Dsi Underground Systems Catalogue Us 01

Mining and Tunneling Products Catalogue

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Table of Contents

Section

Mechanical Rock Bolts, Extension Bolts & Stelpipe Bolts

1

Rebar Rock Bolts

2

Cable Bolts

3

Friction Stabilizers & Expandable Bolts

4

DYWIDAG THREADBAR®

5

Trusses & Slings

6

Specialty Bolts

7

Fiberglass Bolts

8

Resins & Cement Cartridges

9

Mesh, Straps & Plate Washers

10

Eyebolts, Scaling Bars & Utility Hangers

11

Tools & Hardware, Drilling Consumables

12

Lattice Girders, Steel Arches & Props

13

High Performance Grouts & Application Equipment

14

Drilling Fluids

15

Miscellaneous

16

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Mechanical Rock Bolts (Forged Head & Threaded) Nominal 5/8" and 3/4" sizes and 7/8" Forged Head (11/8" Square) + 1/

G

G3 5 48

" (6 mm) up to 10' (3 m)

–

length as specified +1/ 4" (13 mm) over 10' (3 m)

H

– 2

F

I thread length as specified

E

bolt length

33/4" (95 mm) min. 12" (305 mm) max.

USA manufactured bolts: made to ASTM F432 and MSHA approved

T-Dome (1 5/16" Square)

DSI

5

Threaded Both End (TBE)

Dimensions Head Type Type Head Diameter E EBody Body Diameter

FHead Head Across Across FlatsFlats F G Head Across Corners Head Across Corners G

H Head Height Head Height H

I Thread Size, left & right

All bolts bolts All Square 1111//88"" Square T-Dome T-Dome

8" Bolt

5/8"5Bolt /

4" Bolt

3/4"3/Bolt

7/8"

±0.56" (±14.2 mm)mm)±0.68" (±17.3 mm) mm)±0.79" (±20.1mm) ± 0.79" ±0.56" ( ±14.2 ( ± 20.1 ±0.68" ( ±17.3

1.244" - 1.326" (31.60 - 33.68 mm)

0.40" (10.16 mm)

11/8" Square & T-Dome

5/8" -

All bolts

0.40" (10.16 mm)3

11 UNC

5/8"- 11 UNC Thread Size (left and right) I All Bolts All dimensions in accordancewith ASTM F432 & CSA M430-90 specifications

/4"

3/4"-

- 10 UNC

7/8"

10 UNC

7/8"-

All dimensions in accordance with ASTM F432 & CSA M430-90 specifications

Tensile Strength, min. Ultimate Axial Strain www.dsiunderground.com

3/4" Bolt

13,600 lbs 20,000 lbs (60 kN) (89 kN) 22,600 lbs 33,400 lbs (100 kN) (148 kN) Minimum 12%

5/

" Bolt

5/8" Bolt

17,100 lbs (76 kN) 31,200 lbs (139 kN) Minimum 8% May 2013

A29 (gr75 for USA)

C1055 (A29) 5/

" Bolt

- 9 UNC

9 UNC

continued

C1070

C1060 Steel

Yield Strength, min.

mm )

1.125" (27.64 - 28.58 1.088" 1.088" - -1.125" (27.64 - 28.58 mm) mm) 0.906" 0.938" (23.01 23.83 0.906" - 0.938" (23.01 - 23.83 mm) mm) 1.425" - 1.591" (36.19 - 40.41 mm) 1.425" - -1.591" (36.19 - 40.41 mm) mm) 1.244" 1.326" (31.60 - 33.68

1 1/8" Square 1/8" Square 1T-Dome T-Dome 11/8" Square & T-Dome

5/8" Bolt

7Bolt /8" Bolt

3/

" Bolt

C1070M 5/8"

TBE Bolt 28,400 lbs (126 KN) 35,000 lbs (156 KN) Minimum 2.2% Section1-Page1 7/

" Bolt

Mechanical Rock Bolts (Forged Head & Threaded) continued

Technical Data C1060 Steel 5/8"

C1070

Bolt

3/4"

Bolt

5/8"

Bolt

C1070M 5/8"

TBE Bolt

Yield Strength, min.

13,600 lbs (60 kN)

20,000 lbs (89 kN)

17,100 lbs (76 kN)

28,400 lbs (126 kN)

Tensile Strength, min.

22,600 lbs (100 kN)

33,400 lbs (148 kN)

31,200 lbs (139 kN)

35,000 lbs (156 kN)

Minimum 8%

Minimum 2.2%

Minimum 12%

Ultimate Axial Strain

C1055 (A29) 5/8"

Bolt

A29 (Gr.75 for USA) 5/8"

Bolt

3/4"

Bolt

7/8"

Bolt

Yield Strength, min.

15,600 lbs (69 kN)

17,000 lbs (75 kN)

25,100 lbs (111 kN)

34,700 lbs (154.3 kN)

Tensile Strength, min.

24,000 lbs (106 kN)

22,600 lbs (100 kN)

33,400 lbs (149 kN)

46,200 lbs (205.5 kN)

Ultimate Axial Strain

Minimum 10%

Minimum 8%

All mechanical & physical properties in accordance with ASTM F432, ASTM A29 & CSA M430-90 specifications steel special order

5/8"

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Installation Accessories Mechanical Rock Bolts Expansion Shells • for 5/8" & 3/4" UNC threads & 7/8" where applicable • Ø = 11/32" (26 mm) hole size: model F1F, L = 31/4" • Ø = 11/4" (32 mm) hole size: model F11/4B, L = 31/4" • Ø = 13/8" (35 mm) hole size: model F2B, L = 27/8" • Ø = 1 1/2" (38 mm) hole size: model D1L, L = 5" • Ø = 13/4" (45 mm) hole size: model D5-1, L = 3"

Nuts • for TBE rock bolts only • for 5/8" and 3/4" & 7/8" UNC thread: • A.F. = 11/8" square • T = 0.8"

Hardened Round Washers • to ASTM F436 specifications • for 5/8" and 3/4" thread • I.D. = 13/16" • O.D. = 115/32" • T = 0.122" to 0.177"

Spherical Seat (Compensation) Washers • ductile iron ASTM A536 Gr. 65-45-12 • for 5/8" thread: I.D. = 11/16", O.D. = 2", H = 3/4" (model TSW-2) I.D. = 15/16", O.D. = 2", H = 1/2" (model TSW) • for 3/4" thread: I.D. = 13/16", O.D. = 2", H = 13/16" (model TSW-4) I.D. = 15/16", O.D. = 2", H = 1/2" (model TSW)

Installation Tools - for Stopers/Jacklegs • for forged head rock bolts: 11/8" square driver 15/16" square driver (for T-Dome bolts) • for TBE bolts: 11/8" square nutrunner • available with 7/8" hex shank or socket

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Extension Bolt (7/8" High Tensile) 2 Part with Coupler

Dimensions 7/8"

High Tensile Extension Bolt

Body Diameter E

±0.88" (±22.3 mm) 7/8"

Thread Size (left and right) I1

7/8"

Thread Size (left and right) I2

- 9 UNC - 14 UNF

Technical Data 7/8"

High Tensile Extension Bolt

Minimum Yield Strength

57,200 (254 kN)

Typical Ultimate Strength

74,500 (330 kN)

Ultimate Axial Strain

Minimum 1.85%

Torquing Pinch (optional)

Nominal 70 ft - lbs

Hardware

1 5/16" Hex Nutrunner x 7/8" hex socket

Section1-Page4

7/8"

UNC Hex Nut

7/8"

Hardened TSW-1 Spherical Round Washer Seat Washer

May 2013

7/8"

UNF Coupler

D5-1 Shell Plug for resin installation

D5-1 Expansion Shell Ø 13/4"

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Stelpipe Bolts (Groutable Rock Bolts) Nominal ¾" and 1" sizes

Dimensions 3/4"

(19 mm) Stelpipe

1" (25 mm) Stelpipe

Body Diameter E

0.68" (17.3 mm)

0.92" (23.4 mm)

Grout Hole Diameter F

0.34" (8.6 mm)

0.40" (10.2 mm)

3/4”-

Thread Size (left and right) I

10 UNC

1" - 8 UNC

Roll Threading Thread Size / Type 3/4"

- 10 UNC

1" - 8 UNC

Pitch Diameter

Major Diameter

0.6773" to 0.6832" (17.20 mm to 17.35 mm)

0.7353" to 0.7482" (18.68 mm to 19.00 mm)

0.9100" to 0.9168" (32.11 mm to 23.29 mm)

0.9830" to 0.9980" (24.97 mm to 25.35 mm)

Standard UNC 2A Values Left Hand (LH) & Right Hand (RH) threads available

Technical Data 3/4"

(19 mm) Stelpipe

1" (25 mm) Stelpipe

Steel Grade

1022M

Minimum Tensile Strength

Recommended Hole Diameter

Recommended Expansion Shell Ultimate Axial Strain

3/4"

27,000 lbs (120 kN)

50,000 lbs (222 kN)

11/4" to 13/8" (31.8 mm to 35 mm)

13/4" (44.5 mm) Frazer & Jones Model 1" × F9F with bail center hole

Frazer & Jones Model × F 1/4" with bail center hole 15% typical

Specification for the tube bolt steel is selected by Stelpipe's metallurgical department

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May 2013

Section1-Page5

Installation Accessories Stelpipe Rock Bolts Expansion Shells • for 3/4" thread (model F11/4 B): L = 31/4" Ø = 11/4" (32 mm) hole size • for 1 thread (model F9F): L = 31/4" Ø = 13/4

Nuts • for 3/4" thread: A.F. = 11/8" square T = 0.8" • for 1 thread: A.F. = 15/8" hex T = 63/64"

Hardened Round Washers • to ASTM F436 specifications • for 3/4" thread: I.D.= 13/16", O.D. = 115/32", T = 0.122 to 0.177" • for 1 thread: I.D. = 11/8", O.D. = 2", T = 0.136" to 0.177"

Spherical Seat (Compensation) Washers • ductile iron ASTM A536 Gr. 65-45-12 • for 3/4" thread: I.D. = 13/16", O.D. = 2", H = 13/16" (model TSW-4) I.D. = 15/16", O.D. = 2", H = 1/2" (model TSW) • for 1" thread: I.D. = 11/16", O.D. = 2", H = 1/2" (model TSW-1)

Installation Tools - for Stopers/Jacklegs • 11/8" square nutrunner (for 3/4" bolts) • 15/8" hex nutrunner (for 1" bolts) • available with 7/8" hex socket or 31/4" long 7/8" hex shank

Section1-Page6

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Installation Quality Guidelines Mechanical Rock Bolts

The following are items to be aware of when installing mechanical rock bolts (forged head and threaded both end [TBE] bolts): Type of Ground - The nature of the ground must be evaluated. Soft strata requires a larger plate washer and/or expansion shell bearing area. Greater expansion of the expansion shell leaves may be required. Soft ground results in larger hole sizes for a given bit size (bit rattling and reaming). Special anchors are available for soft ground. Excessively hard ground can be detrimental as well. Hard ground can result in poor anchorage as the shell is unable to “bite” into the rock. Scaling - The ground should be thoroughly scaled i.e. barred down, before drilling and bolting. Periodic re-scaling may be required while drilling. Strength and Yield Capacity of Bolt - The mechanical properties of the bolt should be appropriate for the ground conditions, bolt length and bolting pattern. Pull tests and torque-tension tests should be performed to determine yield strengths and anchorage capacities of the bolts being used.

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Condition of Threads - Threads should be inspected before installation. Increased friction on the threads adversely affects the torque tension relationship. Fillet on Forged Head - Forged head rock bolts should be inspected to ensure a fillet of 1/8 " radius is present where the shaft connects to the forged head. Sharp transitions may weaken the bolt. Hole Length - Holes too short for the bolt in use may cause the shell to distort or inhibit proper tensioning of the bolt. Good practice suggests that the hole length should be equal to the bolt length plus shell length. Hole Condition - The hole should be cleaned and examined to ensure the bolt will insert smoothly. Damage to the shell may result if it must be forced into the hole. continued

May 2013

Section1-Page7

Installation Quality Guidelines continued

Oversize Holes - Holes 1/8 " oversized can reduce holding strength by 70%. Oversized holes can be caused using the wrong bit size, leaving the drill running while flushing the hole, soft ground (faults, gouge, etc.) and bent drill steel. Undersized Holes - Undersized holes will not permit the plug in the expansion shell to seat properly. The leaves or bail can break and distort upon forced entry. Undersized holes are usually caused by worn bits and/or wrong bit sizes being used. Friction Flair Expansion Shells - A recent improvement in expansion shell design is the addition of flairs or wings on the bail strap at the bottom of the leaves. Installation is improved as there is no need to set the anchor to keep the bolt from sliding out of the hole during installation. The anchor sets up faster as the plug engages the leaves freely. Spinning of the anchor in the hole is prevented, thereby eliminating the principal cause of bolt failure upon installation.

Resin Anchors - Using a resin cartridge to assist in anchoring mechanical rock bolts is gaining popularity. If used with an expansion shell, the shell must have provisions for the passage of resin around the shell wedge. This ensures proper encapsulation of the expansion shell without causing any damage to the assembly. Expansion Shell Plastic Sleeve - The plastic sleeve holding the leaves together on an expansion shell should be removed prior to installation. If left on it could result in poor anchorage. Set Up of Expansion Shell - Immediately prior to installation the expansion shell should be set to the correct diameter to enable the bolt to be pushed up the hole by hand, set and anchored. If not expanded enough there will be difficulties in anchoring. If expanded too much the end of the bolt can break the bail or leaf attachment prior to the leaves being set.

continued

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Installation Quality Guidelines continued

DSI - Mining’s T-Dome - forged head rock bolts have a special concave head design which when used in conjunction with T-Dome plates, work like a ball-and-socket and correct for angularity without requiring extra washers.

bolt dollies have a 7/8" hex shank and are only 31/4" long. In addition to being the proper size for the rock bolt head or nut, the dolly must also have sufficient socket depth to allow nuts to be run onto the ends of TBE bolts.

Rock Bolt Dollies - Rock bolt installation dollies should only transfer rotational energy to the rock bolt during installation, not percussive energy, when stopers and jacklegs are used. The shank end of the dollie must be short enough to avoid contact with the drill piston. Typically, these rock

Proper Torquing of Bolts - Typically, 3.5 tons of installed tension is required for a rock bolt to set the anchor and tension the bolt to 50% of the yield strength. An approximately linear relationship exists between the applied torque and the tension in a forged head rock bolt.

As TBE bolts turn at both ends during torquing, they generally apply more tension for the same amount of applied torque due to the reduced resistance to friction. However, as a generality: All mechanical rock bolts should be torqued to a minimum of 150 ft-lbs (per ASTM F432). continued

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Section1-Page9

Installation Quality Guidelines continued

Overtorquing - Overtorquing of the bolts must be avoided. With forged head bolts, the heads can be weakened or sheared off. Overtorquing may tension the bolt past it’s yield point which is undesirable. Undertorquing - Undertorquing can result in poor anchorage. Under tensioned bolts are particularly susceptible to blasting damage. Bolts will not apply sufficient compressive force to the ground as per design requirements. Monitoring - In practice, rock bolt tension often drops after installation. Expansion shells can slip due to blasting vibrations, shells can move as high stress concentrations along the leaves cause localized failure of the ground, and finally, the rock can fail under the plate washer. The installation of any ground support system must be monitored to ensure proper procedures and installation quality are maintained. For rock bolts this requires verifying torque and

the placement and spacing of bolts. Torque measurements can be recorded on the wall or plate of the bolt which will permit monitoring of the load on the bolt during the mining cycle. If necessary, bolts can also be re-torqued if loss in tension occurs. Torque testing is best done by a crew supervisor (or dedicated technician) while visiting work areas during his rounds. Education - Proper education of mining personnel and supervisors is mandatory. As manpower turnover is relatively frequent in bolting crews, education must be continuous. Forget this and you waste money. Packaging - Vendors must package bolting products in an acceptable manner both for convenience of use as well as prevention of damage to the product during shipping and handling. Particular care must be paid to wrapping of the thread ends to prevent damage and corrosion. Good packaging costs more but is worth the added cost by reducing wastage on site.

continued

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Installation Quality Guidelines continued

Matching Bolt and Shell Threads - While North American mines typically use UNC thread specs, other countries can use different thread types. Care must be taken not to mismatch shells and bolts from various manufacturers. A minimum UNC class 1A thread spec should be met on all threads as per ASTM F432 guidelines. DSI - Mining exceeds ASTM specs and rolls threads to a class 2A specification.

Proper Grade Plates - Thin or weak plates will deform at low bolt tension. High torques will produce lower tension values. The bolt could also rip through the plate during installation or by bolt loading. Plate should meet ASTM F432 specs. The minimum spec is a grade 2 plate which has less than 0.25 deflection when the load on the plate is increased from 6,000 to 20,000 lbs. Hardened Steel Washers - Hardened steel washers should be used between the forged head or nut and the plate washer. The washer reduces friction and enhances the torque-tension relationship. Minimum grade should be Type 2 (ASTM F432 spec) and hole size in plate washer should be no more than 3/8" diameter larger than bolt size. A spherical seat washer can also be used to reduce friction.

Support Nuts - While they are sometimes used on TBE bolts, the practice of installing a nut below the anchor shell should be avoided on forged head bolts. If the support nut comes in contact with the shell, friction between these two surfaces will prevent the bolt from elongating properly and will give false torque readings as the bolt is tensioned. Headed bolts should be free to elongate into the hole through the expansion shell.

Wooden Washers - Although seldom used nowadays, wooden washers help prevent the plate from cutting into mine screen (mesh) when present. The wood may cause tension bleed off however. Care must be used to watch for rotting of the wood.

TBE Bolt Nuts - Do not run the nut on a TBE bolt to the end of the threads and onto the shank. Strength can be reduced by as much as 50%. Each revolution of the nut onto the shank reduces the thread engagement length. Notching of TBE bolt threads - Notching threads on TBE bolts is a poor installation practice and must be avoided. This practice locks the nut onto the bolt which then makes the TBE bolt act as a forged head bolt. Deep gouging can reduce the bolts strength.

Perpendicular Installation - Bolts should be installed as near perpendicular to the rock surface as possible. Bolts not perpendicular to the plate and rock surface will be marginally weaker and will not be pretensioned properly. The following example using a 5/8 " forged head rock bolt installed with 180 ft-lbs torque illustrates the scope of the problem.

Angle from Perpendicular

Installed Tension

Reduction

Ultimate Breaking Load

Reduction

0

13,030 lbs

-

26,780 lbs

-

10

10,280 lbs

21.1%

25,690 lbs

4.1%

20

5,230 lbs

59.8%

25,060 lbs

6.4"

30

3,280 lbs

74.8%

23,050 lbs

13.9%

Results from lab testing conducted at Stelco.

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Section1-Page11

Rebar Rock Bolts (Forged Head & Threaded) #5 (15M), #6 (20M), #7 (22M) and #8 (25M) Forged Head Rebar

Threaded Rebar

Dimensions Nominal Bar Size E

#5 (15M)

#6 (20M)

#7 (22M)

#8 (25M)

0.625" (16 mm)

0.750" (19.5 mm)

0.875" (22.2 mm)

1.0" (25.2 mm)

Head Across Flats F

1.088" to 1.125" (27.64 mm to 28.58 mm)

Head Across Corners G

1.425" to 1.591" (36.19 mm to 40.41 mm)

Head Height, min. H Thread Size (left and right) I

0.40" (10.2 mm) 5/8”-

11 UNC

3/4"-

10 UNC

7/8"-

9 UNC

1"- 8 UNC

Technical Data - Forged Head - Grade 60 #5 (15M)

#6 (20M)

#7 (22M)

#8 (25M)

Yield Strength, min.

