Installation of Cable Bolts in Up Holes Procedure

1. Purpose

The intent of this procedure is to establish the best practices for installing cable bolts in an up hole. This process may
include tensioning and strapping. Not all cable installations require tensioning, refer to installation prints. Please note
that strapping is covered under KMN-08-GC-PRO-00806 – Strap Installation Procedure.

2. Scope

This procedure applies to any persons installing cable bolts in stopes, or infrastructure.

3. Definitions

3.1. Cable bolt: Cable bolts are the strongest tendon used and are commonly used to support large masses of rock.
Cable bolts are much longer than standard rock bolts and rebar and are cemented into place with grout. They can
be plated and tensioned, or installed untensioned as passive support.

Figure 1 Figure 2
3.2. Grout tube: A 15mm diameter tube extended into the collar of the hole and grout is pumped through it.
3.3. Breather tube: A 5 mm diameter plastic tube installed to the toe of all up holes to expel trapped air while grouting.
3.4. Grout: a cement product that anchors the cable bolt into the hole. The force of the cable bolt against the grout
holds the cable bolt in the hole. Cable bolt capacity increases with a good grout mixture and decreases with a poor
grout mixture. The amount of water (consistency) affects the ultimate strength of the grout. Cement based grouts
can result in chemical burns. Follow all SOP’s and wear appropriate PPE.
4. Up holes

4.1. Site Preparation

4.1.1 Obtain a cable bolting layout/approved plan from your supervisor or from the engineering department.
4.1.2 Inspect work area prior to moving material in. Follow the Safe Work Permit and act accordingly.
Contact your supervisor and/or ground control if the screen is corroded, cut, torn or overloaded with
loose (screen should be in good condition prior to cable installation).
4.1.3 Ensure drilled rings are located and properly identified with painted numbers on the back and walls.
4.1.4 Order cement based on 30 kg per 10 meter hole (one and a half 20 kg bags). Use the total drilled
meters from the cable bolt layout as a guide. For example, a 500 meter job would use an estimated 75
bags of cement [500 m ÷ 10 meters x 30 kg / 20kg = 75 bags]
4.1.5 Store the covered pallets of cement in a clean dry area. DO NOT store pallets of cement outside on
surface. Transport the pallets in the dedicated steel bins.
4.1.6 Bring in all supplies as required.
4.1.7 Follow all comments on the issued layout. The standard cable bolt layout requires two cables to be
installed in each drilled hole. Determine: the length of cables required (precut or site cut), if the
cables have to be tensioned and if the area has to be screened/strapped.
4.1.8 Some layouts indicated that instruments and/or smart cable are to be installed. Report any instrument
and/or smart cable requirements on the cable bolt installation shift report. Refer to KMN-08-GC-
PRO-00818 Extensometer Installation Procedure for the proper installation of ground support
instrumentation.

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4.2. Upholes – Installing the Cables

4.2.1 Cables can be inserted either by hand or by machine.

4.2.2 If using a machine, refer to KMN-08-GC-PRO-00828 for installing reels of cable onto the machine.
4.2.3 Select the proper length cables in accordance with the layout. Pre-cut cables are 8 or 11 metres long.
Continuous cable is available in 300 metre reels and can be cut to any required length.
4.2.4 Cables longer than 11 metres are generally installed using a tractor equipped with a cable bolt pusher
(TW130). For hand installation, a four-man crew is ideal for installation of longer cables: two
positioned on the deck, one on the ground and one runner.
4.2.5 Fence off the work area as described in KOP-SAF-STD-00002 Barricades Standard.
4.2.6 Ensure the collars of the holes are clean and accessible. Do not cut the screen excessively (cutting
away ONE (1) wire should be sufficient to be able to expose the collar of the hole).
4.2.7 Install cables in a manner that minimizes the exposure of personnel working beneath ungrouted cable
bolts (retreat from far end of work area towards entranceway).
4.2.8 Tape the breather tube within 30 cm (1 foot) of the end of the cable. Slice a hole within the last 15 cm
(6 inches) of the tube. The hole must be at least 5 cm (2 inches) long. See Figure 3.

Figure 3
4.2.9 Insert the pair of cables into the hole. Ensure that the breather tube travels freely with the cables.
Ensure that the cables do not kink or become jammed. Insert the bulk cable to the end of the hole, then
withdraw it approximately 1 m, or stop pushing when approximately 2 m of a precut cable is
remaining outside the hole collar.
4.2.10 Place the grout hose between the cables, opposite the breather tube, with the end of the grout tube
close to the back or rock surface. See Figure 4 for correct placement. Tape grout hose to cables. Do
not block the end of the grout tube with tape.
4.2.11 Push the cables with the grout tube into the hole, until the leading end of the grout tube is at least 0.6
metres (two feet) into the collar of the hole. The grout tube should extend past any broken ground.
Adjust Step 4.2.9 as necessary based on ground conditions.

