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ABSTRACT: When mining at great depth, on going time-dependent deformations or unexpected rock failures due to high
stress may be experienced. In order for ground support to survive the large displacements and control the rock mass, yielding
cable bolts have been developed in South Africa and Australia. Decoupling of a significant length of the strand from the
cement grout to allow for large displacement of the reinforcement element means the system is effectively a point anchored
system. Consequently, for cable bolts the performance of the barrel and wedge anchor becomes critical to achieve effective
load transfer. Failure by sliding of anchors relative to the strand under low loads has been observed in several underground
mines in the Eastern Goldfields of Western Australia. This is attributed to a combination of poor installation practices and
corrosion. The results from a number of cable bolt barrel and wedge combinations placed within a corrosion chamber and
subsequently pull tested to determine the load-displacement response are examined. The results show that after 7 months in
the corrosion chamber the barrel and wedge used with a yielding cable bolt failed at loads significantly less than the strand
capacity. The service life can be extended to more than 10 months with the application of barrier corrosion protection. On the
other hand, galvanising of barrel and wedge anchors is not recommended.
1. INTRODUCTION
Corrosion of barrel and wedge anchors and the
consequences for the entire cable bolt performance
is poorly understood, despite the common use of
cable bolts in Australian underground mines since
the 1970s. The use of barrel and wedge anchors to
restrain plates, straps and mesh in cable bolt
reinforcing applications commenced in the early
1980s in Australian mines [1]. Recent developments
in cable bolt design have meant an increased
reliance on anchors to be serviceable for long
periods of time, especially for applications where
the strand is decoupled from the cement grout.
Anchor failures after short time durations and under
low loads have been observed in several
underground mines in the Eastern Goldfields of
Western Australia (e.g. Fig. 1). Failure is often
characterised by the barrel and wedge remaining
intact after being found on the floors of drives with
no evidence of strand rupture [1].
Approximate
original position
of strand tail
Fig. 1.
Anchors with strand receded compared with
original position observed in a WA mine [1].
The Rock
Anchoring
point
Free
Length
Fixed Anchor
Length
Barrel and
Wedge
Anchor
Cable
Tail
Borehole
Strand
Cement
Grout
Decoupling
Sleeve
Steel
Plate
Fig. 2.
Schematic representation of a yielding
cable bolt [1].
2.2. The Element (Strand)
Cable bolts commonly use a 7-wire, stress relieved,
high tensile steel strand with plain (round) wires.
Six wires are laid helically around a slightly larger
diameter central (king) wire. The regular 15.2 mm
diameter strand can be produced to provide a
number of grades that provide differing yield and
ultimate load capacities.
The yielding cable bolt under investigation
comprises of compact strand. Compact strand is
deformed following laying. This results in more
steel for the same nominal diameter and results in a
minimum yield force capacity of 255 kN and a
minimum breaking force of 300 kN. For
comparison, standard plain strand attains 213 kN
and 250 kN respectively [6]. Fig. 3 shows both
grades of cable bolt strand used in Australia.
Fig. 3.
Fig. 4.
3. LABORATORY TESTING
3.1. Preparation of Test Samples
The main component under investigation was the
hemispherical barrel and three-part wedge anchor
installed in conjunction with compact strand.
However, the opportunity was taken to concurrently
test a number of other anchors commonly used with
either compact or plain strand.
In addition, a number of corrosion protection
methods were trialled. The methods included
galvanising of the barrel and three simple and
commonly found barrier corrosion inhibitors such
as grease, bitumen and wax. Some tests were
conducted with galvanised strand. The major focus
of the testing was to determine the effectiveness of
the various corrosion protection methods for the
hemispherical barrel and three-part wedge used with
compact strand. Table 1 is summary of the test
combinations.
Barrel and
Wedge
Anchor
Fig. 5.
Decoupled Region
Anchor Region
Tensioned,
Non-grouted
Strand
Empty
Pipe
Split Pipe
Cement
Grout
Units
mg/L
mg/L
pH units
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
230,000
0.73
5.80
180,000
24,000
310
1
50
0.2
Typical anchor
strength (design)
Load (kN)
200
150
100
Failed anchor
50
0
0
10
15
20
25
30
Displacement (mm)
Strand
compact
compact
compact
compact
plain
galvanised plain
plain
compact
plain
Coating
none
grease
bitumen
wax
none
none
galvanised
none
none
4.3. Galvanised Hemispherical Barrel and ThreePart Wedge with Plain Strand
The anchor consists of the barrel galvanised to a
thickness of 75 m with the three-part wedge
remaining uncoated. The galvanised anchor
performed extremely poorly in the testing, with
failure of one sample in the 3 month test and failure
of all samples in the 7 and 10 month tests at very
low loads (less than 50 kN). Inspection of the
anchors revealed that steel corrosion of the anchor
was low, but oxidising of the galvanising was noted
by the presence of zinc carbonate on the barrel
surface (Fig. 13)
The effectiveness of zinc galvanising to protect steel
from corrosion is well known and documented.
However, zinc metal is considerably softer and
provides a rougher surface than the steel it coats.
This has the effect of increasing the friction at the
barrel/wedge interface due to the steel wedge digging
into the galvanising. This prevents wedge movement
and subsequently leads to shearing of the wedge
teeth and strand slippage. It appears minor levels of
zinc corrosion may further increase the problem.
Failure Mode
7
10
No failure
No failure
No failure
No failure
3
No failure
No failure
Wedge/strand slip
Wedge/strand slip
Failure Load
(kN)
Min
Max
22
111
27
27
Wedge/strand slip
21
47
250
Plain
Strand
200
Load (kN)
Compact
Strand
150
100
50
0
0
10
12
14
16
Displacement (mm)
10.00
9.00
8.00
7.00
Anchor
failure
Anchor
failure
Anchor
failure
6.00
5.00
4.00
3.00
2.00
1.00
0.00
Barrel &
threepart
wedge,
compact
strand
Barrel &
threepart
wedge,
compact
strand,
grease
coating
Barrel &
threepart
wedge,
compact
strand,
bitumen
coating
Barrel &
threepart
wedge,
compact
strand,
wax
coating
Barrel &
threepart
wedge,
plain
strand
Flat
barrel &
two-part
wedge,
compact
strand
Flat
barrel, &
two-part
wedge,
plain
strand
Fig. 15. Total wedge movement of anchors after 10 months in the corrosion chamber.
T max = A i
i =1
(1)