections than with other polymer grids. Fast pick-up: High Tenacity Polyester Grid develops a minimum of 40% of ultimate strength at 5% strain significantly reducing rock movement. Suprgrid develops more strength faster matching the stiffness of wire ropes. 2% strain is equivalent to 10 convergence given 10ft unsupported span during shield recovery. GridMesh is available in rolls made to custom length. The width also can be customized to specific needs but common are 6ft, 8ft and 12ft with 15ft being the maximum width. The grid is produced in the USA with a lead-time of 4-6 weeks.
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46 01/04
6.
INSTALLATION TOOLS
DYWIDAG tools are specifically designed and tested to work with DYWIDAG ground support systems. Using original DYWIDAG tools will guarantee optimal installation times and performance results.
6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9
DYWIDAG bar spin adaptors and nut wrenches DYWIDAG Cable Tensioner Cable spin adaptors (passive, tensionable) Pull Testing Gear Cable Truss jack Friction bolt installer Scaling Bars Rebar/Threadbar Spinners and Nut-Runners General Tools and Hardware
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47 01/04
6.1
DYWIDAG SPIN ADAPTOR

Bar Spanner to mix epoxy resin
The DYWIDAG Spin Adaptor is an installation tool to properly mix epoxy resin cartridge. The Spin adaptor for DYWIDAG bolts takes advantage of the oval shape of the bar. The spin adaptor has a oval shape to fit the bar and allows spinning without any special end preparation of the bolt. DYWIDAG Spin Adapators are made from high strength steel that is heat treated and hardened for long lasting durability DYWIDAG spanners allow for resin mixing DYWIDAG bar installing wrench to suit #6, #7 and #8 DYWIDAG bolts Drive end to suit various bolter drives: 7/8 hex, 1-1/8 square or 1-1/8 hex or as required. When mixing resin, observe the mixing time and number of revolutions recommended by the resin manufacturer.
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48 01/04
6.2 a
CABLE TENSIONER Mark2
A light weight and unique way for pre-loading cable bolts, the DSI Cable Tensioner Mark2 grips the end of the cable bolt and tensions it, leaving only a short tail protruding from the bearing plate (approx. 6 inch). The Cable Tensioner is a single hydraulic ram driven by an air/hydraulic pump or by machine hydraulics. The complete jack weighs 25 lbs. The entire kit (matrix) weighs 51lbs. Two grip handles allow for operation by one person. Unit locks on the cable, until lanyard is pulled to release spring loaded grippers. Can be configured for all cable bolts, from 0.6 to 0.7 and the DSI 0.9 HITEN cable bolt. Capacity: 48,500 lbs Bleed off: 15% i.e. cable lock-off load is 85% of pulling force due to seating loss. (for a typical 12ft bolt)
air actuated hydraulic pump
OPERATION Install the plate and wedge barrel with wedge on the end of the cable bolt. Push the Cable Tensioner on. It will self-lock onto the cable. Tension bolt to the desired load per hydraulic gage included with the unit.
View of lanyard
After stressing, the Cable Tensioner is easily removed by pulling on the lanyard to release the internal grippers.
Product code(s) Matrix (kit) Tensioner jack Pump TEN22152US (51lbs) TENNUNIT22152US TENFP280 (11lbs)
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49 01/04
6.2 b
CABLE TENSIONER CBJ-1

High Pressure System
Page
50 01/04
6.3
CABLE SPIN ADAPTOR

Cable Spanners to mix epoxy resin
for tensionable bolts
for passive bolts
Cable Bolt wrenches allow to mix epoxy resin cartridges. Cable bolt installing wrenches to suit 0.6, 0.7 and 0.9 cable. The spanners suit both passive and tensionable cable bolts. The spanners for tensionable cable bolt have 8 long throat to leave a cable tail protruding after installation and mixing long enough to tension with the DYWIDAG cable tensioner. Drive end to suit various bolter drives: 7/8 hex, 1-1/8 suqre or 1-1/8 hex or as required. Overall spanner length is designed to suit mine specific needs. The cable drive spanners have a patented hardened, internal hex pattern that allows to spin cables without end-preparation which reduces cost for the bolt. When mixing resin, observe the mixing time and number of revolutions recommended by the resin manufacturer.
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51 01/04
6.4
PULL TEST GEAR
Center hole jack Pump Pressure gauge Chair Hoses Claw with pull rod
Complete DYWIDAG pull test gear to conduct underground pull testing of Cable Bolts DYWIDAG Bolts Headed and Threaded Bolts Friction Bolts
Pull gear is set up for testing of nominated bolts to allow non-destructive or destructive load testing. We recommend regular pull testing of bolting system.
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52 01/04
6.5
CABLE TRUSS TENSIONER