18,600 lbs (80 kN)

26,400 lbs (120 kN)

36,100 lbs (155 kN)

47,100 lbs (200 kN)

Tensile Strength, min.

27,600 lbs (121 kN)

39,600 lbs (180 kN)

54,100 lbs (232 kN)

70,600 lbs (300 kN)

Elongation in 8" (200mm)

9% minimum

Technical Data - Threaded - Grade 60 5/8"

- 11 UNC

3/4"

- 10 UNC

7/8"

- 9 UNC

1" - 8 UNC

Yield Strength, min.

13,600 lbs (60.5 kN)

20,000 lbs (89 kN)

27,700 lbs (123.2 kN)

36,400 lbs (161.9 kN)

Tensile Strength, min.

20,300 lbs (90.3 kN)

30,100 lbs (133.9 kN)

41,600 lbs (185 kN)

54,500 lbs (242.4 kN)

Elongation in 8" (200 mm)

9% minimum

Notes: USA - manufactured to ASTM F432 and ASTM A615 specifications; bolts MSHA approved Canada - manufactured to ASTM F432, CSA M430 and CSA G30.18M specifications Grade 40 & 75 available where applicable. Notched rebar optional for bending. www.dsiunderground.com

May 2013

Section2-Page1

MGSD Bar The new DSI hybrid size bar to allow easier insertion through resin and better resin mixing.

Size

Grade

Yield min.

Yield max.

Tensile min.

Tensile Elongation max.

3/4"

75

75,000

87,000

100,000 131,000

7/8"

75

75,000

87,000

100,000 131,000

"A" Diameter

"A" Aim

"C" Nominal

"C" Deviation

8 % min.

0.680"

0.680"-0.686"

0.060"

0.038" min. 0.068" max.

8 % min.

0.796"

0.796"-0.808"

0.054"

0.038" min. 0.068" max.

DEFORMATION HEIGHT "C"

0.1

0.003" 0.004"

"A" DIAMETER

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Installation Accessories Rebar Rock Bolts

Nuts

Domenuts • for 3/4" thread A.F. = 1 1/8" square • for 7/8" thread A.F. = 11/8" square • for 1" thread A.F. = 1 5/8" hex Plain Nuts - used with pinched thread • for 3/4" thread A.F. = 11/8" square • for 7/8" thread A.F. = 11/8" square with flange • for 1" thread A.F. = 15/8" hex Torq Bolts - system available • for 3/4" and 7/8" thread A.F. = 11/8" square Resin Mixing System "crimped thread" Reverse Spin Reverse Drive

Hardened Round Washers • to ASTM F436 specifications • for 3/4" thread: I.D. = 13/16", O.D. = 1 15/32", T = 0.122" to 0.177" 7 • for /8" thread: I.D. = 15/16", O.D. = 13/4", T = 0.136" to 0.177" • for 1" thread: I.D. = 11/8", O.D. = 2", T = 0.136" to 0.177"

Spherical Seat (Compensation) Washers • ductile iron ASTM A536 Gr. 65-45-12 • for 3/4" thread: I.D. = 13/16", O.D. = 2", H = 13/16" (model TSW-4) I.D. = 15/16", O.D. = 2", H = 1/2" (model TSW) • for 7/8" & 1" thread: I.D. = 1 1/16", O.D. = 2", H = 1/2" (model TSW-1)

Installation Tools - for Stopers/Jacklegs Forged Head Rebar Driver (Dollie) • 1 1/8" square driver • available with 7/8" hex socket or 3 1/4" long hex shank Threaded Rebar Nutrunners • 11/8" square nutrunner (for 3/4" & 7/8" bolts) • 15/8" hex nutrunner (for 1" bolts) • available with 7/8" hex socket or 31/4" long hex shank

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May 2013

Section2-Page3

Installation Accessories Tandem Anchor

• patented • slotted shell base removes the chance of severely twisted shells with leaves buckled inward onto the thread • the system incorporates both mechanical (expansion shell) & resin anchorage

Other Rebar Product Variations • coupled bolts • notched bolts (for bending)

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Installation Accessories Tandem Anchor Components • #6 (3/4") or #7 (7/8") headed rebar • expansion shell (usually D8) • support nut • washer (2" or 21/4")

Expansion Shell

• for 13/8" or 11/2" drill holes • Tandem Anchor Bolts are "POINT ANCHOR BOLTS" because the full length of the bolt is placed under tension. Resin is inserted into the drilled hole followed by the bolt. Rotation of the bolt mixes the resin and causes the expansion shell to expand and place the bolt in tension. This system incorporates both mechanical (expansion shell) and resin anchorage.

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Resin

May 2013

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Installation Accessories Two Piece Tandem Anchor Components • #6 (3/4") or #7 (7/8") rebar • 5/8" or 3/4" headed smooth bar • coupling • expansion shell (usually D8) • support nut • washer (2" or 21/4")

Expansion Shell

Support Nut

• Tandem Anchor Combos are "POINT ANCHORS". The primary difference in this unit and the Tandem Anchor is the utilization of two or more individual rods to create a single bolt. This is necessary when the bolt, to be installed, is longer than the coal seam is high and the bending of a single bolt is difficult or impossible.

Rebar

Resin

Coupling

Smooth Bar

Washer

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May 2013

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D-DomeTM Rebar Rockbolts (patent pending) #7 (22m)

regular head for comparison

D-Dome™ head for comparison

Dimensions and Regulatory Requirements • see Rebar Rockbolts page for size and regulatory requirement characteristics of D-DomeTM Rebar Rockbolts

Technical Data • the D-DomeTM Rebar Rockbolts produces up to a 60% increase in head strength versus ASTM F432.95 requirements

Side View Comparison

Traditional headed rebar bolt loaded to 32,000 lbs

D-DomeTM headed rebar bolt loaded to 54,000 lbs

• the D-DomeTM headed rebar bolt offers increased security against roof loading • please contact a local sales representative for a sample product and to arrange for a trial www.dsiunderground.com

May 2013

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Posimix Resin Bolt System

General Features • Manufacture of the “posimix” bolt is the addition of a specially designed spring wire attached to the up hole end of many of DSI rock bolts. • The “posimix” bolting system was designed to assist in the installation of rock bolts with chemical anchors in larger diameter holes (31-38mm) by providing: • substantially enhanced mixing of the chemical anchors, • load transfer capabilities are maximised, • the ability to be installed with a face jumbo as well as hand held machines. • The “posimix” device centralises the bolt in the hole allowing an even distribution of the chemical anchor around the bolt. It also acts as an Archimedes screw pump forcing the chemical towards the back of the hole, assisting in mixing whilst consolidating the anchor for improved load transfer properties.

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May 2013

• In addition to improved mixing properties the “posimix” device also tends to pump the plastic skin of the chemical anchor to the back of the hole which eliminates the ‘gloving’ effect. • All DSI conventional chemical bolts can be manufactured as “posimix” bolts and supplied to suit either left or right hand bolt rotation. • Recommended hole size is 31 to 38mm diameter. • Corrosion protection may be provided by hot dip galvanizing.

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Tension Jack/Pull Test Kit 30 Ton Capacity

General Information • The pull test kit consists of two assemblies: • a mechanical assembly which includes a claw, stand, nut, & spindle • a hydraulic assembly which includes a hollow core ram, hand pump, gauge, & hose • The gauge measures pressure, which is easily converted into tons of load • Suitable for testing virtually all types of rock bolts and soil nails • When testing Split Set™, Swellex™, or forged head bolts, the pull collar must be put onto the bolt BEFORE installation of the bolt • 30 ton units available for sale or rent • Comes complete with wooden crate • Pull test collars available upon request

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May 2013

Section2-Page9

Minicage™ Cable Bolts (Plain & Bulb) 0.5", 0.6" and 0.7" Plain Cable Bolt

Bulbed Cable Bolt

Dimensions 0.5" Cable Bolt Strand Diameter E

0.500" 12.70 mm

0.6" Cable Bolt

+0.026" -0.006"

0.600"

+0.66 mm -0.15 mm

15.24 mm

0.7" Cable Bolt

+0.026" -0.006"

0.700"

+0.66 mm -0.15 mm

17.78 mm

+0.026" -0.006" +0.66 mm -0.15 mm

Physical Properties 0.5" Cable Bolt Product

0.6" Cable Bolt

0.7" Cable Bolt

uncoated 7 wire low relaxation strand

Grade

270 K - 270,000 psi (1860 MPa) ultimate strength

Breaking strength, min

41,300 lbs (183.7 kN)

58,600 lbs (260.7 kN)

76,200 lbs (339 kN)

1% extension under load, min.

37,170 lbs (165.3 kN)

52,740 lbs (234.6 kN)

68,600 lbs (305.1 kN)

Elongation in 24 inch (610 mm) Relaxation after 1000 hrs

3.5% minimum maximum 2.5% with initial load = 70% breaking strength maximum 3.5% with initial load = 80% breaking strength

Specification

ASTM A416, CSA G279-75, CSA G279-M1985

Construction Details 0.5" Cable Bolt Construction Steel area

Difference in wire size (center - outer)

0.7" Cable Bolt

1 center wire & 6 outer wires nom. 0.153 in2 (98.7 mm2)

Standing pitch Weight per 1000 ft Weight per 1000 m

0.6" Cable Bolt

nom. 0.217 in2 (140 mm2)

nom. 0.304 in2 (196 mm2)

12-16 × diameter 520 lbs 775 kg

740 lbs 1102 kg

1110 lbs 1654 kg

min. 0.003" (0.076 mm)

min. 0.004" (0.102 mm)

min. 0.005" (0.127 mm)

Galvanized cable bolts available on request www.dsiunderground.com

May 2013

Section3-Page1

Installation Accessories Cable Bolts End Holding Device - Conventional Style • to hold cable bolt prior to grouting • 2 straps 3/4" x 23/4" (19 mm x 70 mm) • suitable for 2" (51 mm) to 2.5" (64 mm) hole • can be ordered separately and site installed • if factory ordered, straps removed for shipping • not available for double cable bolts

End Holding Device - Fish Hook Style • hooks swaged on with steel tubing • hooks can be bent out to accommodate any hole size • for single or double cable bolts • fitting holds double cables together

0.5", 0.6" & 0.7" Machined Cable Grip - to fasten Plates • rated for full load of cable bolt • Ø 11/4" (32 mm) for 0.5" cable bolts • Ø 11/2" (38 mm) for 0.6" cable bolts • c/w 2 part gripper wedges • available galvanized • optional plastic cap to secure wedges during shipping

0.6" & 0.7" Cast Domed Cable Grip - to fasten Plates • rated for full load of cable bolt • Ø 2" (51 mm) domed face • c/w 2 part gripper wedges • wedges available with or without groove & retaining spring • available galvanized • optional plastic cap to secure wedges during shipping

Section3-Page2

May 2013

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Installation Accessories continued

Passive Spinnable Cable Bolt - for Resin Installation • 0.6" & 0.7" cable available • resin anchored • bulbs provide resin mixing and anchoring • accepts 11/8" square or hex male spinner • available plain or galvanized • cable available in any length • factory assembled

Strand Lok • available with minimum 4 ton or 12 ton terminal • easy installation, no cement to mix • dissipates “impact shock” • maintains bond between cable and resin grout • enhanced one pass support • bulge diameter and spacing variable • ideal for confined spaces • superior shear strength for one pass support • higher ultimate tensile • installed with “high strength low viscosity strand-loc resin” • resin compressive strength exceeding 100 MPA • Youngs modulus 11-13 GPA • custom cartridge diameter and length

Installation Procedure • drill a 1¼" hole to a depth which will allow the bolt to bottom out when fully inserted • insert the Strand-Lok resin cartridges • manually push the Strand Bolt into the resin to within 2' or 3' of full penetration • Spin the Strand Bolt through the resin to complete the insertion and then continue spinning for an additional 10 seconds at full insertion • on tensioned installations allow sufficient time for the resin to gel and gain strength before torquing

Notes • the 12 ton terminal is designed for where collar support is needed • a recessed terminal has been designed to be used in close quarters where the protruding termnal would be an obstruction • a coupled extension drill steel has been designed to keep the "extension" drill hole size at 1¼"

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May 2013

Section3-Page3

Installation Accessories continued

0.6" & 0.7" Dogbone Cable Coupler • rated for full load of cable bolt • used to join cables for slings or trusses • used to wrap failing pillars • requires 2 sets of wedges (included)

Grout and Breather Tubing • ¾" ID x 7/8" OD black poly tubing (400' roll) • ¾" ID x 7/8" OD high density grout tubing (400' roll) • ½" ID x 5/8" OD regular poly tubing (400' roll) • 3/8" ID x ½" OD high density poly tubing (500' roll) • black poly tubing rated for 100 psi • yellow high density tubing rated for 200 psi

Section3-Page4

May 2013

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Cable Bolt 0.6" or 0.7" Passive and Tensionable Cable Diameter

0.6" gr270

0.7" gr270

Weight

0.74 lbs/ft

1.11 lbs/ft

Bore Hole Diameter

1" to 1.375"

1" to 1.375"

Cross Sectional Area

140 mm

196 mm2

Ultimate Strength [1000 lbs] Yield Strength [1000 lbs] Min. Elongation in 2ft Typical Plate

2

58.6

76.2

46

68.6

3.5%

3.5%

gr6 w/ 13/8" hole

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 11/8" hex or square male spinner. • 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: strip cage 13/8" hole: plunge bulb 1¾" hole: bond head • Ultra low passive heads can be provided for low clearance situations.

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May 2013

Section3-Page5

CBJ-1 Cable Bolt Tensioning Jack For installation of bearing plates Specifications • for 0.6" (15.2 mm) or 0.7" (17.8 mm) cable bolts • maximum load 25 ton @ 10,000 psi (225 kN @ 70 MPa) • stroke = 3" (75 mm) • double acting hollow core ram • aluminum construction - weighs only 10 lbs (4.5 kg) • requires double acting hydraulic pump or hand pump • L = 11.75" (300 mm) • D = 4" (102 mm)

Parts 1) Regularly ensure autogripper is screwed hand tight into the hollow core ram. 2) Ensure the cable strand is free from mud and dust. Also regularly clean the autogripper wedges.

Seal Kit includes: 1 - 2.25" AN wiper 1 - 2.25" x 2.75" x 3.75" rod seal 1 - 1.25" x 1.75" x 0.250" rod seal 1 - 2.31" O-ring 1 - 2.875" T-seal

Section3-Page6

May 2013

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Torque Tension Relationship for CB1-1 Cable Jack with 3.4:1 Intensifier Specifications • for 0.6" (15.2 mm) or 0.7" (17.8 mm) cable bolts • stroke = 3" (75 mm) • double acting hollow core ram • aluminum construction - weighs only 10 lbs (4.5 kg) • requires double acting hydraulic pump or hand pump • L = 11.75" (300 mm) • D = 4" (102 mm)

.6 Cable Tensioner with 3.4:1 Intensifier Pressure Vs. Load (LBF) 0.6" Cable Tensioner with 3.4:1 Intensifier Pressure Vs Load (LBF) 2000 PSI Maximum Inlet Pressure 2000 Psi Maximum Working Pressure 35,000 30,000

Load (LBF)

25,000 20,000 15,000 10,000 5,000 0

0

250

500

750

1000

1250

1500

1750

2000

Pressure (Psi)

Note • cylinder area = 5.01 in² • 2000 psi is the maximum pressure allowed for use with 0.6" cable

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May 2013

Section3-Page7

Operating Procedure For intensified cable truss tensioner

• Ensure that all hydraulic fittings are tightened before operation, and that the unit is in good working order. Check the following: • There are no major dents in the housing. • That the autogripper assembly (gold in color) is fully tightened against the face of the piston. • That the autogripper wedges are in good condition and are not chipped, dented or missing teeth. • That there are no major leaks in the system. • Monitor during use the following • The autogripper remains screwed in tight against the face of the piston • The gripper wedges do not become too dirty • That the wedge teeth do not wear too badly. The autogripper wedges are designed for reuse, but eventually need replacing. • Before placing the tensioner onto the cable, ensure the cable has minimal dirt and or dust on its surface. This dirt and dust will make it harder for the wedges to grip the cable.

Section3-Page8

May 2013

• Slide assembly onto the tail of the cable until the tensioner nose is fully seated against the wedges of the dogbone/wedge barrel. A minimum of one inch of cable tail should protrude from the end of the autogripper assembly. (If the cable does not protrude from the back of the tensioner the minimum one inch length the jaws will not grip the cable properly. There is significant risk that the cable will strip the wedge teeth). • Pressurize the cylinder to the desired load (2,000 psi/17 ton maximum for the 0.6” x 30 ton cable – see appendix 1 for a pressure versus load plot). If the cylinder runs out of travel before the load is reached, release the pressure and slide the cylinder on further and repeat the tensioning process. • The following wear components are available for purchase from your local DSI supplier (appendix 2): • Autogripper assembly • Autogripper wedges • O-Ring kit • Banana Nose

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Cable Tensioner Mark2 For tensioning cables and installing plates Specifications 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"). The Cable Tensioner is a single hydraulic ram driven by an air/hydraulic pump or by machine hydraulics. • The jack weighs 25 lbs. The entire kit (jack and pump) 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 12' bolt)

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. After stressing, the Cable Tensioner is easily removed by pulling on the lanyard to release the internal grippers.

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May 2013

Section3-Page9

HI-TEN Strand Bolt

Physical Properties Yield Strength

108,000 lbs

Ultimate Tensile Strength

124,000 lbs

Uniform Elongation

3-4%

Mass Per ft

1.90lb

Cable (Strand) Diameter

0.9"

General Features

Installation Guidelines

• The DSI HI-TEN Strand Bolt is a cable designed to be installed as a long rock bolt which is capable of being post-tensioned at the face, or out-bye, to loads of up to 27 tonnes using the DSI Tensioner Unit. • The HI-TEN Strand Bolt is manufactured from 21 wire strand having a 12mm square, for mixing chemical anchors, welded to one end of the strand. • The HI-TEN Strand Bolt has a special collar and segmented wedge, which can sustain collar loads of between 57 and 60 tons. • The HI-TEN Strand Bolt is designed for high pre-tensioning using a point anchor system. • If full encapsulation is required, extra slow speed chemical anchors of 20 minutes set time are available. • The HI-TEN Strand Bolt can also be effectively used with cementitious grouts. • The HI-TEN Strand Bolt concept allows a longer than seam height bolt to be installed at up to 30° from the vertical at the face, or out-bye, to supplement existing strata reinforcement. Compatible domed plates are available to be used with the HI-TEN Strand Bolt. • The HI-TEN Strand Bolt system is patent pending.

Section3-Page10

May 2013

• 28mm hole diameters are preferred. • Hole depth is critical. Hole depth should be approximately 155mm shorter than the bolt length. • This allows for sufficient tail to fit accessories, roof plate, collar/wedges & Tensioner Unit. • After insertion of the chemical anchors the bolt is rotated through the anchors while pushing the bolt, fully, to the back of the hole. • It is important to follow the chemical manufacturers recommended mixing and hold times as printed on the chemical anchor cartons. DO NOT OVER MIX. • The tensioner unit is connected to the HI-TEN Strand Bolt and tension applied. • For further details refer to DSI’s Tensioner Unit user instruction guide.

Standard Lengths & Packaging • Standard HI-TEN Strand Bolts lengths range from 4100 to 8100mm. • Collar/wedge assemblies are supplied separately to the bolt. • Non-standard requirements are available by negotiation.

