Roof Support Systems
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A Troubleshooting Guide for Roof Support Systems |
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Tensioned Rebar Bolts
EXCESSIVE THREAD TAKE-UP DURING TIGHTENING
EXCESSIVE BLEED OFF
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| Possible Cause | Solution |
| C.3 Residual Torque - Torque Inhibitor | Replace nuts |
| C.4 Thread Binding | If torque inhibitors are defective replace nuts. If bolt ends are sharp replace bolts |
| A.2 Severe Installation Angle | Use angle compensation device if installation angle exceeds 5-degrees |
| C.10 Plate Galling | Replace nuts/plates or use hardened washers |
| A.1 Excessive Thrust | Adjust bolter setting and instruct operator in proper installation procedure |
| C.2 Torque Inhibitor Too Strong/Weak | Replace nuts |
| A.23 Irregular Roof Surface | Use wedges and/or cap blocks to improve surface contact |
| A.8 Washer Too Soft | Replace washers |
| A.17 Plate/Washer Mismatch | Replace plates/washers |
| C.11 Plate/Nut Mismatch | Replace nuts/plates |
| A.9 Defective Threads | Replace bolts or nuts |
| Possible Cause | Solution |
| Severe Roof Loading | If widespread determine cause and upgrade support system |
| A.4 Plate/Bolt Mismatch | Use higher grade plate |
| A.2 Severe Installation Angle | Use angle compensation device if installation angle exceeds 5-degrees |
| A.12 Plate Hole Too Large | Use hardened washers or replace plates if out of specification |
| A.11 Defective Plate | Replace plates |
| A.17 Plate/Washer Mismatch | Replace plates or washers |
| C.11 Plate/Nut Mismatch | Replace nuts and/or plates or use hardened washers |
| A.8 Washer Too Soft | Replace washers |
| A.23 Irregular Roof Surface | Use wedges and/or cap blocks to improve the surface contact or use higher grade plate |
| A.3 Applied Torque Too High | Adjust bolter torque setting |
| Possible Cause | Solution |
| Severe Roof Loading | If widespread and loading exceeds bolt capacity use larger diameter or higher grade bolts |
| C.4 Thread Binding | If caused by defective threads, soft shear pins, or sharp bolt ends replace nuts and/or bolts |
| C.3 Residual Torque-Torque Inhibitor | Replace nuts |
| C.2 Torque Inhibitor Too Strong | Replace nuts |
| C.10 Plate Galling | Replace nuts/plates or use hardened washers |
| A.3 Applied Torque Too High | Adjust bolter torque setting |
| A.2 Severe Installation Angle | Use angle compensation device if installation angle exceeds 5-degrees |
| A.23 Irregular Roof Surface | Use wedges and/or cap blocks to improve surface contact |
| Possible Cause | Solution |
| C.8 Premature Tightening | Instruct operator in proper installation procedure or if torque inhibitor is too weak replace nuts |
| C.9 Plate Held Too Far From Roof | Instruct operator in proper installation procedure or if torque inhibitor is too weak replace nuts |
| C.12 Grouted Length Too Short | Lengthen the grout column or try different support system |
| A.3 Applied Torque Too Low | Adjust bolter torque setting |
| A.1 Excessive Thrust | Adjust bolter settings and instruct operator of proper installation procedure |
| B.9 Cracks In Roof | Increase the grout volume to make up for lost grout or adjust anchorage zone |
| B.4 Improper Hole/Deformed Bar Size | Do not exceed manufacturer's recommended grout annulus |
| C.6 Poor Strata-Anchorage Exceeded | Lengthen the grout column |
| B.15 Smooth Hole | Change bits or vary the drilling parameters |
| Possible Cause | Solution |
| C.2 Torque Inhibitor Too Strong/Weak | Replace nuts |
| C.8 Premature Tightening | Instruct operator in proper installation procedure |
| B.5 Improper Grout Mixing | Instruct operator in proper installation procedure |
| C.4 Thread Binding | Replace bolts/nuts |
| C.9 Plate Held Too Far From Roof On Installation | Instruct operator to hold the plate closer to the roof as recommended by the manufacturer |
| B.7 Hole too Short | Hole length should be 1" longer than the bolt length |
| C.3 Residual Torque-Torque Inhibitor | Replace nuts |
| A.3 Applied Torque Too High | Adjust bolter torque |
| Possible Cause | Solution |
| A.4 Plate/Bolt Mismatch | Use higher grade plate |
| Severe Roof Loading | If widespread determine cause and upgrade support system |
| A.23 Irregular Roof Surface | Use wedges and/or cap blocks to improve surface contact or use higher grade plate |
| A.2 Severe Installation Angle | Use angle compensation device if installation angle exceeds 5-degrees |
| C.11 Plate/Nut Mismatch | Replace nuts and/or plates |
| A.17 Plate/Washer Mismatch | Replace washers and/or plates |
| A.12 Plate Hole Too Large | Use hardened washers or replace plates if out of specification |
| A.11 Defective Plate | Replace plates |
| Possible Cause | Solution |
| A.3 Applied Torque Too High | Adjust bolter torque setting |
| C.4 Thread Binding | If caused by defective threads, soft shear pins or sharp bolt ends, replace nuts and/or bolts |
| C.2 Torque Inhibitor Too Strong | Replace nuts |
| C.3 Residual Torque-Torque Inhibitor | Replace nuts |
| C.10 Plate Galling | Use hardened washers or replace nuts and/or plates |