for 0.6" cable truss coupler
Ram Area: 6.77 inch2 30 ton center hole jack (double acting) Auto-release internal grippers Open throat banana nose with centering ring to fit cable truss coupler (dogbone) Total Weight: 56 lbs We recommend to stress 0.6 cable trusses to 20 tons minimum.
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53 01/04
6.6
FRICTION BOLT
INSTALLATION ACCESSORIES
Page
54 01/04
6.7
SCALING BARS
Page
55 01/04
6.8
Rebar Bolt Tools

FOR STOPERS/JACKLEGS
Page
56 01/04
6.9
General Tools
AND HARDWARE
Page
57 01/04

Straps

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DYWIDAG-SYSTEMS INTERNATIONAL

Trusses & Utilities

Bolt Summary Overview

Bolt type and size

1.1 DYWIDAG THREADBAR

Wedge will hold 92,000 lbs.

1 . 2 Self-Drilling Hollow Core Bolt

1.250 1.375 1.750

Ultimate Load [1000lbs]

Yield max bolt Load diameter [1000lbs] [inch]

1 . 5 Expansion Shell Bolt

1 . 6 Headed Resin Bolt

1. 7 Tension Rebar Bolt

1 . 8 Set-Tension Rebar Bolt

3 . 2 mega Expandable Anchor

#8 79 59.3 2.7 1.122 1 11%

#8 50T 100 70 2.7 1.268 1.13 11%

#9 100 75 3.4 1.268 1.13 11%

#10 127 95.3 4.3 1.433 1.25 11%

** larger sizes such as #14, #18 are also available

Cast Anchor nut

Cast Hex Nut

Cast Eye Nut

Material is ductile iron ASTM A-521 grade 80-55-06

Torque Tension Relationship

1- 150 187.5 150 4.39 1.46 7%

SELF DRILLING BOLT

INSTALLATION Detailed installation instructions are available.

Double Corrosion Protection by Grouting

Patent application filed

higher grades up to 67,500 lbs ultimate are available

EXPANSION SHELL BOLT

7/8 gr75 46,200 lbs 34,700 lbs

typical plate w/ hole*

Turn to 1.5.1 for selection of available expansion shells

Type F2B UNC thread 5/8

F9F 30,000 1.75

EXPANSION SHELL BOLT

HEADED RESIN BOLT

#7 gr60 54,100 lbs 36,100 lbs

#8 gr60 71,100 lbs 47,400 lbs

TENSION REBAR BOLT

0.68 75 33.4 25.1

0.81 75 46.2 34.7

TENSION REBAR BOLT

190 + Nm 135 190 Nm 100 155 Nm 80 - 110 Nm 50 - 70 Nm 40 - 50 Nm

SET-TENSION REBAR BOLT

0.68 75 36.3 27.2

0.81 75 49.9 37.4

Turn to 1.5.1 for selection of available expansion shells

0.6" or 0.7" Passive and Tensionable

Also available are 0.5, 0.62 and 0.9 upon request.

The Wedge Anchorage of the cable bolt

HI-TEN STRAND BOLT

EXPANDABLE FRICTION ANCHOR

Product code(s) MH8030 6x4x5/16 L x 4

PACKAGING Bundles of 10 units or larger quantities on pallets.

Turn to 1.5.1 for selection of available expansion shells

Patent application pending in USA

TRUSSES AND SLINGS

Patented in US and Canada

6X6 DEFORMED PLATE

Length x Width 300 x 278mm 12 x 11inch 400 x 278mm 15.75 x 11inch

BUTT300S USA BUTT300GS USA BUTT400SWA BUTT400GS