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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. (i.e. 50% of the capacity of the cable)

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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May 2013

Section3-Page11

Friction Stabilizers Nominal sizes 33mm, 39mm and 46mm

Dimensions FS-33

FS-39

FS-46

Taper Diameter A

11/8" (28 mm)

13/16" (30 mm)

11/2" (38 mm)

Taper Length B

2 3/8" (60 mm)

2 1/2" (65 mm)

2 1/2" (65 mm)

Slot Width C

1/2"

(13 mm)

5/8"

(2.5 mm)

3/32"

Steel Thickness D

3/32"

Bolt Size E

1 5/16" (33 mm)

(16 mm)

7/8"

(2.5 mm)

(22 mm)

1/8"

11/2" (39 mm)

(3 mm)

113/16" (46 mm)

All dimensions nominal

Technical Data FS-33

FS-39

FS-46

Recommended Nominal Bit Size

13/16" to 1 5/16" (31 to 33 mm)

1 3/8" to 11/2" (35 to 38 mm)

111/16" to 13/4" (43 to 45 mm)

Available Tube Lengths

3' to 8' (0.9 to 2.4 m)

3' to 10' (0.9 to 3.0 m)

3' to 12' (0.9 to 3.7 m)

Typical Breaking Capacity

24,000 lbs (107 kN)

28,000 lbs (124 kN)

40,000 lbs (178 kN)

Minimum Breaking Capacity

16,000 lbs (71 kN)

20,000 lbs (89 kN)

30,000 lbs (133 kN)

3 to 6 tons (27 to 53 kN)

3 to 6 tons (27 to 53 kN)

6 to 10 tons (53 to 89 kN)

Recommended Initial Anchorage Ultimate Axial Strain

Typical 16%

18” & 24” (0.46 m & 0.61 m) utility hangers also available - not intended for ground support Also available hot dip galvanized to ASTM A123, CSA G164 specifications

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May 2013

Section4-Page1

Installation Accessories Friction Stabilizers Plate Washers • minimum A-36 material (36,000 psi yield) • A = 6" square • B = FS-33 & FS-39: 3/16" thick; FS-46: ¼" thick • C = FS-33: 36mm (17/16") diameter FS-39: 41mm (15/8") diameter FS-46: 48mm (17/8") diameter

Standard Driver Tool - for Stopers/Jacklegs • with 7/8" round x 4¼" long shanked end • available in low profile design (9¼" long) • L = FS-33: 13", 24", 36" and 42" overall FS-39: 13", 24", 36" and 48" overall FS-46: 13", 24" and 36" overall

Female Driver Tool - for Stopers/Jacklegs • with 7/8" hex socket • available in 12° and 11° tapers • L = FS-33: 9¼" overall FS-39: 9¼" overall FS-46: 9¼" overall

Threaded Driver Tool - for Mechanized Bolters • with R32 and R38 rope thread • available in low profile design (9¼" long) • L = FS-33: 18", 24" and 32" overall FS-39: 18", 24" and 32" overall FS-46: 18", 24" and 32" overall

Female Threaded Driver Tool - for Mechanized Bolters • with R32 and R38 rope thread socket • L = FS-33: 7½", 9¼" and 14" overall FS-39: 7½", 9¼" and 14" overall FS-46: 7½", 9¼" and 14" overall

Section4-Page2

May 2013

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Installation Quality Guidelines Friction Stabilizers The following are items to be aware of when using/installing friction stabilizers: Type of Ground - The nature of the ground must be evaluated. Soft strata requires a longer anchorage length to be effective. Soft ground results in larger hole sizes for a given bit size (due to bit rattling and reaming). Scaling - The ground should be thoroughly scaled (i.e. barred down) before drilling and bolting. Periodic re-scaling may be required while drilling. Strength and Yield Capacity of Bolt -The mechanical properties of the bolt should be appropriate for the ground conditions, bolt length and bolting pattern. Pull tests should be performed to determine initial anchorage of the friction bolts. Proper Grade Plates - Thin or weak plates will deform at low bolt tension. The bolt could also rip through the plate during installation or by bolt loading. Plates should meet ASTM F432 specs. Hole Condition - The hole should be cleaned and examined to ensure the friction bolt will insert smoothly. Variation in hole diameters (due to differing strengths of rock strata or excessively fragmented ground) can yield variations in anchorage capacities at various elevations. Hole Length - If holes are drilled too short then the bolt will stick out of the hole and the plate will not make contact with the rock surface. Damage to the bolt will result if an attempt is made to drive the bolt further than the hole length will permit. The hole should thus be a few inches deeper than the bolt length being used. Oversize Holes - The hole size required for the friction stabilizer is the most crucial aspect of the installation. The holding power of the bolt relies on the fact that the hole is smaller than the diameter of the bolt. The larger the hole relative to the bolt diameter, the less the holding force (at least initially). Oversized holes can be caused by using the wrong bit size, leaving the drill running while flushing the hole, soft ground (faults, gouge, etc.) and bent steel.

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Undersize Holes - If the hole size is too small relative to the friction size then it becomes extremely difficult to install the bolt. The bolt can be damaged i.e. kinked or bent when installed. Undersized holes are usually caused by worn bits and/or wrong bit sizes being used. If integral steel is used with a stoper or jackleg, the hole diameter decreases with each change of steel (normal practice requires smaller bits be used as one drills deeper into the hole). With each reduction in hole diameter the anchorage capacity increases. Integral steel often results in crooked holes and should be avoided whenever possible. Drive Times - For a typical 5 or 6 foot friction bolt, a stoper or jackleg will drive the bolt into the hole in 8 to 15 seconds. This drive time corresponds to proper initial anchorages of the stabilizer. Faster drive times should serve as a warning that the hole size is too large and thus the initial anchorage of the bolt will be too low. Longer drive times indicate smaller holes sizes probably caused by bit wear.

continued

May 2013

Section4-Page3

Installation Quality Guidelines continued

Bit Selection - Button bits are commonly up to 2.5mm larger than their slated size. A 37mm button bit may in reality be 39.5mm in diameter when new. This is too large for an SS- 39 friction. Button bits do wear quickly however, increasing anchorage capacity and increasing drive times. Cross or “X” bits, on the other hand, are sized true to stamped size usually within 0.03". They hold their gauge very well but tend to drill slower than button bits. They are preferable to button bits for friction installation where possible. Perpendicular Installation - Bolts should be installed as near perpendicular to the rock surface as possible. This ensures the welded ring is in contact with the plate all round. Bolts not perpendicular to the plate and rock surface will result in the ring being loaded at a point which may cause early failure. Unlike other rock bolts, spherical seat washers are not available to correct for angularity with frictional stabilizers. Installation Driver Tools - Driver tools must transfer percussive energy to the bolt during installing, not rotational energy. This is opposite to most other forms of ground support. The shank end of the driver must be the proper length to contact the drill piston in stopers and jacklegs (i.e. 4¼" long for 7/8" hex drill steel). The shank end on the drivers is round so as to not engage the rotation of the drill. The driver tools must have the proper end shape to fit into the friction without binding and causing damage to bolt during installation. Education - Proper education of mining personnel and supervisors is mandatory. As manpower turnover is relatively frequent in bolting crews, education must be continuous. An informed workforce will save money in the long run. Monitoring - Installation must be monitored to ensure proper procedures and quality are maintained. Pull-test measurements should be routinely conducted on friction stabilizers to check initial anchorage values.

Section4-Page4

May 2013

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OMEGA-BOLT®

Physical Properties 12 Tonnes Standard

12 Tonnes Plus

16 Tonnes Plus

24 Tonnes Standard

24 Tonnes Plus

Minimum Breaking Load (kN)

120

115

150

240

220

Minimum Elongation

10%

20%

20%

10%

20%

1.08

1.42

1.42

1.42

0.078

0.078

0.118

0.118

1.7 to 2.05

1.7 to 2.05

1.7 to 2.05

Profile Diameter (in) Material Thickness (in)

1.08 0.078 to

11/2

11/4

to

11/2

Hole Diameter Range (in)

11/4

Optimal Hole Diameter (in)

13/8 to 11/2

13/8 to 11/2

13/4 to 2

13/4 to 2

13/4 to 2

300 bar

300 bar

300 bar

300 bar

300 bar

Inflation Pressure * 1 tonne = 1.1 ton

General Features • The DSI OMEGA-BOLT® is an expandable rock bolt with excellent elongation properties designed to accommodate ground movement. The OMEGA-BOLT® is a folded steel tube with a welded ferrule on each end. • The OMEGA-BOLT® is safe and easy to install. The OMEGA-BOLT® is inserted into the drilled hole and inflated using high pressure water. • The OMEGA-BOLT® is inflated to the exact shape of the drilled hole and can tolerate a large variation in hole diameter.

Standard Lengths & Packaging • Standard lengths available include 5ft, 6ft, 7ft, 8ft, 10ft, 12ft, 2.4m, 3.0m • Standard pack of 100

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May 2013

Section4-Page5

OMEGA-BOLT® continued

Custom Protective Coatings In general, regular expandable rock bolts are not resistant to corrosive environments. To alleviate this problem in mining and tunneling applications, DSI is using a special coating that isolates and actively protects the steel. Neither coating interferes with normal installation procedures.

Zinc Epoxy Coating Zinc Coated OMEGA-BOLT® rock bolts are recommended for mid-term support in tunneling, civil engineering and mining applications, where non acidic to slightly acidic corrosive environments can be expected. This coating consists of a zinc rich epoxy coating that acts as a physical barrier as well as a galvanic protection against corrosion. Product Application • High Humidity or ground water • Alkaline (low pH) • Basic (high pH) • High Abrasive Environment

Polymer Acid Impervious Coating Polymer coated OMEGA-BOLT® rockbolts are endorsed for mid-term support in tunneling, civil engineering and mining applications, in most environments, where highly acidic corrosive environments are found. This polymer coating creates a physical barrier that is impenetrable by most acids, bases, alkalizes and highly electronegative solutions. This includes but is not limited to sulfuric acid, hydrochloric acid and sodium hydroxide. This coating is also highly abrasion resistant. Product Application • Highly Acidic and Basic Solutions (H2SO4, HCl, NaOH) • High Alkaline Solutions • High Abrasive Environment

Section4-Page6

May 2013

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Omega Pump Hydraulic Pump

Inlet Air Pressure Range

Outlet water psi

70 to 100 psi

280 to 300 bar (4060 to 4350 psi)

Electric Pump

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May 2013

Section4-Page7

DYWIDAG THREADBAR® (Black & Galvanized) #6 (19mm) through #14 (44mm)

Dimensions Nominal Bar Size E

Max. Bar Diam. F

#6

#7

#8

#10

#11

#14

3/4" (19 mm)

7/8" (22 mm)

1" (25 mm)

11/4" (32 mm)

13/8" (35 mm)

13/4" (44 mm)

0.86" (21.8 mm)

0.99" (25.1 mm)

1.12" (28.4 mm)

1.43" (36.3 mm)

1.61" (40.9 mm)

1.86" (47.3 mm)

All dimensions in accordance with ASTM F432 & CSA M430-90 specifications

Technical Data Nominal Size

Yield Strength (min.)

Ultimate Strength (typ.)

Nominal Weight

#6

33,000 lbs (146 kN)

44,000 lbs (195 kN)

1.50 lbs/ft (2.24 kg/m)

#7

45,000 lbs (200 kN)

60,000 lbs (270 kN)

2.04 lbs/ft (3.04 kg/m)

#8

59,300 lbs (263 kN)

79,000 lbs (350 kN)

2.67 lbs/ft (3.98 kg/m)

#10

95,300 lbs (425 kN)

127,000 lbs (564 kN)

4.30 lbs/ft (6.41 kg/m)

117,000 100,000lbs lbs (520 kN)

156,000 lbs 2.67 lbs/ft (693 kN)

5.31 lbs/ft (7.91 kg/m)

#14**

169,000 lbs (750 kN)

225,000 lbs (1000 kN)

7.65 lbs/ft (11.38 kg/m)

#8

70,000 lbs (310 kN)

100,000 lbs (445 kN)

2.67 lbs/ft (3.98 kg/m)

Gr. 100 ( Gr. 690/825)

Gr. 75 (Gr. 517/ 690)

Gr. 100 (Gr. 690/ 825)

70,000 #11 lbs (310 kN)

(445 kN)

(3.98 kg/m)

Also available hot dip galvanized to ASTM A123 and CSA G164 specifications All mechanical and physical properties in accordance with ASTM A615-92b and CSA G30.18M-92 specifications THREADBAR® is left hand (LH) thread only unless otherwise noted ** Right hand (RH) thread

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May 2013

Section5-Page1

DYWIDAG THREADBAR® THREADBAR® Torque Tension Relationship Threadbar Torque Tension Relationship 30,000 25,000

Tension (Lbs.)

20,000 15,000 10,000 5,000

0

0

100 200 300

400 500 600

700 800

900 1000 1100

Torque (Ft. - Lbs.)

#5 Grade 150 #8

Grade 75

#9

Grade 75

#10 Grade 75 #11 Grade 75 #14 Grade 75 #18 Grade 75 #6

Section5-Page2

May 2013

Grade 75

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THREADBAR® Hardware (Black & Galvanized) Hardware

#6

#7

#8

#10

#11

#14

Anchornut

stock

stock

stock

stock

stock

n/a

Hex Nut- Cast

stock

stock

stock

stock

stock

n/a

Hex Nut Machined Coupler - Cast Coupler Machined

special order special order special order special order special order stock

stock

stock

special order special order special order

stock

n/a

n/a

n/a

stock

stock

stock

Bevelled Washer

stock

stock

stock

stock

stock

stock

Eyenut - Cast

n/a

stock

stock

n/a

n/a

n/a

Eyenut Machined

n/a

n/a

n/a

Expansion Shell

n/a

special order special order

special order special order special order

stock

n/a

n/a

Also available hot dip galvanized to ASTM A123 and CSA G164 specifications.

THREADBAR® Spinners & Nutrunners THREADBAR® Spinners & Nutrunners

#6

#7

#8

Oval Spinner × 7/8" Hex Socket × 7/8" Hex Shank

stock

stock

stock

Threaded Spinner × 7/8" Hex Socket × 7/8" Hex Shank

special order

special order

special order

Nutrunner × 7/8" Hex Socket × 7/8" Hex Shank

stock

stock

stock

Other sizes available by special order T-thread, rope thread, 1" hex, etc .bar spinners and nutrunners available by special order

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May 2013

Section5-Page3

All Thread Rebar (Grade 690) Nominal 5/8" (15 mm) through 11/4" (32 mm)

Dimensions #5

#6

#7

#8

#10

5/8"

3/4"

(15 mm)

(19 mm)

7/8" (22 mm)

1" (25 mm)

11/4" (32 mm)

3/4" (19.0 mm)

7/8" (22.2 mm)

1" (25.4 mm)

11/8" (28.6 mm)

13/8" (34.9 mm)

0.31 in2 200 mm2

0.44 in2 285 mm2

0.60 in2 385 mm2

0.79 in2 500 mm2

0.1.20 in2 800 mm2

#5

#6

#7

#8

#10

Yield Strength min.

23,000 lbs (100 kN)

33,150 lbs (145 kN)

45,100 lbs (200 kN)

58,900 lbs (260 kN)

90,000 lbs (408 kN)

Ultimate Strength

28,800 lbs (130 kN)

41,300 lbs (188 kN)

56,300 lbs (255 kN)

73,800 lbs (335 kN)

112,500 lbs (510 kN)

Nominal Weight

1.04 lbs/ft (1.55 kg/m)

1.50 lbs/ft (2.36 kg/m)

2.0 lbs/ft (3.04 kg/m)

2.7 lbs/ft (3.93 kg/m)

3.4 lbs/ft (5.06 kg/m)

Nominal Diameter E

Thread Diameter F

Cross-Sectional Area F

Technical Data

Ultimate Axial Strain

5% to 8% typical

Cold Rolled Threads

5 threads per inch for all bar sizes This bar exceeds the physical properties of ASTM A615

Hardware

Hex Nut

Section5-Page4

Hemispherical (Anchor) Nut May 2013

Coupler

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Installation Quality Guidelines Rebar and DYWIDAG THREADBAR® Bolts

The following are items to be aware of when using/installing resin grouted rebar and DYWIDAG rock bolts: Type of Ground - The nature of the ground must be evaluated. Soft strata requires a larger plate washer bearing area and a longer anchorage length if point anchored. Soft ground results in larger hole sizes for a given bit size (due to bit rattling and reaming). This can adversely affect the mixing of the resin. Scaling - The ground should be thoroughly scaled i.e. barred down, before drilling and bolting. Periodic re-scaling may be required while drilling. Strength and Yield Capacity of Bolt - The mechanical properties of the bolt should be appropriate for the ground conditions, bolt length and bolting pattern. Pull tests should be performed to determine yield and ultimate strengths of the bolts as well as resin anchorage capacities. Condition of Rebar Threads - Threaded rebar should be inspected before installation. Increased friction on the threads can adversely affect tensioning of the rebar. DYWIDAG threads are generally immune to defects and damage.

Fillet on Forged Head Rebar - Forged head rebar bolts should be inspected to ensure a fillet of 1/8" radius is present where the shaft connects to the forged head. Sharp transitions may weaken the bolt. Shelf Life of Resin - Resin has a practical shelf life. Although the chemical ingredients do not change with time, most resin cartridges are water based and thus dry out with age. The shelf life thus refers to the workability of the resin cartridge. Aged cartridges are still effective; however, because they are drier, the ingredients are crumbly and harder to mix properly. The bolts are more difficult to insert through old resin as well. Set times may also be reduced somewhat with older resin. The resin cartridge box will have the manufacturing date written on it. Resin should be used as soon as possible. Stock should be rotated so older resin does not accumulate. Storage - Resin should be stored in a cool location to maximize shelf life. Elevated temperatures dry out the resin cartridges. Temperature and Set Time - Temperature greatly affects the gel (set) time of resin cartridges. A 20ºF rise in temperature reduces the set time by approximately 50%. Conversely, a 20ºF drop in temperature will approximately double the set time of the resin. Resin should be stored and used at room temperature whenever possible. continued

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May 2013

Section5-Page5

Installation Quality Guidelines continued

Resin Usage Hole diameters (inches) ASTM

1"

11/4"

13/8"

11/2"

A615 Bar Size

15/8"

11/2"

15/8"

13/4"

17/8"

2"

21/4"

40

Cartridge Diameter (mm) 23

28

32

32

32

35

35

40

40

40

#6(3/4")

18.5"

13"

-

-

-

-

-

-

-

-

#7(7/8")

-

16"

14"

-

-

12.5"

-

-

-

-

-

#8(1")

-

22.5"

17.5"

12.5"

-

15.5"

11.5"

12"

-

-

-

-

-

-

15.5"

-

18.5"

17"

13"

-

-

#10(1-1/4") #11(1-3/8")

-

-

-

-

-

-

-

23"

16"

12"

-

#14(1-5/8")

-

-

-

-

-

-

-

-

-

-

11"

• Chart indicates inches of bolt encapsulation based on standard 12" length Lokset resin cartridge. • This chart is prepared as a guide based on average drilling conditions in concrete or rock. Field trials should be conducted to determine actual resin requirements. • Example: When a 11/2" hole is drilled, using a 1" diameter deformed rebar bolt, one 35 mm x 12" cartridge will grout 15.5 linear inches of the bolt. • Inches grouted include a typical 15% loss. • Blank spaces are non-recommended bolt/hole combinations.