| A.2 Severe Installation Angle | Use angle compensation device if installation angle exceeds 5-degrees |
| A.23 Irregular Roof Surface | Use wedges and/or cap blocks to improve surface contact |
| Possible Cause | Solution |
| A.3 Applied Torque Too High | Adjust bolter torque setting |
| A.2 Severe Installation Angle | Use angle compensation device if installation angle exceeds 5-degrees |
| B.2 Defective Bolt | Replace bolts |
| A.23 Irregular Roof Surface | Use wedges and/or cap blocks to improve the surface contact or use higher grade or larger diameter bolts |
| A.9 Defective Threads | Replace bolts |
| C.2 Torque Inhibitor Too Strong | Replace nuts |
| C.4 Thread Binding | If caused by defective threads, soft shear pins, or sharp bolt ends replace nuts and/or bolts |
| Possible Cause | Solution |
| A.3 Applied Torque Too High | Adjust bolter torque setting |
| A.4 Plate/Bolt Mismatch | Use higher grade plate |
| A.23 Irregular Roof Surface | Use wedges and/or cap blocks to improve surface contact or use higher grade plate |
| A.11 Defective Plate | Replace plates |
| A.12 Plate Hole Too Large | Use hardened washers or replace plates if out of specification |
| A.17 Plate/Washer Mismatch | Replace washers and/or plates |
| C.11 Plate/Nut Mismatch | Replace nut/plate or use hardened washers |
| Possible Cause | Solution |
| C.12 Grout Length Too Short | Increase grout length or try different support system |
| B.4 Improper Hole-Deformed Bar Size | Do not exceed manufacturer's recommended grout annulus |
| B.15 Improper Mixing | Instruct operator in proper installation procedure |
| B.9 Cracks In Roof | Increase grout volume to make up for lost grout |
| C.8 Premature Tightening | Instruct operator in proper installation procedure |
| C.6 Poor Roof Strata-Anchorage | Increase grout length or vary anchorage zone |
| B.15 Smooth Hole | Change bits or vary drilling parameters |
| Possible Cause | Solution |
| C.2 Torque Inhibitor Too Strong/Weak | Replace nuts |
| C.9 Plate Held Too Far From Roof On Installation | Instruct operator in proper installation procedure |
| C.8 Premature Tightening | Instruct operator in proper installation procedure |
| B.5 Improper Mixing | Instruct operator in proper installation procedure |
| B.7 Hole Too Short | Drill hole 1" longer than the bolt length |
| A.3 Applied Torque Too Low | Adjust bolter torque setting |
| Possible Cause | Solution |
| C.2 Torque Inhibitor Too Weak | Replace nuts |
| B.5 Improper Mixing | Instruct operator in proper installation procedure |
| C.1 Bent Bolt | Straighten bolt completely after bending or use nuts with stronger torque inhibitor |
| B.14 Crooked Hole | Instruct operator in proper drill alignment while drilling |
| C.7 Viscous Grout | Replace grout or use nuts with stronger torque inhibitor |
| Possible Cause | Solution |
| C.5 Limited Thread Engagement | Replace nuts |
| C.4 Thread Binding | Replace nuts |
| C.2 Torque Inhibitor Too Strong | Replace nuts |
| A.9 Defective Threads | Replace bolts or nuts |
| Possible Cause | Solution |
| B.12 Excessive Bolt Bending | Instruct operator not to bend bolts more than 60-degrees and never more than 90-degrees |
| C.12 Grout Length Too Short | The grout length should be long enough to completely encapsulate the notch or coupled bolts should be used |
| B.2 Defective Bolt | Replace bolts |
| Possible Cause | Solution |
| C.2 Torque Inhibitor Too Strong | Replace nuts |
| C.9 Premature Tightening | Instruct operator in proper installation procedure |
| B.5 Improper Mixing | Instruct operator in proper installation procedure |
| C.12 Grout Length Too Short | Increase grout length |
| A.3 Applied Torque Too Low | Adjust bolter torque setting |
| B.4 Improper Hole-Deformed Bar Size | Do not exceed manufacturer's recommended grout annulus |
| C.6 Poor Strata-Anchorage Exceeded | Increase grout length |
| B.9 Cracks In Roof | Increase grout volume to make up for lost grout or change anchorage zone |
| B.15 Smooth Hole | Change bits or vary drilling parameters |
| C.4 Thread Binding | If caused by defective threads, soft shear pins, or sharp bolt ends replace nuts and/or bolts |
| Possible Cause | Solution |
| A.2 Severe Installation Angle | Use angle compensation device if installation angle exceeds 5 degrees |
| Severe Roof Loading | If widespread determine cause and upgrade support system |
| A.17 Plate/Washer Mismatch | Replace washers or plates |
| A.12 Plate Hole Too Large | Use hardened washers or replace plates if out of spec. |
| A.23 Irregular Roof Surface | Use wedges and/or cap blocks to improve surface contact or use a higher grade plate |
| A.3 Applied Torque Too High | Adjust bolter torque setting |
| A.8 Washer Too Soft | Replace washers |
| Possible Cause | Solution |
| A.8 Washer Too Hard | Replace washers |
| A.2 Severe Installation Angle | Use angle compensation device if installation angle exceeds 5 degrees |
| A.12 Plate Hole Too Large | Replace plates |
| A.23 Irregular Roof Surface | Use wedges and/or cap blocks to improve surface contact or use higher grade plates |
| A.17 Plate/Washer Mismatch | Replace plates or washers |