Resin Size, Bolt Size and Hole Size - The size of the bolt relative to the cartridge and hole size is critical. The above chart gives the recommended combinations of bar, hole and cartridge sizes. The numbers in the chart refer to the yield i.e. length of encapsulation of the bolt per 12" resin cartridge. Blank spaces are non-recommended bolt and hole combinations.

Oversize Holes - If the hole size is too large relative to the bolt size, poor mixing of the resin will result. The grout yield per resin cartridge will also be reduced. This is particularly important with point anchored bolts. Oversized holes can be caused by using the wrong bit size, leaving the drill running while flushing the hole, soft ground (faults, gouge, etc.) and bent drill steel.

Hole Condition - The hole should be cleaned and examined to ensure the resin cartridges and the rock bolt will insert smoothly.

Undersized Holes - Undersized holes will result in insufficient bonding of the bolt to the rock. Difficulties in inserting the bolt into the hole may also be experienced. Undersized holes are usually caused by worn bits and/or wrong bit sizes being used.

Hole Length - If holes are drilled too short then excessive lengths of the bolt will stick out of the hole. The plate may not be effectively installed. If holes are drilled too long then resin will be wasted at the end of the hole. This will reduce the encapsulation length for a point anchored rock bolt and can reduce the load capacity of the bolt. The bolt may not be able to be tensioned adequately.

Section5-Page6

May 2013

continued

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Installation Quality Guidelines continued

Spinning of the Bolt - refer to Resin and Cement cartridge section (Section 9). Underspinning - The bolt is spun into the resin cartridge to mix the two separate components (the catalyst and the resin matrix). Improper mixing will result in a poor installation. Underspinning results in inadequate mixing of the resin and insufficient gelling may occur. Operators will complain the resin will not set up. No Spinning - If the bolt is simply pushed through the resin cartridge without rotation, a detrimental effect may be caused by the resin catalyst being picked up by the end of the bolt. This may cause both undercatalysed and overcatalysed areas to be created. Overcatalysed resin yields an understrength crumbly type of anchor. Undercatalysed resin stays soft virtually indefinitely because it does not have enough catalyst to speed up the gelling reaction. Overspinning - Overspinning will grind up the resin as it sets. Poor anchorage will result. The bolt may not be able to be tensioned properly. Consequently, the operator will once again complain the resin is not setting up! Tensioning with Fast/Slow Set Resins - As a general guideline, when bolts are to be tensioned, fast set resin should be used at the toe of the hole for 1/3" the bolt length (minimum 24"). Slow set resin is used for the remaining 2/3" length to fully encapsulate the bolt. The slow set must be sufficiently slow to allow the plate washer and nut to be installed and the bar tensioned before the resin set up. Rebar bolts can be tensioned by torquing the nut. DYWIDAG bolts require a greater torque to achieve adequate tension. continued

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May 2013

Section5-Page7

Installation Quality Guidelines continued

Proper Grade Plates - Thin or weak plates will deform at low bolt tension. The bolt could also rip through the plate during installation or by bolt loading. Plates should meet ASTM F432 standards.

Perpendicular Installation - Bolts should be installed as near perpendicular to the rock surface as possible. Bolts not perpendicular to the plate and rock surface will be marginally weaker and will not be pretensioned properly. Spherical seat washers are available to correct for angularity. Hardened Steel Washers - Hardened steel washers should be used between the forged head or nut and the plate washer. The washer reduces friction and enhances tensioning in threaded rebar. Minimum grade should be ASTM F436 Type 1 or 2 and hole size in plate washer should be no more than 3/8" diameter larger than bolt size if a spherical seat washer is not used. Rock Bolt Dollies - Installation dollies should only transfer rotational energy to the bolt during installation, not percussive energy when drills are used to rotate the bolt. The shank end of the dollie must be short enough to avoid contact with the drill piston in stopers and jacklegs. Typically, these rock bolt dollies have a 7/8" hex shank and are only 3¼" long. Besides being the proper size for the rock bolt head or nut, the dolly must also have sufficient socket depth to allow nuts to be run onto the threaded portion of the bolt.

Section5-Page8

May 2013

Gloves - Gloves and eye wear should be worn when handling resin. Odour - Polystyrene monomers in the resin have a particularly noticeable smell. Properly installed bolts (i.e. properly set up resin) will have no odour. The smell of styrene underground implies broken cartridges at the work place or insufficiently mixed resin in the hole. Education - Proper education of mining personnel and supervisors is mandatory. Resin anchored bolts in particular require skilled miners. As manpower turnover is relatively frequent in bolting crews, education must be continuous. Forget this and you waste money. Monitoring - Installation must be monitored to ensure proper procedures and quality are maintained. Pull-test measurements should be routinely conducted on resin anchored bolts. Torque measurements can also be taken on threaded rebar bolts and monitored for changes. Torque testing is best done by a crew supervisor (or dedicated technician) while visiting work areas during his rounds. Packaging - Vendors must package bolting products in an acceptable manner both for convenience of use as well as prevention of damage to the product during shipping and handling. Particular care must be paid to wrapping of the thread ends to prevent damage and corrosion. Resin cartridges must be robust so as to not rip or tear during normal handling. Good packaging costs more but is worth the added cost by reducing wastage on site.

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SanJuan EZ TRUSS ASTM F432 gr6 -Nominal 30 Ton Capacity 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. A piece of 0.6" cable is inserted into the end of truss shoe automatically engaging the cable grip wedges. This can be done 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.

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May 2013

Section6-Page1

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

Section6-Page2

May 2013

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Cable Slings

Uses

Installation

Cable slings can be used as primary ground support in drifts, for the construction of sill mats and for wrapping pillars. Cable slings are particularly useful in soft, yielding ground or in areas prone to rockbursts.

Holes are always drilled 8' (2.4m) in length and are generally oriented at approximately 45 degrees. Three cement cartridges are immersed in water, and when ready, inserted into the first hole and tamped to the end. One end of the cable is then inserted manually into the hole. The cable is slid into the gap in the end of the friction stabilizer and the bolt is fully installed. The same process is repeated for the other end of the cable.

Materials Each sling is comprised of a length of cable (see chart below) with drive blocks or buttons, 2 pc. of 5' (1.5m) 39mm friction stabilizers and a minimum of 6 cement cartridges (32mm diameter), three per hole. Cables can be either 0.5" (12.7 mm) or 0.6" (15.2 mm).

If properly installed the friction stabilizers will hold approximately 1 ton per foot of length and will immediately tension the cable. Blocks or wedges can be inserted between the cable strand and the rock. After the cement cures the full strength of the cable can be mobilized.

Cable Length and Spacing Distance Between Holes

Drill Hole Length

Total Length of Cable

11.5' (3.5 m)

8' (2.4 m)

27.5' (8.3 m)

13.1' (4.0 m)

8' (2.4 m)

29.1' (8.8 m)

14.8' (4.5 m)

8' (2.4 m)

30.8' (9.3 m)

16.4' (5.0 m)

8' (2.4 m)

32.4' (9.8 m)

18' (5.5 m)

8' (2.4 m)

34' (10.3 m)

19.7' (6.0 m)

8' (2.4 m)

35.7' (10.8 m)

In Mexico cable slings are supplied complety assembled and ready to install.

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May 2013

Section6-Page3

DCP Bolt Double Corrosion Protection by Grouting The DCP bolt combines ease of installation with durable long-term corrosion protection.

Patent application filed

• The hex drive nut and domed washer are integrated. • The nut has grouting channels through it. • 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. The bar is completely encased in grout even at the critical inside of the nut for maximum corrosion protection.

Technical Data Bar Size/Grade

#7 (22 mm) Gr. 60

#7 (22 mm) Gr. 75

#7 (22 mm) Gr. 100

Thread Yield Strength, min.

27,700 lbs (123 kN)

34,700 lbs (154 kN)

46,200 lbs (205 kN)

Thread Yield Strength, min.

41,600 lbs (185 kN)

46,200 lbs (205 kN)

57,800 lbs (267 kN)

Recommended Hole Size

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13/4" (45 mm) or 2" (51 mm)

May 2013

Section7-Page1

DCP Bolt Typical Installation Procedure

Description The DSI Double Corrosion Protected Bolt (DCP Bolt) is a pre-tensioned & post-grouted rock bolt. It allows for immediate ground support using an expansion shell and has a high density corrugated polyethylene (HDPE) sheath along the bar length that provides long term corrosion protection and load transfer. The system can also be provided with triple corrosion protection (TCP Bolt) using special anti-corrosion bars, galvanizing or epoxycoating. Components The DCP Bolt comprises a 7/8" diameter steel bar pre-assembled with an expansion shell, corrugated polyethylene (HDPE) sheath attached to a grouting bell and domed hex nut (36mm A/F). The nut is slotted for post-grouting. The required dome plates are supplied separately and are generally ASTM F432 grade 2 or 3 material. Bolt Handling DCP bolts must be kept clean at all times. Care must be taken not to damage the HDPE sheath, grout bells and expansion shells during shipping and handling. Drilling Depending on the size of the expansion shell, drill either 45mm or 50mm (1¾" or 2") holes the total length of the bolt plus 50mm (2"). Thoroughly flush the hole with water after drilling. Ensure that the bearing surface for the dome plate is within ± 15 degrees from being perpendicular to the bolt.

Installation Slide a plate over the top of the bolt and insert the pre-assembled DCP bolt into the hole until the domed plate bears against the strata. Do not rotate the bolt while inserting. Important: ensure that the HDPE sheath does not scrape against the collar of the hole. Pre-Loading Once the plate is hard against the rock face, apply left-hand rotation to engage the expansion shell. Pre-load the DCP bolt to the required torque. Use a torque wrench with a 36mm (13/8") deep socket. Note: percussion must not be used for tightening the nut. Load Testing (if required) A minimum of 30mm (1.2") of bolt thread must protrude behind the nut. Install the testing equipment and perform loading tests – however, do not overstress the bar. Warning: never stand behind the jack during testing and read DSI’s Safety and Operating Instruction prior to testing. Post-Grouting The cement grout mixture must be thick enough to adhere to an overturned hand (mayonnaise consistency). The optimal water:cement ratio is 0.30:1 by weight for Type I-II cement. This is equivalent to 0.3 lbs of water per 1 lb of cement or 3.4 gallons of water per 94 lb sack of cement. A typical 2 or 3 stage progressive cavity pump can pump a 0.30:1 water:cement ratio grout through a ¾" hose for 15m (45-ft) and 6m (10-ft) of bolt. continued

Section7-Page2

May 2013

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Typical Installation Procedure continued

If the grout is thinner than 0.3:1 it may run out of the hole. If thin grout is kept in the hole the water will bleed away from the grout thus failing to fully encapsulate the bolt. The normal post-grouting steps are: • Prepare grout with proper amounts of water and cement. • Pump some grout to the end of the hose, check consistency and stop pumping. [Install a ball valve in the hose near the Chicago fitting to control grout flow.] • Attach Chicago fitting to DCP bolt grouting adapter. • Connect the DCP bolt grouting adapter onto the bayonet mount of the grouting bell, rotating to the right and tightening with the handle on the adapter. • Open ball valve and restart pumping at a slow to medium rate until grout appears around the plate. • Stop pumping and disconnect the adaptor. Important: if grout drains from the nut and/or the plate, the bolt must be grouted again with a thicker grout mix. • Move to a new bolt & repeat above steps. • Clean the grout adaptor thoroughly after use. • Warning: when grouting, the operator should wear the prescribed protective equipment in addition to gloves and safety glassed. Consult the applicable MSDS.

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May 2013

Section7-Page3

DYNA® Tork Bolt DYNA® Tork bolt is designed with a spiral mixing blade to ensure ultimate mixing of DSI resin in the borehole. This blade design has a dual propose: to mix the resin properly and provide anchorage for static ground support. The cone is designed to yield and transfer dynamic loads into the resin in rock burst conditions, absorbing the energy through controlled deformation. This ploughing effect through the resin will ensure that most of the kinetic energy in a rock burst is contained within the rock-mass. The DYNA® Tork bolt is the ultimate Dynamic Rock Support Solution for deep mining where it provides proper anchorage in a regular static mining environment, and ultimately yielding support in dynamic rock burst conditions. 1055 Modified Steel Elongation

10%

Yield Strength

448 MPa 93 kN

65.000psi 20,904 lb

Ultimate Tensile Strength

660 MPa 143 kN

65,700 psi 32,160 lb

Recommended Domed Washer Plate

1/4"

6.3 mm × 150 mm × 150 mm

Thread Diameter

19.05 mm

Bore Hole Diameter

× 6" × 6" 3/4

in

33 mm

Hemispherical Pinnut (dia × len × hole dim)

46 mm × 18 mm × 19 mm

Dynamic Bolt Energy Absorption: 15 kJ tested, 23 kJ tested, 30 kJ tested

Dome Plate

Technologically Advanced –Unique Mixing Helix – Patent Pending

1055 Modifi ed Smooth Bar

Section7-Page4

May 2013

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DYWI® Drill Self-Drilling Bolt R25N

Bar Size Diameter over threads

R32N

R32S

R38N

R51N

[in] / [mm]

0.984

25

1.260

32

1.260

32

1.496

38

2.008

51

[in ] / [mm ]

0.378

244

0.614

396

0.756

488

1.111

717

1.455

939

Ultimate Strength

[1000 lbs]

45.0

62.9

80.9

112.4

179.8

Yield Strength

[1000 lbs]

33.7

51.7

62.9

89.9

141.6

[lbs/ft] / [kg/m]

1.5

2.3

2.3

3.4

2.8

4.1

4.0

6.0

5.6

8.4

[ft] / [m]

39.4

12

52.5

16

65.6

20

78.7

24

98.4

30

Cross sectional area of bar

Weight Maximum Drilling Depths

a)

2

c)

2

The DYWI® Drill Self-Drilling bolt is a fully threaded hollow bar that initially serves as a drill rod, utilizing a lost bit. The thread is made to 15010208. 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 *UCT is unconfined compressive strength

Installation DSI Hollow Bar System is typically installed using rotary percussive drilling. This technique enables high rates of installation, good directional stability and also helps to consolidate the grout within the borehole. Rotation speeds should be sufficient to cut a true borehole (120-150 RPM for soil nails; 100-130 RPM for mini piles), as opposed to displacement of the soil with the drill bit through percussion and heavy feed pressures (driven installation). Drilled boreholes ensure enlarged grout bodies together with better permeation of the grout into the surrounding ground. Feed pressures on the drill rods should be regulated in accordance with the cutting performance of the drill bit. Simultaneous Drilling and Grouting Suitable for granular soils and fills. This installation method utilizes a Grout Swivel, grout pump and drifter. The technique combines drilling and grouting as a single operation, ensuring that grout

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is placed over the full length of the borehole. For ground conditions where borehole collapse is anticipated or where subsequent grout injection down the center of the bar is problematical, simultaneous drilling and grouting is the preferred solution. Grouting pressures should be regulated to maintain circulation at all times (typically up to 100 psi), with a small amount of grout return visible at the mouth of the borehole. Pressures in excess of 100 psi are generally only required for specialist applications (i.e. anchors in cohesive soils or mining applications). The choice of grout pump varies between applications, but basic requirements are as follows: a) thorough mixing of the grout – to avoid blockages at the drill bit, b) delivery of a continuous volume – to ensure consistent grouting, c) maintenance of sufficient pressure. May 2013

Section7-Page5

Self Drilling Bolt continued

Accessories Grout Swivels Grout Swivels are used for simultaneous drill and grout installation, to inject grout into the bore of a rotating DSI Hollow Bar. The unit comprises of a heat treated shaft (to withstand the impact energy from the hammer drive) and a housing into which the grout is pumped. Inlet ports within the shaft enable grout to be pumped into the bore of the bar.

Grout Swivel (hand held installation)

A locator frame is required (bolted to the drill sledge) to prevent the housing from rotating with the shaft, as well as positioning it at the correct location to enable unrestricted operation of the hammer. Drill Bits

Grout Swivel (rig installation)

EX / EXR Hardened cross cut drill bit, suitable for the majority of applications including narrow bands of soft rock. (EXR denotes retroflush version)

EXX Tungsten carbide chisel drill bit. EXX is the hardest drill bit available, for strong rock, hard seams and concrete footings.

Soil types: Fills, Shales, and Gravels.

Rock types: Strong rock, Metamorphic and Igneous Rocks i.e. Slate and Granite.

Diameters Available for Both Drill Bit Types R25 1.65", 2" R32 2", 3" R38 3", 3.5" R51 3.5", 4.53" Drill Tooling A range of drill accessories are available, to enable connection between the output drive of the drilling head and the different DSI Bar diameters.

Air Flush Shank (hand held installation)

Section7-Page6

May 2013

Balance Rod

Reducing Coupler

Reducing Coupler (with centre bridge)

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Threaded Fiberglass Bolts (Solid & Groutable) Nominal 3/4" (20 mm) & 1" (25 mm)

Dimensions 3/4"

E Diameter F Grout Hole Diameter E Thread Size/Type

(20 mm) Bolt

3/4"

(20 mm)

not available 3/4"

right hand

1" (25 mm) Bolt

1" (25 mm) Hollow Bolt

1" (25 mm)

1" (25 mm)

not available

1/2"

(12 mm)

1" right hand

1" right hand

1" (25 mm) Bolt

1" (25 mm) Hollow Bolt

20" (500 mm) of each end is threadable with a nut.

Technical Data 3/4"

(20 mm) Bolt

Resin Type

polyester / epoxy resin

Glass Type

E - glass

Glass Content (by weight)

75% minimum

E-Modulus, minimum

5,075 ksi (35,000 MPa)

Breaking Strain, maximum

3% maximum

Cross Sectional Area

0.439 in² (284 mm²)

0.701 in² (452 mm²)

0.526 in² (339 mm²)

Tensile Strength, minimum

31,500 lbs (140 kN)

50,500 lbs (225 kN)

38,000 lbs (170 kN)

Shear Strength, minimum

6,200 lbs (28 kN)

11,000 lbs (45 kN)

10,000 lbs (45 kN)

Nut/Thread Strength, min.

18,000 lbs (80 kN)

20,000 lbs (90 kN)

19,000 lbs (85 kN)

40 ft-lbs (55 Nm)

40 ft-lbs (55 Nm)

40 ft-lbs (55 Nm)

Weight

0.37 lbs/ft (0.55 kg/m)

0.59 lbs/ft (0.88 kg/m)

0.44 lbs/ft (0.66 kg/m)

Nut Dimensions (octagonal)

1.65" A.F. × 3.1" long (42 mm A.F. × 80 mm)

2" A.F. × 3.1" long (51 mm A.F. × 80 mm)

2" A.F. × 3.1" long (51 mm A.F. × 80 mm)

Nut Break Out Torque

Fibreglass Plate

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4.7" square x 3/4" thick (120 square x 20 mm thick)

May 2013

Section8-Page1

Fibreglass Dowel Fully Formed Threaded & Ribbed FRP Dowels

Physical Properties

12.5 Tonne Dowel 15 Tonne Dowel 20 Tonne Dowel 30 Tonne Dowel 38 Tonne Dowel

Ultimate Tensile Strength

125 kN

150 kN

200 kN

300 kN

380 kN

Nut/Thread Tensile Strength

55 kN

85 kN

85 kN

95 kN

95 kN

Single Shear Strength

45 kN

50 kN

57 kN

65 kN

74 kN

Nut Breakout Torque

30 ft/lbs

35 ft/lbs

40 ft/lbs

40 ft/lbs

40 ft/lbs

650-800 gms

675-850 gms

720-875 gms

750 gms

775 gms

20 mm

20 mm

20 mm

20 mm

22 mm

Nominal Cross Sectional Area of Bolt

310 mm2

310 mm2

310 mm2

310 mm2

325 mm2

Thread Length

150 mm

200 mm

200 mm

200 mm

200 mm

Major Bar Diameter (thread)

25.4 mm

25.4 mm

25.4 mm

25.4 mm

25.4 mm

Specific Gravity (grams/cm )

1.7-2.0

1.8-2.1

1.9-2.15

1.95-2.2

2.0-2.25

Mass per Meter (Std-HD) Nominal Bolt Diameter

3

Notes: - HD - High Density Version - 20 and 22mm bolt diameters available

General Features • The dowels are pull formed (matched die) fibreglass construction and are ribbed over its full length to provide maximum load transfer. • Thread form is of a sinusoidal type, nominally 150mm long and 25mm diameter, and is fitted with an integral drive nut with radial face. • All fibreglass dowels are designed to be used with chemical anchors and be fully encapsulated. • Bolts over 2400mm in length are available in all dowel types by negotiation. • Australian Patent Numbers 631881 and 65494 are applicable to these bolts.

Installation Guidelines • 26-27mm hole diameters are preferred. Holes over 28mm diameter are not recommended. • Hole depth is critical. Hole depth should be shorter than the bolt to allow for the height of the washer and nut.

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May 2013

• After insertion of the chemical anchors, the bolt is rotated through the anchor(s) while being pushed to the back of the hole. • It is important to follow the chemical manufacturer’s recommended mixing and hold times as printed on the chemical anchor cartons. DO NOT OVER MIX. • For further details regarding installation procedures refer to DSI’s “Practical Guide to Rock Bolting”.

Standard Lengths & Packaging • Standard bolt lengths range from 1200 to 1800mm in 300mm increments. • Other lengths are available by negotiation. • 1200mm long dowels are packed in 10’s then palletized in lots of 1000. • 1500 and 1800mm long dowels are packed in 10’s then palletized in lots of 500.

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Ground Lok™ Pourable Resin Grout Description Ground Control Pourable Resin Grout is a 2 component, free flowing polyester anchor. Each kit consists of a liquid resin supplied in a mixing pail, and a cup of liquid hardener. The Ground Control Pourable Resin Grout is outstanding for grouting dowels and anchor bolts concrete, rock and masonry.

3.

Once cured, the product forms an effective corrosion barrier from a pH of 2 through to a pH of 11. Working compressive strength is obtained at six times the indicated pot life.

Specifications Working Compressive Strength: 65 MPa, (9,500 P.S.I.) Ultimate Compressive Strength: 83 MPa, (12,000 P.S.I) Example: 30 cm, (12) of grouted #7 rebar in a 3.0 cm, (1¼") hole in 4000 P.S.I. limestone, has an ultimate pull strength of 107,000 N, (24,000 lbs.) Specific Gravity: 1.8 Shelf Life: Four months under ideal storage conditions Packaging: Pail of grout and cup(s) of hardener Kit Size: 3.5 L, (0.78 Imp. Gal.), 213 cubic inches Pot Life: 17 min. at 30 degrees C, (86F) 20 min. at 25 degrees C, (77F) 24 min. at 20 degrees C, (68F) 30 min. at 15 degrees C, (59F) 37 min. at 10 degrees C, (50F)

4.

5.

Directions For Use 1. Hole Preparation The holes should be drilled with rotary percussion type equipment such that the hole side walls are not smooth. The drill hole must be clean and free from debris, oil and grease. The hole should be dry, but a good bond can be obtained in wet or underwater holes if sufficient sidewall deformities exist. 2. Mixing Instructions Note the pot life-temperature relation and proceed by suspending all solids in the grout followed by adding the cup(s) of hardener to the mixing pail of grout and stirring the mixture as rapidly as feasible until no streaking of the www.dsiunderground.com

6.



hardener is observed in the grout-hardener mixture. The proper ratio is obtained when all of the hardener is added to the grout. UNDER NO CIRCUMSTANCES should any foreign substance be added to the grout-hardener mixture. Installation Pour the grout-hardener mixture into the drill hole to a level about 2/3 full. Insert the dowel or anchor bolt and work it back and forth to avoid air entrapment. Assume the final position of the dowel or anchor bolt, top up the hole with liquid grout and allow the grout to gel in that position. The grout will gel in one and one-half times its pot life at the given temperature. Working loads can be applied in six times the pot life. Cleaning Cleaning of tools, spills or runs is best accomplished before the grout has hardened by wiping off excess and further cleaning the surfaces with acetone (propanone), or another type of high grade mineral spirit, making certain that the surface is compatible with the spirit used. Remove empty containers from the job site and dispose of according to area regulations. Caution This product is intended for industrial use only. Avoid contact with eyes and prolonged contact with skin. Use protective measures. In case of eye contact, flush with water for at least 15 minutes. If irritation develops, contact a physician. The kit contains: benzoyl peroxide, polyester resin, styrene and inert fillers. If taken internally, consult a physician immediately. Formula for Determining Resin Requirements Hole Volume - Bar Volume = Annulus Volume Hole Volume = 3.1416 x radius of hole squared x length (in inches) Bar Volume = 3.1416 x radius of bar squared x length (in inches) Example: Using a 1¼" hole and 1" bar 8' long Hole = 3.1416 x (1.25/2) 2 x (8x12) = 118.08 cubic inches Bar = 3.1416 x (½) 2 x (8 x 12) = 75.40 cubic inches Grout Required = 42.68 cubic inches 213 / 42.68 = 4.99 holes per kit May 2013

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FASLOC® Resin Cartridges Polyester Resin Anchoring System A. THE CARTRIDGE

Description The FASLOC® resin in the cartridge is used to anchor bolts to the surrounding strata. This unification of the resin, bolt and strata layers provides the necessary strength and rigidity to prevent sag by acting as a reinforcement which anchors the individual stratified layers of rock into a single high strength beam. The two-compartment cartridge shown in illustration A above consists of a heat-sealed tube of polyester film clipped at both ends. One compartment contains a dark gray resin; the other, a light gray catalyst. A cross section of the cartridge is shown in illustration B. A film barrier of heat sealed polyester film prevents migration between the resin and the catalyst to provide optimum shelf life. The excellent chemical resistance of the film minimizes migration from the inside and the absorption of contaminants from the outside.

The light-weight, dimensionally stable casing of film is strong enough to withstand rough handling, but shreds quickly and thoroughly during the installation procedure. FASLOC® is thixotropic and fast setting. This reduces viscosity during insertion of the bolt and permits relatively low installation force and torque. The results are fast installation, rapid achievement of full strength, and a minimum tendency for ungelled resin to drip from the holes during installation. B. CROSS SECTION

heat seal

light gray

dark gray

heat seal continued

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May 2013

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FASLOC® Resin Cartridges continued

Performance Data

Fig. 1. Resin anchorage related to compressive strength of rock

1. Figure 1 represents the range of anchorage strengths for estimating requirements.

12000-1 5000 PS I - Gran ites 6000 -800 0 PS I - Lim eston 18 es 00 -22 0 0P 70 SI 0-S 80 ha 0 les PS /Sa Ind M sto ud ne st s* on es /S ilts to ne s

2. Depending upon the compressive strength of the rock being considered, the diameter of the hole may affect the anchorage strength – the larger the diameter, the larger the contact area. 3. Pull test under field conditions should be used to determine actual requirements. 4. Gel times are faster when temperatures exceed 55°F and slower when temperatures are below 55°F.

*Sandstones will vary since they are often intermixed with shales.

5. For RPM not shown in the Mix Table, determine minimum spin time based on 30 revolutions. 6. For 1-minute and lower gel times, the spin times indicated exceed the minimum 30 revolutions necessary for mixing. The additional spin times generates heat to achieve the stated gel times. 7. Mixing the resin and catalyst components in Gel time @ 55°F

4

Mix Table

50 RPM 300 RPM 600 RPM 800 RPM

B-Fast, TR

N.R.

6-7

3-4

3

G-HV,QC

N.R.

6-7

3-4

3

12-15

6-8

3-5

3-4

1 minute

12-15

6-8

3-8

3-6

11/2 minutes

12-15

6-8

3-8

3-6

2 minutes

12-15

6-8

3-8

3-6

2-4 minutes

12-15

6-8

3-8

3-6

7 minutes

12-15

6-8

3-8

3-6

1/2

minute, QC1

2 min. 1 min. 1/2 min. QC, TR, B-Fast

Spin Times, Sec.

N.R. - Not recommended

3 Gel Time (minutes)

Product Type

Fig. 2. Gel time

2

1

0

35

45

55

a cartridge creates a strong three dimensional polymer matrix that is reinforced with limestone filters. Most of the anchorage strength is reached in 5 to 10 times the product gel time.

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65

75

85

95

continued

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Section9-Page3

FASLOC® Resin Cartridges continued

General Installation Instructions • The installation procedures should be followed carefully to ensure successful application of FASLOC® resin grouting. • Various factors affect installation. These instructions are general guidelines. Mine tests must be conducted with bolts to determine actual “mix” and “hold” times. • Bolts should be installed as soon as possible in newly-exposed roof. Roof that has shifted or sagged offers least chance for successful support.

1 Insert necessary FASLOC® cartridges into the hole.

2 Push the bolt into the hole to a point just below the roof line. Slow rotation of the bolt during insertion is optional.

• Do not use ruptured or broken cartridges. • Refer to M.S.D. sheets and Product Bulletin for additional technical and safety data.

Safe Handling Precautions Caution: Do not open or puncture cartridge. Physical contact with liquid contained in cartridge may cause mild irritation. Safety glasses or eye shield should always be used when roof bolting is done. In case of eye contact, immediately fl ush with plenty of water for at least 15 minutes. Call a physician.

3 Rotate the bolt as indicated above.

In case of skin contact, fl ush skin with water. Prolonged contact with skin may cause mild irritation. Irritation should subside when material is removed.

4a Fully Grouted Bolts Push the bolt upward with the maximum thrust available from the machine and hold until FASLOC® hardens. Do not rotate after Step 3. Damage to partially gelled resin may result.

For complete safety information, refer to the Material Safety Data Sheets. Copies will be furnished upon request. Cartridges are fi lled with inert fi llers, water, polyester resin and activator (active ingredients include low levels of styrene and modifi ed benzoyl peroxide). FASLOC® cartridges are for industrial use only and are intended for use in conjunction with bolts. The relationship between hole dimensions, bolt size and the size and number of cartridges is critical to good performance. Your DSI representative will be glad to assist in determining the proper combinations for specifi c applications.

4b Tension Rebar & Combination Bolts Hold the bolt until the resin has hardened. This period of strength development will vary depending on gel time, product temp. and mine conditions. When resin has hardened, rotate the bolt until the desired torque is developed.

4c Resin Point Anchor Bolts When FASLOC® is used to supplement mechanical shell anchors, spin-to-lock.

continued

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FASLOC® Resin Cartridges continued

Uses

Storage Recommendations

FASLOC® has been a leading supplier of polyester resin cartridges to the mining industry for over 30 years. FASLOC® resin cartridges allow for quick and reproducible anchoring of many varieties of bolts and cables. In mine roof support, FASLOC® systems reinforce strata, providing strength and rigidity in untensioned systems, and ensure a durable anchorage for FASLOC® resin grouted tensioned bolts. The reinforcement technique bonds the individual stratified layers of rock into a single, high strength beam. FASLOC® resin cartridge can also be used in many other reinforcement, stabilization, and anchoring applications. The reliability of the anchorage system, plus ease of use and minimal resin setting times, will increase productivity and safety.

For maximum shelf life, FASLOC® cartridges should be stored away from direct sunlight in a reasonably cool, well-ventilated, dry area. Storage life is up to 1 year, depending on ambient temperature conditions. Under adverse conditions shelf-life is reduced. To ensure proper storage, the product should not be subjected to temperatures in excess of 85°F for prolonged periods. Storage is recommended under cover, on original pallets with adequate ventilation. If stored in trailers in hot weather, door should be left ajar or a sun screen erected over the trailer. Conversely, while cold storage does not adversely affect the shelf-life of FASLOC®, it should be warmed to a range of 50°60°F before using to assure gel times within the specified range (see Figure 2).

Advantages

The time required for cases of FASLOC® to warm or cool to ambient temperature is dependent on both the initial temperature and how the cases are stacked. Where the initial temperature is anywhere between 25° and 85°F, cases will come within 5° of ambient temperature in 48 hours when stacked in single columns with 4 sides of each case exposed to the air. Multiple columns should be separated by at least 2" to assist air circulation between columns.

The proprietary FASLOC® package has a distinct advantage over other resin systems due to: • High catalyst/resin ratio • Uniform installation time • Mixing efficiency

Cartridge Diameters Nominal diameters for both imperial and metric are available. Diameters are as follows: Imperial

Metric

0.9"

23 mm

1"

25 mm

11/8"

28 mm

13/16"

30 mm

11/4"

32 mm

13/8"

35 mm

19/16"

40 mm

Cartridge Lengths Cartridges are available in lengths from 12" to 60".

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Section9-Page5

Cement Cartridges Non-shrink Cementitious Anchor Grout Uses

Physical Properties

Cement cartridges were developed to anchor mine and tunnel rock bolts (rebar and THREADBAR®) and to anchor steel dowels in concrete.

Characteristics Package type - Pellon (petroleum based fabric) Appearance (dry) - firm, dusty Appearance (wet) - rigid, easy to hold Soak time - 1.5 minutes maximum

Advantages • Convenient easy to handle cartridge form • Fast curing compared to ordinary cement grouts • Controlled setting times • No on-site mixing, just immerse in water • Thixotropic and non-shrink • No special grout pumping equipment required • High strength • Non-toxic, non-combustible and chloride free • No rotation

Description The system consists of an easy to handle cartridge containing a cementitious compound encased in a perforated package which, when immersed in water, will allow controlled wetting of contents, forming a thixotropic grout. The cartridge is then inserted into the hole and the deformed bolt or dowel is pushed in.

Instructions for Use 1. Remove required number of cartridges from package. 2. Immerse cartridges in water until there are no signs of air release (bubbling) from the cartridge. Do not leave for longer than 5 minutes in water. 3. The cement grout will begin to set in 20 minutes after initial water emersion; therefore the bolt must be installed within this time period. However, it is recommended that the wetted cartridges be used within 15 minutes to obtain optimum results. 4. Insert cartridges into a clean hole. Tamp with a loading stick. 5. Insert the bolt. Bolt will rupture the cartridges allowing the grout to fill the annular space between the bolt and the hole. After 12 hours the grout will typically withstand the full yield point load of the deformed bolts or dowels.

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May 2013

Compressive strength 2 hours: 1700 psi (12 MPa) 4 hours: 2000 psi (14 MPa) 24 hours: 3200 psi (21 MPa) 3 days: 5500 psi (35 MPa) 7 days: 6800 psi (43 MPa) Anchorage Values (typical) 4 hrs: 500 lbs/inch (90 kg/cm) 8 hrs: 1800 lbs/inch (320 kg/cm) 12 hrs: 2100 lbs/inch (375 kg/cm) 24 hrs: 3000 lbs/inch (540 kg/cm)

Shelf Life 12 months or more in a dry location

Packaging 25 mm x 305 mm - 50/bag 28mm x 305 mm - 50/bag 32mm x 305mm - 50/bag 38mm x 305 mm - 50/bag

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Mesh Welded Wire Mesh • to ASTM A185 specifications • wire to ASTM A82 specs (75,000 psi tensile) • minimum weld shear strength (lbs) = 35,000 x wire cross sectional area (in2) • ends flush cut for safer handling • available galvanized • T = 4 (0.232"), 6 (0.192"), 8 (0.160"), 9 (0.144") and 10 (.0128") gauge • W = 48" to 96" wide • L = 48" to 24' long sheet or to 100' long roll • S = 4" x 4" spacing typical but variable (as shown)

Chainlink Mesh (Frost Fencing) • galvanized to ASTM A392 specifications • T = 6 (0.192"), 9 (0.144"), 11 (0.120") and 12 (0.106") gauge • W = 4', 5', 6', 7', 8' and 10' wide • L = rolls 25', 50' and 100' long • S = 2", 2½" and 3" opening size

Expanded Metal Mesh • carbon steel to ASTM A1011 specifications • up to 4x stronger than welded wire mesh at joints • available galvanized • T = 12 gauge (0.106") • W = 4', 5' and 6' • L = 4' to 10' • S = 3" x 6" opening size

Gabion Mesh • to ASTM A975 specifications • galvanized • weight = 0.365 lbs/ft2 • T = 11 gauge (0.120") • W = 2m (79") or 3m (118") • L = 30m (99') • S = 3.25" x 4.5" opening size

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Formed Mesh Mesh Channels For construction of shotcrete barricades and fill fences • mesh to ASTM A185 specifications • wire strand to ASTM A82 specifications (75,000 psi tensile minimum) • minimum weld shear strength (lbs) = 35,000 x wire cross sectional area (in2) • ends flush cut for safer handling • T = 6 gauge (0.192") • H/W = 3" x 3, 6" x 7.5", 7.5" x 9" • L = 10' • S = 4" x 4" spacing

Mesh Retainers For construction of soil retaining walls • mesh to ASTM A185 specifications • wire strand to ASTM A82 specifications (75,000 psi tensile minimum) • minimum weld shear strength (lbs) = 35,000 x wire cross sectional area (in2) • ends flush cut for safer handling • available galvanized • support struts hold mesh at 80˚ angle • T = mesh and support struts 4 gauge (0.225") • H/W = 18" x 18", 18" x 22", 18" x 24" and 20" x 22" • L = 10' • S = 4" x 4" spacing

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May 2013

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Shotcrete Mesh Panels Shotcrete Mesh Panels are constructed with black or galvanized mesh and burlap cloth. Stiffeners are incorporated for three-dimensionable stability. The panels can be various sizes depending on application. They are lightweight and can be cutto-shape with small bolt-cutters. When Shotcrete is applied to the panels, the result is a durable wall, which is resilient to close proximity blasting.

Advantages • Fast and easy to erect • Non-corrosive if galvanized mesh is used. • Concussion-resistant

Uses • Construction of walls for lunchrooms • Utility rooms • Building bulkheads • Protective wall for shaft areas

Installation • Install grouted dowels on 2-4' centers around perimeter of proposed wall • Tie 1/2" rebar to the dowels and form a grid of approximately 2-3' squares • Tie the Shotecrete Mesh Panel forms to the rebar grid using tie wire. The rib stiffener of the panel is then tied to the rebar. The panels must be butted together and wire tied about every foot. Panels can be easily trimmed to conform to tunnel of drift irregularities using ordinary bolt-cutters. • Apply Shotcrete through rebar grid. • Can also be attached to existing beams on structures.

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‘Gun Quip’ Wall & Support System • Shotcrete panel • ventilation walls - temporary or permanent. • fireproof underground work shops and offices. • provides rock support with rock bolt installation • protective reinforcing around elevators and shafts. • extra protection on walls and roofs near expensive machinery or electrical substations. • comes complete with backing or plain • manufactured under ASTM A02

panel side view

Technical wire specifications • ASTM 510 wire composition • ASTM A82 • wire size 14 gauge (WO.5) • nominal diameter - wire diameter 0.080" (2.032 mm). Specify wire diameter. 0.081" +.001" (2.0574 mm + .0254 mm) • Tensile maximum: 130,000 psi (896 MPa) minimum: 110,000 psi (758 MPa)

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Polymesh DYWIDAG Polymesh is comprised of high tenacity yarns, woven into a stable interlocking grid structure and then coated with PVC for protection during installation. Polymesh is used for longwall recovery mats as well as rib and roof control. Longwall recovery mats are fabricated and assembled to minespecifications. • Light weight - reduces cost and handling time. • No sharp edges, reducing injury hazard associated with chain link and welded wire. • 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. • Both FRAS and Non-FRAS available (FRAS - Fire Resistant and Anti-Static))

DSI Grades

Polymesh is available in rolls made to custom length. The typical roll lengths are 30 m, 50 m and 100 m.The width also can be customized to specific needs but common are 1.25 m and 2.5 m with 5 m being the maximum width.

Tensile strength (ASTM-D4595) MD

XMD

MD

XMD

at 2% strain

ultimate

lbs/ft

kN/m

1

All Polyester

Minimum aperture size Weight (ASTM-D5261) ultimate

elongation

inch

mm

oz/yd2

g/m2

55/55

440

440

55

55

18 × 23%

1.30

33

12

375

55/55

440

440

55

55

18 × 23%

2.40

60

12

375

80/80

650

650

80

80

18 × 23%

1.25

31

15

500

80/80

650

650

80

80

18 × 23%

2.40

60

15

500

200/80

1,600

650

200

80

18 × 23%

1.25

31

23

780

200/200

1,600

1,600

200

200

18 × 23%

1.05

26

38

1288

MD = machine direction, XMD = Cross Machine Direction 1 2% strain is equivalent to 10" convergence given 10ft unsupported span during shield recovery.

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May 2013

Section10-Page5

Polymer Mining Grid DSI Polymer Mining Grid is an alternative to weld wire mesh products and can be used as a supplemental support structure between roof/rib bolts in any underground mining and or tunneling operation. It is corrosion resistant and is especially applicable to any screening project when it will need to be "mined through" such as for pillar wrapping or for pilot tunnels. It is also especially useful in corrosive environments.

Physical Properties Physical Characteristics

Test Methods

Data

Structure

Bi-Oriented Geogrids

Mesh Type

Rectangular Apertures

Standard Color

White

Polymer Type Carbon Black Content

Polypropylene ASTM D4218

No

Flame Retardant

ISO 9705

Yes

Packaging

ISO 10320

Rolls in Polyethylene bags with I.D. labels.

Dimensions Dimensional Characteristics Test Method

Unit

Aperture MD

mm

59.5

b,d

Aperture TD

mm

56.5

b,d

g/m²

270

b

Roll Width

m

4.0

b

Roll Length

m

25.0

b

Roll Diameter

m

0.3

b

Roll Volume

m³

0.4

b

Gross Roll Weight

kg

61.0

b

Mass Per Unit Area

ISO 9864

FR 270 Notes

Technical Data Technical Characteristics

Peak Tensile Strength

Test Method

ISO 10319

Unit

FR 270

Notes

MD

TD

kN/m

20.0

20.0

a,c,d

%

13.0

10.0

b,c,d

Yield Point Elongation ISO 10319

Notes: a) 95% lower confi dence limit values, IS) 2602 b) Typical values c) Tests performed using extensometers d) MD: machine direction (longitude to the roll) TD: transversal direction (across roll width)

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Straps (Mats) W-Strap (Mat) • T = 12, 14, 16 gauge • W = 5" to 13" • L = 54" to 240" • C = hole size/spacing to customer specs

Rock Bolt Strap • A36 material (36,000 psi yield) • T = 12 gauge to ¼" • W = 4" to 8" • L = 48" to 120" • C = hole/slot size/spacing to spec

Expanded Metal Mesh Strap • 1008 material (30,000 psi yield) • T = 8 gauge (0.164") • W = 15" • L = 88.5" • deburred for safer handling

Welded Wire Mesh Strap • to ASTM A185 specifications • T = 0/0 gauge (0.306") • W = 12" • L = 84" and 108" • S = 4" x 4" spacing

Custom sizes and/or galvanizing available on request

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May 2013

Section10-Page7

Roof Channel Description • 2 material grades - A36 and 65000psi minimum yield • Length and hole spacing - to customer specifi cations • Width - nominal 5-1/2 inches • Thickness T-2 - minimum 0.100 inc T-3 - minimum 0.125 inch T-4 - minimum 0.145 inch T-5 - minimum 0.165 inch

Design Features a) holes punched on the sides for hanging cables and ventilation materials b) channel ends have the corners rounded such reducing sharp corners and prevent cuts to the miners hands and backs in low coal

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May 2013

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Bearing Plates (washers) Flat Plate - for General Use • minimum A-36 material (36,000 psi yield) • A = 4" to 12" square • B = 1/8" to 1½" thick • C = hole diameter as required • bent corner, grout slots & keyholes available

Domed Plate - Use with Anchornuts, Cable Grips or Spherical Seat Washers • minimum A-36 material (36,000 psi yield) • A = 5", 6", 8" and 12" square (rect 4" x 6") • B = 1/4" or 3/8" thick • C = hole diameter as required

Friction Bolt Plate - for Use with Friction Stabilizers • minimum A-36 material (36,000 psi yield) • A = 6" square • B = FB-33 & FB-39: 3/16" thick; FB-46: ¼" thick • C = FB-33: 36mm (1 7/16") diameter FB-39: 41mm (1 5/8 ") diameter FB-46: 48mm (2") diameter

Embossed Plate (Donut plate) • minimum A-36 material (36,000 psi yield) • A = 6" and 8" square • C = 13/16" to 11/8 " • available in Gr. 2 or Gr. 3 rating

Push-on-Plate - for installing Screen/Mesh (Threaded Bolts and OMEGA-BOLT® Rockbolts) • heat treated to HRC 45 minimum • A = 5" square • B = 0.068" thick • C = 5/8", ¾" and 7/8" available • magnetic installation tool available

T-Dome Plate - for use with T-Dome Rock Bolts • minimum A-36 material (36,000 psi yield) • A = 4", 5" & 6" square • B = ¼" thick • C = 7/8" diameter

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Section10-Page9

Bearing Plates (washers) continued

Conventional Header Plate

D

• minimum A-36 material (36,000 psi yield) • A = 6" • B = 10" and 16" • C = grade 2 and 3 • D = hole diameter as required

A

B

C

Low Profile Header Plate

D

• minimum A-36 material (36,000 psi yield) • A = 6" • B = 16" • C = grade 2 and 3 • D = hole diameter as required

A

B

C

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May 2013

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Bearing Plates (washers) continued

D

8 x 12 Header Plate • minimum A-36 material (36,000 psi yield) • A = 8" • B = 12" • C = grade 2 or grade 3 • D = hole diameter as required

A

B

C

T-Channel Plate

D

• minimum A-36 material (36,000 psi yield) • A = 4" • B = 9" • C = grade 2 and 3 • D = hole diameter as required

A

B

C

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Section10-Page11

Shotcrete (Spider) Plate (Black & Galvanized)

Description DSI shotcrete anchor plates are constructed specifically for use with rock bolts and shotcrete. Reinforcing bar is custom bent and welded to conventional rock bolt anchor plates. Plates are 5" x 5" x ¼", 6" x 6" x ¼" or 3/8". Hole size can be from 7/8" to 1½". Rise on spider can be made to any height required for depth of shotcrete.

Advantages

Installation

• Fast and easy to use. • Greatly improves “punching” shear of shotcrete. • Provides enlarged bearing area for higher load carrying capacity.

1. Install DSI shotcrete plates in the same manner as conventional plates. 2. Apply shotcrete to the rock surfaces and ensure the plates and rebar wings are embedded at least 38 mm (1½").

Where to Use

Materials

Any areas where bolting precedes shotcreting, especially in poor rock conditions, where improved bearing capacity of the ground support is desirable.

Plate material Grade A-36 (36,000 psi) meets or exceeds ASTM F432 deflection criteria. Rebar meets ASTM A-615 and CSA G30.18M specs.

Dimensions

Center Hole

Form

Weight

5"× 5" × 1/4"

1.2"

Flat

4.5 lbs

6"× 6" × 1/4"

1.2"

Flat

6.4 lbs

3/8"

1.2"

Flat

9.6 lbs

5"× 5" ×

Custom sizes available upon request

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May 2013

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Butterfly Plate Length x Width

Thickness

Hole Diameter

Net weight black

Net weight galv.

300 × 278 mm 12 × 11 inch

1.9 mm

50 mm = 2 inch

2.87 lbs

2.95 lbs

400 × 278 mm 15.75 × 11 inch

1.9 mm

50 mm = 2 inch

3.73 lbs

3.83 lbs

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, 6 in2) • 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.

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Product Code(s) 12 × 12" black

BUTT300S USA

12 × 12" galv.

BUTT300GS USA

12 × 16" black

BUTT400SWA

12 × 16" galv.

BUTT400GS

May 2013

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Surface Control Plates 23" and 19" General Information • the 23" diameter is "special" order • the 19" diameter is stock production • all plates have the "rolled edge" to provide for safe handling • large diameter plates for surface control • these plates are to be used in conjunction with a roof bolt and roof plate

23" Description • 23" diameter with a 13/8" center hole • available in a variety of mill thicknesses from 0.022" to 0.050" cold rolled or coated steel

23"

19" Description • 19" diameter with a 1" center hole • 19" diameter with a 13/8" center hole • available in a variety of mill thicknesses from 0.022" to 0.050" cold rolled or coated steel

19"

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May 2013

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Star Plates For general use (may require spherical seat washer) • special grade deep draw steel • 25 ton capacity • A = 6" diameter • B = only 3/16" thick • C = 1½" diameter • weighs only 1.6 lbs (730 g)

Star Plate Specifications The most important features of any roof plate are stiffness, yield strength and area of contact with the rock, especially under high loads. To determine these parameters the DSI Research and Development team have developed a testing method which very closely simulates underground coal mining conditions. Figure 1 illustrates the performance of the new Star Plate (and compares it with other common roof plates) for conditions commonly encountered in Australian underground coal mines. The Star Plate yield load is close to the yield strength of the most widely used AX type bolt. Apart from the high strength of the Star Plate (despite its relatively thin plate thickness of 5mm) it has the additional advantage of providing a larger bearing area when heavily loaded as shown in Figure 2. The Star Plate is a further example of DSI Research and Development Team’s world leading technology in Strata Reinforcement Products, that seeks safe, cost-effective solutions for the underground mining industry.

Figure 1: Typical Load vs. Displacement characteristics of STAR PLATE used with wire mesh compared with two conventional domed plates tested on a flat surface of medium strength bed of 25-30Mpa compressive strength.

* 150X150X8mm Domed Plate Figure 2: Plates under heavy load.

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* 150X150X10mm Domed Plate

* 150X5mm Star Plate

May 2013

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Eyebolt Butt Welded Eyebolt • 44W material (60,000 psi) • E = Ø 9/16" if 5/8"-11 UNC thread Ø 11/16" if ¾"-10 UNC thread • L = 18" and 24" under eye • 5/8" rated for 2,300 lbs • ¾" rated for 3,600 lbs

Welded Return Eyebolt • 44W material (60,000 psi) • E = Ø 9/16" if 5/8"-11 UNC thread Ø 11/16" if ¾"-10 UNC thread • L = 18" and 24" under eye • 5/8" rated for 2,300 lbs • ¾" rated for 3,600 lbs

Forged Slusher Eyebolt • 5140 Alloy (120,000 psi) • E = Ø11/8" • L = 18" and 24" under eye • ¾"-10 UNC thread • rated for 9,000 lbs

Forged Oval Eyebolt • 5140 Alloy (120,000 psi) • E = Ø5/8" and ؾ" • L = 12" and 18" under eye • 5/8"-11 and ¾"-10 UNC thread • 5/8" rated for 4,000 lbs • ¾" rated for 6,000 lbs

Cable Eyebolt • E = 0.6" cable diameter • F = Ø11/8" fittings, 1045 steel (80,000 psi) • L = approx. 28" overall • 5/8"-11 and ¾"-10 UNC thread • 5/8" rated for 2,100 lbs • ¾" rated for 2,800 lbs

continued

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Section11-Page1

Eyebolt continued

Open Eyebolt & “L” Bolt • DSI supplies welded, bent, open, and “L” bolts as well as custom manufacturing them to your length and threading requirements. These bolts are generally used for hanging piping, cable, and equipment. • High strength steel. Grade 100 K. • Bar diameteres: 5/8", ¾", 7/8" • Expansion shells: Included.

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May 2013

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Scaling Bars Hexagonal Solid Steel • AISI 1080 or equivalent steel • T = 7/8" hex (¾" special order) • weight = 2.3 lbs/ft • angle chisel on one end • moil point (shown) or straight chisel on other end • optional rubber hand grip • L = 4', 6' and 8'

Hexagonal Solid Aluminum • 6061-T6 hexagonal aluminum • T = 1" hex • weight = 1.1 lbs/ft • tips AISI 1080 or equivalent • angle chisel on one end • straight chisel on other end • optional rubber hand grip • L = 4', 6', 8', 10' and 12'

Square Steel Tube (Swaged) • HSS tubing ASTM A500C • T = 1" x 1" x 0.100" wall • weight = 1.2 lbs/ft • tips ¾" octagon AISI 1080 or equivalent • angle chisel on one end • moil point on other end • optional rubber hand grip • L = any length to 20'

Square Aluminum Tube (Swaged) • 6063-T5 aluminum tubing • T = 1" x 1" x 0.095" wall • weight = 0.4 lbs/ft • tips ¾" octagon C1080 or equivalent • angle chisel on one end • moil point on other end • optional rubber hand grip • L = any length to 20'

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May 2013

Section11-Page3

Utility Hangers Pipehanger (J-Bolt) (J-Hook) - for 3/16" Chain or 1/4" Chain • 1060 material (100,000 psi) • E = Ø9/16" • L = 18" and 24" overall • rated for 2,000 lbs

Bullhorn - Square Timber Support • 44W material (60,000 psi) • E = Ø1", Ø11/8" and Ø1¼" • L = 18", 24", 30" and 36" • S = 8" x 8", 10" x 10" and 12" x 12"

S-Hook Hanger • 44W material (60,000 psi) • E = Ø5/16" • L = 8½" overall • also available plastic coated (for electrical use)

Sill Nut (Eye Nut) • available in: ductile iron - 2000 lb rating 5140 alloy - 4000 lb rating • L = 4½" overall • 5/8" - 11, ¾" - 10, 7/8" - 9, and 1" - 8 UNC thread

J-Nut • available in: ductile iron - 500 lb rating • L = 4½" overall • 5/8" - 11, ¾" - 10 and 7/8" - 9 UNC thread

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May 2013

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Keyhole and Hanging Brackets Service Line Keyhole Brackets are used in conjunction with service line slots pre-punched in W-Strap vee’s. 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 Mining Products.

Plastic Blasting Wire Hangers

Hook Type Pipe Hangers

Screen Hangers • Save on unnecessary additional bolting just to hang screen. • Quick, easy screen positioning. • Squeeze them shut.

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Railbolt C-1060 Steel Pipe: ¾" SCH: 40

May 2013

Section11-Page5

Tools & Hardware, Drilling Consumables Miners Wrench Holder • mild steel construction • fits onto standard safety belts • holds hammer head and regular wrench models

Muck Scoop (Pelican Pick) • with wooden handle • replacement handles available • L = 32"

Raise Rascals (Folding Degree Rules) • made from heavy duty plastic • both metric and imperial measurements • degrees on one side, 0/0 grade on other • comes with level bubble • 6-12" long when folded, 24" (60 cm) unfolded • also available in aluminum (metric only)

Raise Ladders • with 3" standoff legs • T = 1" sched 40 pipe • W = 12" • L = 8' and 10' • custom sizes available

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May 2013

Section12-Page1

Tools & Hardware, Drilling Consumables continued

Drill Bits • spade and wing bits • for wet and dry drilling • diameter 26 to 30 mm typical • thread shanks M16 or ½" whitworth • or spigot shanks in small figure 8, 3/8" square or ½" x 3/8"

Drill Rods For dry drilling – fabricated scroll or twisted scalloped type • pinned or threaded joints available • different drive ends to suit bolter ( 7/8" hex, square drive, etc)

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May 2013

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Lattice Girders and Steel Arches 3 bar type

Dimensions O.P. Bar Size Weight

H

B

e

H1

Ix

Sx

ly

By

[in]

[in]

[in]

[in2]

[in2]

[in2]

[in2]

Joint Plate Size Length

Type S3 S2 S1 [lbs/ft] [in]

Size

Unit Wt

Wt[lbs]

[in]

[lbs]

3/8 × 5 × 5

2.7

3/8 × 6 × 6

3.8

3/8 × 7 × 8

6.0

3/8 × 8 × 91/2

8.1

3/8 × 8 × 91/2

8.1

3.70 3.94 2.01

3.441

1.716

2.324

1.180

4 9/16

3.2

8.26

3.94

4.676

2.226

2.395

1.216

4

9/16

3.2

6.95

4.50 5.60 2.42 2.75 5.544

2.295

5.064

1.846

5 5/16

3.5

8.59

4.77

2.20

7.376

2.886

5.135

1.867

5 1/2

3.7

8 11

11.83 5.16

2.69

12.108 4.465

8.226

2.991

5 3/4

3.9

6 8

7.07

5.50 7.09 2.94 3.76 8.937

3.036

8.950

2.526

5

9/16

4.4

8.70

5.77

2.59

11.741 3.751

9.028

2.548

6 3/4

4.6

12.05 6.16

3.18

18.883 5.854 14.840 4.188

7 1/16

4.8

3.21

7

11/16

8.0

7

13/16

8.1

6 10 6 8

0.39°

6 10

0.39°

6 10

95

Unit

[in]

6.72

8 11 115 6 8

8 11 130 6 8

8 11

0.47°

6 10

7.94

6.25 8.66 3.37 4.50 12.182 3.636 13.906

9.58

6.52

2.91

15.849 4.416 13.985 3.229

12.92 6.91

3.69

25.208 6.953 23.342 5.390

7.76

6.87 8.66 3.69 5.12 15.015 4.068 13.906 3.211

9.39

7.14

3.15

19.379 4.929 13.977 3.229

12.73 7.53

3.93

30.623 7.794 23.342 5.390

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L5 × 3 × 1/2×

0.47°

6 10

1.88

L4 × 3 × 3/8×

70

6 8

0.39°

50

[in]

Foot Plate

8 1/8

8.4

8 1/8

8.4

8

5/16

8.6

8

3/4

9.3

May 2013

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Lattice Girders and Steel Arches continued

4 bar type

Dimensions O.P.

0 [mm]

Type 100

140

220

10

10

12

H [in]

B [in]

3.94

A Bars [in2]

Ix [in2]

Sx [in2]

ly [in2]

Sy [in2]

1.2

6.42

2.47

3.40

1.72

Joint Plate

Foot Plate

Size Length Unit W [in] [in] [lbs]

5

7.61

5.19

6

8.88

5.44

1.8

9.77

3.59

4.56

2.31

51/4

5.6

7

10.23

5.69

2.4

10.04

4.94

5.75

2.92

51/2

5.9 6.1

8

13.43

5.94

3.1

19.34

6.52

6.97

3.54

53/4

10

17.16

6.44

4.9

33.50 10.41

9.34

4.75

6

6.4

61/2

6.9

1.2

11.54

3.42

7.32

2.66

63/4

7.2

7.01

1.8

17.32

4.95

10.03

3.65

7

7.5

10.51

7.26

2.4

24.55

6.77

12.98

4.72

71/4

7.7

8

13.71

7.51

3.1

33.38

8.90

16.10

5.66

71/2

8

10

17.42

8.01

4.9

56.39 14.10 22.65

8.24

8

8.5

83/8

8.9

5

7.88

6.76

6

9.14

7

5.51

L5 × 3 1/2×

180

10

S Weight Bar [lbs/ft] Size

5

8.51

8.34

1.2

20.28

4.64

12.85

3.63

6

9.78

8.59

1.8

30.13

6.70

17.82

5.03

85/8

9.2

7

11.51

8.84

2.4

42.29

9.14

23.34

6.58

87/8

9.6

8

14.35

9.09

3.1

56.94 11.99 29.32

8.27

81/8

9.7

85/8

10.3

7.09

10

18.06

9.59

4.9

94.44 18.89 42.33 11.94

5

9.80

9.91

1.2

28.45

5.55

19.84

4.58

915/16

10.6

6

11.06

10.16

1.8

42.06

8.01

27.71

6.40

103/16

10.9

7

12.43

10.41

2.4

58.75 10.93 36.57

8.44

107/8

11.1 11.8 11.9

6.66

8

15.63

10.66

3.1

78.74 14.32 46.29 10.65

1011/16

10

19.34

11.16

4.9 129.41 22.51 67.88 15.68

118/16

Section13-Page2

May 2013

Size [in]

Unit Wt [lbs]

1/2 × 5 × 7

5.0

1/2 × 7 × 9

8.3

1/2 × 8 × 101/2

11.9

5/8 × 10 × 12

21.2

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Steel Rib Supports

*Other variations available on request.

DSI Underground Systems Inc. can bend I, WF, H sections ranging from 4" to 27" in depth (DSI Underground Systems Inc. has formed W14x287 lb ft with 2" flanges). Curvatures range from a minimum radius of 10 times the beam depth for 4" and 6" sections to 14 times the depth of section for larger beams. While DSI Underground Systems Inc. has worked

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with 30' sections, it is recommended the sections not exceed 22'. DSI Underground Systems Inc. also recommends against the use of lighter-weight sections when the radius of curvature is less than 25 times the depth of section. DSI Underground Systems Inc. also fabricates straight beams, forepoling sheets, steel lagging, tie rods, foot plates and pipe spacers.

May 2013

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Accessories Used with Ribs Butt Joint • Butt plate height: Rib Depth plus 1" • Width: Flange width plus 1" • Thickness: 4" and 5" sections – 3/8" 6" sections – ½" 8" sections – 5/8" 10" sections – ¾" 12" sections – 1" • Bolt size (A325) and quantity: 4" sections: (2) ¾" dia 5" and 6" sections: (2) 1" dia 8" and 10" sections: (4) 1" dia 12" sections: (6) 1" dia The above are for normal loading conditions. For extreme conditions, a full-moment strength joint may be required.

Foot Plate • 4" sections: ½" x 7" x 7" • 5" sections: 5/8" x 9" x 9" • 6" sections: 5/8" x 9" x 9" • 8" sections: ¾" x 12" x 12" • 10" sections: 1" x 14" x 14" • 12" sections: 1¼" x 16" x 16"

Tie Rods • A529 rod stock with 4" N.C. thread each end • Length=rib spacing + 6" • With 4" and 6" sections: ¾" dia. • With 8" and 10" sections: ¾" dia. • With 12" and above: structural spreaders are recommended

Pipe Spacers • Schedule 40 pipe stock • Length=rib spacing – web thickness • With ¾" dia. Tie rods: 2" dia. • With ¾" dia. Tie rods: 2" dia.

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May 2013

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Adjustable Support Jacks FastJax • 12" Adjustable Tops • 100 Ton Yield Strength • Available in 6" increments from 4' to 9' high • Can be fitted with yieldable dish, yolk to suit box beam or flat plate top • No loose pieces or grout bags

RBS Posts

SUPPORT LOAD, klps

• 6" or 9" Adjustable Tops • 90 Ton Yield Element • 10 Ton Setting Load • Diameters available from 6" to 10" • Pine Posts • No loose pieces or grout bags

0

1

2

3

4

5

6

7

8

DISPLACEMENT, inches

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May 2013

Section13-Page5

Mastercast and Traditional Overcasts Mastercast • Rapid Assembly as few as six major pieces • All sizes available in 12" increments • Reusable and galvanized panels • Chanel ends for wingwalls • Light and Heavy Duty versions • Ships complete with all tools

Traditional Overcasts • Strong - Made with Wide Flange Beam • All Steel - No Aluminum • Quick Erection - 2-4 Hours • Most Sizes • Reuseable

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May 2013

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VTS Props The pressure flows through the setting gun and filling valve into the interior of the prop and causes the internal prop and the piston to telescope. After having been set against the support (articulated bar) the prop is braced with the setting force existing in the setting line, thus immediately supporting the roof.

The Salzgitter Hydraulic Props, now produced by VTS and marketed in North America by DSI Underground Systems Inc., offer safety on the face. They can be easily maintained and operated, and, according to the requirements and depending on the prop type, readily extended with slip-on extension pieces. The VTS Props are set by hydraulic pressure pump and fed into the setting gun via a setting line installed in the face. The setting gun will be put on the filling valve of the prop, mechanically secured with a one-hand locking mechanism, and operated by one hand.

Due to the rock pressure the prop can now be loaded till the set pressure on the operating valve will have been reached. If the nominal pressure is reached, the operating valve will open and some hydraulic fluid will be sprayed off till a pressure spring will close the operating valve again. This process repeats itself every time the nominal pressure is reached. Thus, the prop remains always protected from overload by the rock pressure. Large lifting heights permit a large range of convergences. Due to the possible extensions according to the prop types, the prop length can be readily adapted underground to the changes of the face heights. The prop can be withdrawn with a releasing key that — extended by means of a rope or a chain — actuates the releasing valve from a safe place of the miner and lets the hydraulic fluid escape from the cylinder. An installed return spring rapidly retracts the internal prop. Herewith, the prop is ready for use again for a new setting operation. continued

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May 2013

Section13-Page7

VTS Props continued

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May 2013

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VTS Props continued

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May 2013

Section13-Page9

Crib Systems Tri-Log™ Wood Crib

Tri-Log™ Crib System

Introducing the Tri-Log™ System, the new cribbing method from DSI Underground Systems Inc. that saves you time and money. It is designed to replace four and nine point cribs as well as other four-sided structural wood systems. This system uses only three pieces to build each course compared to four or more pieces for the competitive systems. That’s 25% fewer pieces, so you’ll benefit from significant reductions in labor, handling and transportation costs.

• Lowest cost system • Capacities up to 1,000 tons • 100% contact area • Stable triangle base • Single specie hardwood • Pieces lock together • Less pieces to haul • Less pieces to erect Patent No. 6,079,910

The unique interlocking design delivers 100% contact between the nested timber layers. This efficiency means Tri-Log™ cribs give up to 50% more support than the average four point crib. The tripod configuration and interlocking design provide superior stability, allowing higher aspect ratios than conventional cribbing. The angle-cuts of the notches reduces stress at the overlap and maximizes carrying capacity throughout the load cycle. Tri-Log™ cribs are slid into place tight to the roof rather than having to be lifted over the previous course and can also be used with ACI prestressing grout bags or headers. The finished wedge-shaped cribs promote more efficient ventilation and air flow than solid square or rectangular cribs. Tri-Logs™ are available in standard lengths up to 60” in either 4" or 6" sizes to handle capacities in excess of 800 tons. Custom designs for virtually any capacity can be produced.

Section13-Page10

May 2013

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Steel 4-Flange Liner Plates DSI Underground Systems Inc. selection of underground supports, the widest in the world, affords the contractor, the designer, and the owner a matchless combination of high performance and tunneling at low cost. One of these products alone - liner plates - offers these outstanding advantages: • Economy of construction in time, excavation, material, manpower. • Maximum support per given length with minimum weight of steel. • Standard variation of plate design for all shapes of tunnels in dry or wet ground. • Predictable strength, fire resistant. • Continuous support during the critical mining phase in soft ground tunneling. • Easy to store, handle and erect, whether the tunnel is straight, curved, circular, elliptical or horseshoe in shape. • Gasket plates that seal joints, stop water leakage and reduce air loss when water is a problem. Steel liner plates provide a relatively light-weight, easy-to-handle, safe support for soft ground tunneling because the ground that supplies the loading also supplies the resistance to the load. The liner plate assembly simply distributes and transmits the load to the surrounding earth. As a steel liner plate ring takes load vertically, it tends to deflect inward at the top and outward at the sides. The ground resists deflection of the lining by developing a passive force equal in magnitude and opposite in direction to the force exerted by that of the lining. The diagram on the left illustrates this principle. The ability of the surrounding ground to resist the outward bulge of the liner plate ring is the key to vertical load support. With the ring confined to a small amount of deflection, the thrust line induced by the load is forced to follow the ring of liner plates. Thus, the ability of the assembly to withstand the applied load depends upon its ability to transmit ring thrust from plate to plate around the ring. Obviously, this ability is enhanced by the four-flange design of DSI Underground Systems Inc. plates.

There are various methods for determining the required strength of tunnel linings. Nevertheles, the type of ground, the location and depth of cover, the size and length of the tunnel, level of ground water, superimposed loading, and history always guide these calculations.

DSI Underground Systems Inc. liner plates can be purchased in 16" and 24" widths as corrugated or smooth plates. Liner plates are formed from one piece of metal to provide longitudinal and circumferential flanges. The plates can be galvanized and/or bituminously coated and grout holes with plugs can be included. For special conditions gasketed liner plates and tapered liner plates can also be manufactured. Liner plates can be installed alone or in conjunction with steel ribs if additional support is required. Corrugated and Smooth Liner Plates

continued

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May 2013

Section13-Page11

Steel 4-Flange Liner Plates continued

General Specifications The following paragraphs are offered as a guide for those who write and issue specifications for steel liner plates as underground supports.

Scope

Material Specifications Thickness tolerances shall conform to AASHTO specification for Highway Bridges, Section 16, or comparable AREMA Manual for Railway Engineering, Chapter 1, Section 4~15.

These specifications are intended to cover the fabrication and installation of liner plates in tunnels constructed by conventional methods. Tunnels excavated by full face, heading and bench, or multiple drift procedures are considered conventional methods. Liner plates used with any construction method utilizing a full or partial shield, a tunneling machine, or other equipment which will exert a force upon the liner plates to propel, steer, or stabilize the equipment are considered special cases and are not covered by these specifications.

The Tunnel Liner Plates shall be fabricated from structural quality, hot rolled, carbon steel sheets or plates conforming to the specification of ASTM designation A1011.

Description

All plates shall be formed from one piece of metal to provide longitudinal and circumferential flanges. They shall be punched for bolting on both longitudinal and circumferential flanges in accordance with the manufacturer's standard spacing, and shall be a multiple of the plate length so that plates having the same curvature shall be interchangeable and will permit staggering of the joints.

Cold-formed steel liner plates conforming to the specifications below shall be furnished to the sizes and dimensions required on the plans. Such plates shall be installed at the locations designated on the plans or as designed by the engineer or the responsible authority. Design and shape of the liner plates shall be such that erection and assembly of the liner plate structure can be completely and readily erected from inside the tunnel.

The mechanical properties of the flat plate and sheets before cold forming shall be: Tensile Strength psi 42,000 Min. Yield Strength psi 28,000 Min. Elongation in 2", % 30 Min.

Forming and Punching of Liner Plates

Grout holes with plugs shall be provided at spacing sufficient to allow filling of all voids with grouting material.

Plates shall be accurately curved to suit the tunnel cross section, and all dimensions are of such size and accuracy that plates of similar curvature will be interchangeable. Bolts on both the longitudinal and circumferential joints shall connect all plates. Grout holes 2" in diameter shall be provided, as shown on the plans, to permit grouting as the erection of tunnel liner plates proceeds.

continued

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May 2013

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Steel 4-Flange Liner Plates continued

Galvanizing and Coating Where liner plates are used as temporary supports, and the permanent support is monolithic concrete or reinforced concrete pipe, and the opening between the back of the pipe and the inside of the liner plate is filled with grout or sand, liner plates are furnished black, not coated. When so specified, the liner plates will be galvanized to meet the current ASTM Specification A 123. In addition, the liner plates when so specified, shall be bituminous coated to meet the current AASHTO Specification M190.

Bolts and Nuts Bolts and nuts used with four-flange liner plates shall be not less than ½" diameter for 7 gage plates and lighter, and not less than 5/8" diameter for liner plates heavier than 7 gage. They shall be quickacting coarse thread with material conforming to ASTM Specification A307. When required, the bolts and nuts shall be hot dip galvanized to conform to ASTM Specification A 153.

Installation Liner plates shall be assembled in accordance with the manufacturer's instructions. Voids occurring between the liner plates and the surrounding ground shall be pressure grouted as directed by the engineer in charge to completely fill all voids. The grout shall be forced through the grouting holes provided in the liner plates.

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May 2013

Section13-Page13

Typical Liner Plate Installations Three basic ways sof installing plates in tunnels or shafts are illustrated here; each has its advantage in a particular application or ground condition. Liner Plates Only The most obvious advantages of this structure are that maximum support per foot of tunnel is obtained with minimum weight of steel. Liner plates, properly grouted or backfilled as tunneling progresses, form a dependable structure in either cohesive or non-cohesive ground. Liner plate structures generally require no additional support in tunnels up to 14' in diameter.

Ribs Inside Liner Plates To give extra support to a liner plate structure in large diameter or heavy load conditions, ribs can be added inside the ring. Liner plates then act as lagging and are normally lighter in gage. This additional support usually requires an increase in the diameter of the driven bore to maintain the dimensions of the finished inside diameter. This method is often used in shaft construction.

Liner Plates Between Ribs This type of structure is less common than ribs inside liner plates because it is harder to erect. It does offer a practical trade-off under certain tunneling conditions.

Section13-Page14

May 2013

www.dsiunderground.com

Grouting Pump Systems ICTUS

Pump Model ICT 060G Ratio : 8,1 Inlet Pressure : 4bar Output Pressure : 28bar Delivery JMin. Grout : 30 litres’ min. Delivery JMin. Water : 37 litres’ min

Mixer Model ICT 5001 mixer Capacity : 3 HP Bucket Capacity : 85 litre

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May 2013

Section14-Page1

VK Grout Plugs VK Grout Plugs – Type “A” Product No.

Hole Diameter

Pipe Size

13"

17"

21"

24"

30"

36"

48"

60"

72"

84"

96"

A125L-A125R

11/4"

1/2"

x

-

-

x

-

x

x

x

x

x

x

A138L-A138R

13/8"

1/2"

x

-

-

x

-

x

x

x

x

x

x

A150L-A150R

11/2" EX

1/2"

x

-

-

x

-

x

x

x

x

x

x

A175L-A175R

13/4"

1/2"

x

-

-

x

-

x

x

x

x

x

x

A187L-A187R

157/64" AQ

1/2"

x

-

-

x

-

x

x

x

x

x

x

A200L-A200R

2"

1/2"

x

-

-

x

-

x

x

x

x

x

x

A212L-A212R

21/8"

1/2"

-

x

-

x

-

x

x

x

x

x

x

A225L-A225R

21/4"

1"

-

x

-

-

-

x

x

x

x

x

x

A238L-A238R

223/64" BQ

1"

-

x

-

-

-

x

x

x

x

x

x

A250L-A250R

21/2"

1"

-

-

-

-

-

x

x

x

x

x

x

A275L-A275R

23/4"

11/4"

-

-

x

-

-

x

x

x

x

x

x

A300L-A300R

263/64" NQ

11/4"

-

-

x

-

-

x

x

x

x

x

x

A350L-A350R

31/2" NC

11/4"

-

-

x

-

-

x

x

x

x

x

x

A375L-A375R

325/32" HQ

11/4"

-

-

x

-

-

x

x

x

x

x

x

A387L-A387R

329/32" HW

11/4"

-

-

x

-

-

x

x

x

x

x

x

A483L-A483R

353/64" PQ

2"

-

-

x

-

-

x

x

x

x

x

x

Product Numbers shown above are for standard plug lengths - 13" for EX and AQ; 17" for BQ; 21" for NQ, NC, HQ, HW

Section14-Page2

May 2013

www.dsiunderground.com

Margo Type Plugs Product No.

Hole Diameter

Pipe Size

18"

24"

36"

48"

60"

72"

84"

96"

108"

120"

M-112

11/4"

1/2"

x

x

x

x

x

x

x

x

x

x

M-125

13/8"

1/2"

x

x

x

x

x

x

x

x

x

x

M-137

11/2" EX

1/2"

x

x

x

x

x

x

x

x

x

x

M-162

13/4"

1/2"

x

x

x

x

x

x

x

x

x

x

M-175

17/8" AQ

1/2"

x

x

x

x

x

x

x

x

x

x

M-187

2"

1/2"

x

x

x

x

x

x

x

x

x

x

M-200

21/8"

1/2"

x

x

x

x

x

x

x

x

x

x

M-212

21/4"

1"

x

x

x

x

x

x

x

x

x

x

M-225

23/8" BQ

1"

x

x

x

x

x

x

x

x

x

x

M-237

21/2"

1"

x

x

x

x

x

x

x

x

x

x

M-262

23/4"

1"

-

x

x

x

x

x

x

x

x

x

M-287

3" NQ

1"

-

x

x

x

x

x

x

x

x

x

M-337

31/2" NC

2"

-

x

x

x

x

x

x

x

x

x

M-350

33/4" HQ

2"

-

x

x

x

x

x

x

x

x

x

M-387

4"

2"

-

x

x

x

x

x

x

x

x

x

M-437

41/2"

2"

-

x

x

x

x

x

x

x

x

x

M-450

43/4"

2"

-

x

x

x

x

x

x

x

x

x

M-462

47/8"

2"

-

x

x

x

x

x

x

x

x

x

M-487

5"

2"

-

x

x

x

x

x

x

x

x

x

To order, add the overall length to the product no.: e.g.: an AQ plug 36" long is Product No. M-175-36

Margo Plugs - to Seal Drill Holes

• tightening the nut expands the rubber sleeves • plug is hollow for drainage • ball valve (sold separately) may be threaded onto end

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May 2013

Section14-Page3

Drill Hole Safety Plug Product Number

Drill Hole Size

Item

P-125

XRP

Safety Plug

P-138

13/8"

Safety Plug

P-150

EX

Safety Plug

P-175

13/4"

Safety Plug

P-187

AQ

Safety Plug

P-200

2"

Safety Plug

P-212

21/8"

Safety Plug

P-238

BQ

Safety Plug

P-300

NQ

Safety Plug

P-387

HQ

Safety Plug

Wrenches are available for above plugs.

Section14-Page4

May 2013

www.dsiunderground.com

DIAMOND SEAL® Absorbent Polymer for Lost Circulation

Description DIAMOND SEAL is a water-swellable but not water-soluble, 100% crystalline synthetic polymer. DIAMOND SEAL absorbs hundreds of times its own weight in water. It is intended for use primarily as a lost circulation material for horizontal directional drilling.

Applications/Functions • Lost circulation material for horizontal directional drilling • Prevent inadvertent returns in river crossing applications • Stabilize borehole in cobble and gravel • Stabilize unconsolidated formations

Advantages • Rapid water absorption • Effective in mitigating lost circulation • Economical-small quantity yields large volume • Easy to use • Non-fermenting

Recommended Treatment For slug treatment • Add ½ to 1 pound (0.25 - .5 kg) DIAMOND SEAL per joint As a pill: • Add DIAMOND SEAL at 10 – 20 lb/100 gallons of drilling fluid • Add DIAMOND SEAL at 12 – 24 kg/m3 of drilling fluid Treatment for Loss of Circulation or Inadvertent Returns in HDD Operations: (Prior to pumping, remove all in-line screens in circulating system) Add the following to existing drilling fluid and displace: BAROLIFT® - 0.25 – 0.5 lb/100 gallons (0.3 – 0.6 kg/m3) TM N-SEAL - 3 – 5 lb/100 gallons (3.6 – 6.0 kg/m3) DIAMOND SEAL - 10 – 20 lb/100 gallons (12 – 24 kg/m3)

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May 2013

Section15-Page1

EZ-MUD® DP Borehole Stabilizing Dry Polymer

Description EZ-MUD DP is a free-flowing, dry granular synthetic polymer containing partially hydrolyzed polyacrylamide/ polyacrylate (PHPA) copolymer. EZ-MUD DP, a water-soluble polymer, disperses and dissolves in fresh water rapidly. When mixed with fresh water, EZ-MUD DP hydrates quickly and forms a clear, viscous fluid. With its high molecular weight and optimum charge density, EZ-MUD DP provides excellent borehole stability through a coating mechanism (encapsulation).

Applications/Functions • Stabilize reactive clay and shale formations • Keep trench excavation open during the construction • Produce high viscosity solids-free slurry • Enhances rheological properties of a low-solids drilling mud • Enhance core recovery in continuous wireline coring operations • Flocculate non-reactive solids in reserve pit at low concentrations • Reduces torque and drag

Advantages • Disperses easily with minimal shear • Efficient shale/clay stabilizer and viscosifier • Imparts high degree of lubricity • Compatible with other drilling fluid additives when added in proper sequence • Non-fermenting • No petroleum distillates involved • Breaks down chemically with bleach (sodium hypochlorite) • NSF/ANSI Standard 60 Certified

Section15-Page2

May 2013

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EZ-MUD® PLUS Polymer Emulsion

Description EZ-MUD PLUS is a high molecular weight version of EZ-MUD with improved properties. EZ-MUD PLUS, a liquid polymer emulsion containing partially hydrolyzed polyacrylamide/polyacrylate (PHPA) copolymer, is used primarily as a viscosifier and borehole stabilizer to prevent reactive shales and clays from swelling and sloughing. The liquid form makes mixing easy. EZ-MUD PLUS is also added to low-solids drilling fluids to increase lubricity and to improve the carrying capacity of air/foam injection fluids.

Applications/Functions • Stabilize reactive shale and clay formations • Improve borehole and excavation stability • Enhance slurry rheological properties • Alleviate mud rings, bit balling and booting-off in clay formations • Reduce drill pipe torque and pumping pressure • Minimize rod chatter in diamond core drilling • Create “stiff-foam” and maintain foam integrity • Flocculate non-reactive solids in reverse pit at low concentrations

Advantages • Mixes easily with minimum shear in fresh water • Efficient shale/clay stabilizer and viscosifier • Non-fermenting • Cost effective - small amounts produce desired results • Breaks down chemically with bleach (sodium hypochlorite) • NSF/ANSI Standard 60 Certified

Notes • Make-up water used to mix EZ-MUD PLUS should meet the following quality: Water pH between 8.5 - 9.5 • Reduce total hardness of make-up water by adding soda ash (sodium carbonate) at 0.5 to 1 pound per 100 gallons (0.6 – 1.2 kg/m3) of make-up water. • EZ-MUD PLUS can be chemically broken down with liquid bleach in regular household concentration (5% sodium hypochlorite). Use one gallon of liquid bleach per 100 gallons (10 liters/m3) of fluid formulated with EZ-MUD PLUS. Do not use perfumed liquid bleach or solid calcium hypochlorite.

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May 2013

Section15-Page3

HOLEPLUG® Graded Sodium Bentonite

Description HOLEPLUG is a naturally occurring Wyoming sodium bentonite clay that is a sized and graded chip material used to seal and plug earthen boreholes. HOLEPLUG is available in two particle size grades: • HOLEPLUG ¾" (100% of particles pass through ¾" screen; all particles retained on 3/8" screen) • HOLEPLUG 3/8" (100% of particles pass through 3/8" screen; all particles retained on a ¼" screen)

Applications/Functions • Highly recommended for use in grouting annulus in all types of wells, particularly environmental monitoring well applications • Seal above gravel packs • Plug decommissioned boreholes • Stemming shotholes • Seal around conductor pipe • Seal lost circulation zones • Shut off artesian flow

Advantages • Prevents entry of surface water into boreholes • High swelling potential • In situ swelling to provide a superior seal with excellent casing stabilization • Easier to apply than pellets • Cost effective • Simple to apply, mixing not required • Prevents vertical movement of fluids in the hole between porous zones • Forms a permanent, flexible downhole seal • Allows hole re-entry • Rehydratable • NSF/ANSI Standard 60 certified

Recommended Treatment Plugging and Stemming Drill Holes Due to shipping and handling, a small amount of fine bentonite particles may be present. For optimum results, HOLEPLUG® should be poured over a mesh or screen with ¼" (6.4 mm) openings to “sift out” the smaller particles. The screen should be large enough (approx. 1 yd2 or 1m2) to be folded into a “V” shape to allow sifting while the product is being poured into the hole. Also, HOLEPLUG should be poured slowly. Allow approximately two minutes to pour a 50-lb (22.7 kg) bag.

Section15-Page4

May 2013

www.dsiunderground.com

HOLEPLUG® continued

Application Amounts

Amounts of HOLEPLUG® Required for Plugging Applications Hole Diameter

Hole Volume

Pounds HOLEPLUG® Needed to Fill One Foot

Feet Filled by One Bag HOLEPLUG®

Bags HOLEPLUG® Needed to Fill 100 ft

(inches)

(ft³/ft)

2

0.022

1.6

32.6

3.2

2.5

0.034

2.4

20.5

5.0

3

0.049

3.5

14.3

7.0

3.5

0.067

4.8

10.4

9.6

4

0.087

6.3

7.9

12.6

4.5

0.110

7.9

6.3

15.8

5

0.136

9.8

5.1

19.6

5.5

0.165

11.9

4.2

23.8

6

0.196

14.1

3.5

28.2

6.5

0.230

16.6

3.0

33.2

7

0.267

19.2

2.6

38.4

7.5

0.307

22.1

2.3

44.2

8

0.349

25.1

2.0

50.2

8.5

0.394

28.4

1.8

56.8

9

0.442

31.8

1.6

63.6

9.5

0.492

35.4

1.4

70.8

10

0.545

39.2

1.3

78.4

11

0.660

47.5

1.1

95.0

12

0.785

56.5

0.89

113.0

15

1.227

88.3

0.57

176.6

18

1.767

127.2

0.39

254.4

20

2.182

157.1

0.32

314.2

25

3.409

245.1

0.20

490.8

30

4.909

353.4

0.14

706.8

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May 2013

Section15-Page5

PENETROL® Wetting Agent

Description PENETROL, a water miscible, non-ionic wetting agent, is designed to counteract the sticking tendencies of clay.

Applications/Functions • Reduce or eliminate bit balling • Reduce surface tension of drilling fluid, which allows faster chip removal without continuously grinding the hard shale formations • Improve drilling efficiency by preferentially coating the bottom-hole assembly and drill string • Minimize differential sticking • Increase bit life and reduce drill pipe and bottom-hole assembly wear

Advantages • Easy to mix • Effective in low concentrations • Compatible with other Baroid drilling fluid additives • Biodegradable • NSF/ANSI Standard 60 certified

Recommended Treatment Added uniformly through entire circulation system • 1 to 4 quarts of PENETROL per 100 gallons of drilling fluid • 2.5 to 10 liters of PENETROL per m3 of drilling fluid As a slug down drill rods to counteract the sticking tendencies of clay • 1 to 2 quarts of PENETROL per drill rod • 1 to 2 liters of PENETROL per drill rod Alternate Application • Dilute 1 gallon of PENETROL with 10 gallons of water and inject one gallon of mixture per minute into the pump suction • Dilute 3.8 liters of PENETROL with 38 liters of water and inject 3.8 liters of mixture per minute into the pump suction

Section15-Page6

May 2013

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POLY-BORETM Borehole Stabilizing Dry Polymer

Description POLY-BORE is a free flowing, water-soluble, easy mixing, 100% dry granular polymer. POLY-BORE is a very high molecular weight partially hydrolyzed polyacrylamide (PHPA) polymer. When mixed with fresh water, a small quantity of POLY-BORE provides a clear, solid-free, viscous borehole stabilizing fluid for use in drilled shaft, auger drilling, horizontal directional boring, trenching excavation and reverse circulation (RC) rotary drilling. POLY-BORE is not designed to be used in conjunction with bentonite based fluids.

Applications/Functions • Provide a clay-free boring fluid • Stabilize reactive clay and shale formations • Enhance core recovery in continuous wireline coring operations • Provide high cohesiveness to bind excavated sandy soil and gravel • Facilitate the removal of drilled spoils from augers and increase excavation rate • Maximize load transfer for drilled shaft application

Advantages • Disperses easily with minimal shear • Efficient shale/clay stabilizer and viscosifier • Does not require solids control unit to clean the slurry • Promotes stable and gage borehole • Results in maximum skin friction and ultimate end bearing capacity for a drilled shaft • Non-fermenting • No petroleum distillates involved • Breaks down chemically with bleach (sodium hypochlorite) • NSF/ANSI Standard 60 certified

Recommended Treatment Drilling • Add 0.5 to 1 pound of POLY-BORE dry polymer per 100 gallons of fresh water (0.6 - 1.2 kg/m3 ) slowly through the hopper. (See Mix Instructions below) Mix Instructions • 15 to 20 minutes to allow POLY-BORE to hydrate • Measure the funnel viscosity of the polymer slurry and adjust according to required specifications Notes: • Water pH between 8.5 – 9.5 • Reduce total hardness of make-up water by adding soda ash (sodium carbonate) at 0.5 to 1 pound per 100 gallons (0.6 - 1.2 kg/m3) of make-up water. www.dsiunderground.com

May 2013

Section15-Page7

QUIK-GEL® Viscosifier

Description QUIK-GEL is an easy-to-mix, finely ground (200-mesh), premium-grade, high-yielding Wyoming sodium bentonite. QUIK-GEL imparts viscosity, fluid loss control and gelling characteristics to freshwater-based drilling fluids.

Applications/Functions • Mix with fresh water to form a low-solids drilling fluid for general drilling applications • Viscosify water-based drilling fluids • Reduce filtration by forming a thin filter cake with low permeability • Improve hole-cleaning capability of drilling fluids • Mix with foaming agents to make “gel/foam” drilling fluids for air/foam drilling applications

Advantages • NSF/ANSI Standard 60 certified • Single-sack product and cost effective • Provides lubricity for drilling fluids • Mixes easily and quickly reaches maximum viscosity • Yields more than twice as much mud of the same viscosity as an equal weight of API oilfield grades of bentonite

Recommended Treatment

Mix slowly through a jet mixer or sift slowly into the vortex of a high-speed stirrer.

Approximate Amounts of QUIK-GEL® Added to Freshwater Application/Desired Result

lb/100 gal

lb/bbl

kg/m3

Normal Drilling Conditions

15-25

6-10

18-30

Unconsonlidated Formations

35-50

15-21

42-60

Make-Up for Gel/Foam Systems

12-15

5-7

14-18

• 1 bbl = 42 U.S. gallons

Additional Information Note: • For optimum yield, pre-treat make-up water with 1 - 2 pounds of soda ash per 100 gallons of water (1.2 - 2.4 kg/m3) Section15-Page8

May 2013

www.dsiunderground.com

QUIK-GEL GOLDTM Viscosifier

Description QUIK-GEL GOLDTM high-yield viscosifier is a selectively mined, premium sodium bentonite designed for water well, minerals exploration and other industrial drilling applications. QUIK-GEL GOLD high-yield viscosifier provides an optimized grind size which results in easy mixing and rapid hydration characteristics. The enhanced viscosity development, filtration properties and resultant fluid stability make QUIK-GEL GOLD high-yield bentonite viscosifier the new benchmark in the industrial drilling applications market.

Applications/Functions • Viscosify freshwater-based drilling fluids • Mix with fresh water to form a low-solids drilling fluid for general drilling applications • Reduce filtration by forming a thin filter cake with low permeability • Improve hole-cleaning capability of drilling fluids • Mix with foaming agents to make “gel/foam” drilling fluids for air/foam drilling applications

Advantages • NSF/ANSI Standard 60 certified • Single-sack product and cost effective • Optimized grind size for enhanced mixing and yield • Easy to mix and quickly reaches maximum viscosity • Yields more than twice as much drilling fluid of the same viscosity as an equal concentration of API grade bentonite

Recommended Treatment

Mix slowly through a jet mixer or sift slowly into the vortex of a high-speed stirrer.

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May 2013

Section15-Page9

QUIK-GEL GOLDTM continued

Approximate Amounts of QUIK-GEL GOLDTM High-Yield Viscosifier Added to Freshwater Application/Desired Application/DesiredResult Result

lb/100 gal

lb/bbl

kg/m kg/m33

NormalDrilling Drilling Conditions Conditions Normal

15-25 15-25

6.3-10.5 6.3-10.5

18-30 18-30

UnconsonlidatedFormations Formations Unconsolidated

25-40 25-40

10.5-16.8 10.5-16.8

30-48 30-48

Make-Up for Gel/Foam Systems Make-Up For Gel/Foam Systems

12-15 12-15

5.0-6.3 5.0-6.3

14-18 14-18

•• 1 bbl = 42 U.S. gallons 1 bbl = 42 U.S. gallons

Additional Information Note: • For optimum yield, pre-treat make-up water with 1 - 2 pounds of soda ash per 100 gallons of water (1.2 - 2.4 kg/m3).

Packaging

QUIK-GEL GOLDTM high-yield viscosifier is packaged in 50-lb (22.7-kg) multiwall paper bags.

Section15-Page10

May 2013

www.dsiunderground.com

CORE-LUBETM Core Tube Lubricant

Description CORE-LUBE is a natural, linseed-based soft soap used as a core tube lubricant on diamond core drills.

Applications/Functions • Facilitate the core sliding into the inner tube • Lubricate the core lifter • Minimize wear on the inner tube • Formulate a non-polluting water-based solution for cleaning inner tube components and rig equipment

Advantages • Improves core recovery • Extends length of core run in broken ground • Lengthens useable life of downhole wireline components

Recommended Treatment As aid in core recovery • A handful or saturated swab of CORE-LUBE may be smeared inside the bottom of the inner tube before it is inserted into the drill rods. Also, a liberal amount may be applied to the core lifter parts. As a cleaning solution for drill rig components • Mix one quart of CORE-LUBE with 50 gallons of water or 5 litres of CORE-LUBE per m3 of water.

Packaging

CORE-LUBE is packaged in 25-lb (11.4 kg) resealable plastic pails with wire bail handles.

www.dsiunderground.com

May 2013

Section15-Page11

Unit Conversion Chart

Unit Conversion

www.dsiunderground.com

Metric Metric

Imperial Imperial

millimeter (mm) 11millimeter (mm) 0.3048 meter (m) 0.3048 meter (m) 0.9144 meter (m) 0.9144 meter (m) 1 meter (m) 1 meter (m) 1 kilogram (kg) 1 kilogram (kg) 1 tonne (t) 1 tonne (t) 1 megapascal (MPa) 1 megapascal (MPa)

0.03937 inch inch (in) (in) 0.03937 1 foot (ft) 1 foot (ft) 1 yard (yd) 1 yard (yd) 1.0936 yd 1.0936 yd 2.2046 pounds (lb) 2.2046 pounds (lb) 0.9842 ton 0.9842 ton 145 pounds/square inch (psi) 145 pounds/square inch (psi)

May 2013

Section16-Page1

USA DSI Underground Systems, Inc. 9786 S Prosperity Road West Jordan, UT 84081, USA Phone: +1-801 973-7169 Fax: +1-801 973-7172 DSI Underground Systems, Inc. 447 DuPont Rd. Martinsburg, WV 25404, USA Phone: +1-800 332-3308 Fax: +1-304 274-4194 DSI Underground Systems, Inc. 700 Technology Drive South Charleston, WV 25309, USA Phone: +1-800 547-4751 Fax: +1-304 553-0924 DSI Underground Systems, Inc. 5400 Foundation Blvd. Evansville, IN 47725, USA Phone: +1-812 214-2968 Fax: +1-888 309-0882 DSI Underground Systems, Inc. 9344 Sunrise Road Cambridge, Ohio 43725, USA Phone: +1-800 457-7633 Fax: +1-740 432-2827 DSI Underground Systems, Inc. 26161 Old Trail Road Abingdon VA 24210-7631, USA Phone: +1-276 623-2784 Fax: +1-276 623-8273 DSI Underground Systems, Inc. 1774 Mellwood Ave Louisville KY 40206-1756, USA Phone: +1-502 473-1010 Fax: +1-502 473-0707 DSI Underground Systems, Inc. 1032 East Chestnut Street Louisville KY 40204-1019, USA Phone: +1-502 583-1001 Fax: +1-502 583-7865 Canada DSI Canada Ltd. 3919 Millar Avenue Saskatoon SK S7P 0C1, Canada Phone: +1-306 244-6244 Fax: +1-306 931-3481

DSI Canada Ltd. 199 Mumford Road Unit C&D Lively ON P3Y 1L2, Canada Phone: +1-705 692-6100 Fax: +1-705 692-0441 DSI Canada Ltd. 853 Boulevard Rideau Rouyn-Noranda, QC J9Y 0G3, Canada Phone: +1-819 762-0901 Fax: +1-819 797-1367 Mexico DS International S.A. de C.V. Carretera a Base Aérea Militar No. 1002 Bodegas 13, 14 & 15 Parque Industrial FERRAN San Juan de Ocotán, Zapopan, Jalisco México CP 45010 Phone: +52-33-3366-57-94 Fax: +52-33-3366-58-03 Brazil DSI Underground Brasil Rua Um, 276 Distrito Industrial da bela Fama Nova Lima/MG, Brazil Phone: +55-31-35 42 02 00 Fax: +55-31-35 42 08 10 Chile DSI Chile Industrial Ltda. Las Encinas #1387 Valle Grande Lampa, Santiago de Chile, Chile Phone: +56-2-596 96 20 Fax: +56-2-596 96 69 Colombia DSI Colombia S.A.S Carrera 43A No. 8 sur – 15 Oficina 403 Edificio Torre Oviedo Medellín, Colombia Phone: +57-4-403 12 00 Fax: +57-4-403 12 01 Peru DSI Peru S.A.C. Calle Rodolfo Beltran No. 947 Lima 1, Perú Phone: +51-1-431 3157 Fax: +51-1-638 3201

ARGENTINA AUSTRALIA AUSTRIA BELGIUM B O S N I A A N D H E R Z E G O V I N A BRAZIL CANADA CHILE CHINA COLOMBIA C O S T A R I C A CROATIA C Z E C H R E P U B L I C DENMARK EGYPT ESTONIA FINLAND FRANCE GERMANY GREECE GUATEMALA HONDURAS H O N G K O N G INDONESIA ITALY JAPAN KOREA LEBANON LUXEMBOURG MALAYSIA MEXICO NETHERLANDS NORWAY OMAN PANAMA PARAGUAY PERU POLAND PORTUGAL QATAR RUSSIA S A U D I A R A B I A SINGAPORE S O U T H A F R I C A SPAIN SWEDEN SWITZERLAND TAIWAN THAILAND

Please Note: This brochure serves basic information purposes only. Technical data and information provided herein shall be considered non-binding and may be subject to change without notice. We do not assume any liability for losses or damages attributed to the use of this technical data and any improper use of our products. Should you require further information on particular products, please do not hesitate to contact us.

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