For precut cables that need to be tensioned: leave at least 0.7 m (2.5 feet) of cable tail hanging out of
the hole (if the cable does not reach the toe). Adjust tail according to back conditions.
OR
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For precut cables that do not need to be tensioned or for bulk cable: push the cables to the toe of the
hole. (Bulk cables are cut later in the sequence.)

Breather

Wedge

Grout tube
centered
between
cables
Figure 4 Figure 5 Figure 6

4.2.12 Ensure that the grout tube extends to within 2 metres of the floor, prior to cutting from the reel.
4.2.13 Apply foam into the collar to seal the hole against grout leakage. Foam should extend into the collar of
the hole at least 0.3 metre (1 foot) and the entire void space within the hole collar must be filled with
foam. When applying the foam wear goggles or a face shield. Empty aerosol cans are to be disposed
of at 75 shop. Open the valve on the larger canisters (10 lb and 16 lb) to relieve the pressure once the
canister is empty, and leave the valve open for safe tank disposal.
4.2.14 Wedge the cables into place using wooden wedges. Do not crimp or crush the grout or breather
tubes!!
4.2.15 Test the cables for movement. If the cables can be pulled out, more wedges are required, or the
wedges have to be hammered further into the hole collar.
4.2.16 While holding the cable, use a clove hitch knot to tie a safety rope onto the cable near the collar and
secure it to the screen. See Figure 6 for an example of a clove hitch knot.
4.2.17 Ensure that the foam still has a proper seal; be sure to check any nearby bolt holes or for large cracks
that could allow the grout to leak. Add more foam to the collar/cracks as required.
4.2.18 Cut the breather tube from the reel at a length which allows it to reach the floor at least two rings or 5
metres horizontally away from the hole location.
4.2.19 For bulk cables, move the grout and breather tubes away from the hole collar, ensuring that they do
not pulled out, and that they are not damaged. Secure them with ropes as required.
4.2.20 Follow KMN-08-CT-PRO-00301 Hot Work Procedure when cutting bulk cable with torches or
grinders. Leave the grout and breather tubes out of the way until the cables have cooled. Use thermal
camera or heat gun to check for hot spots, and execute all tasks listed in Hot Work Permit.
4.2.21 Have an operational water hose available – the spray valve has to be on the deck or basket.
4.2.22 When cutting with a grinder, use a proper face shield. Only wheels graded A-30 or better may be used
for cutting. Refer to KOP-SAF-GDL-00006 Hand Held Grinders Guideline and KOP-SAF-GDL-
00004 Portable Power Tools Guideline for tool and grinding wheel selection.
4.2.23 For bulk cables that need to be tensioned: Cut both cables at least 0.7 m (2.5 feet) or more away
from the collar of the hole, adjusting for back conditions. Ensure cuts are clean, and no slag or burrs
remain which would prevent the block, cable grips and jack from sliding freely over the cut end.
OR
For bulk cables that are un-tensioned, cables should be cut no closer than 20 cm (8 inches) from the
collar to allow the cable to be checked for load (pig tailing). Do not damage grout or breather tubes
while cutting, and ensure that the safety rope is not damaged.

4.3 Up Holes – Grouting

Caution: Failure to properly prepare the grout will result in inadequate cable bolt capacities which may result in
extremely hazardous ground conditions. This step is arguably THE most important step in cable bolting.
Respect the recipe for the type of grout you are using.

CRITICAL
!
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Caution: Portland Cement based grout is corrosive with a pH level of 12 – 14 (caustic). It can result in burns
and/or blindness. If clothing or skin comes into contact with any dry cement powder, mixed grout or any liquid
that may contain grout:
 Apply Neutralite to the affected area
 Go to refuge or lunchroom and remove any contaminated clothing
 If grout or dry cement powder enters the eyes, immediately flush with water or use an eye wash
station, and flush for at least 10 minutes. Immediately make arrangements to go to the Occupational
Health Center.
 Clean grout off exposed skin immediately. Wash with clean water and with a pH neutral or moderately
acidic soap such as Dove or Ivory
 Re-apply Neutralite to the affected area
 Contact Supervisor
 Do NOT put on contaminated clothing: use disposable coveralls and striped vests
 Go to the Occupational Health Centre for evaluation if grout has entered eyes, or if there is rash or any
evidence of chemical burns on the skin
 Wash contaminated items and clothing such as coveralls before using them again.

4.3.1 Perform a prestart on the mixer, pump and hoses. Inspect for any visible signs of damage, wear or
waste material left in the tank. Correct as necessary. Ensure all hoses are connected and free from
obstructions, and are long enough to allow the worker to not be exposed to fresh grout falling from an
uphole. Assemble the grout pump and apply form oil as required to aid in clean up. Grout can be
ejected with considerable force. Be aware of your surroundings - watch that the grout hose does not
come off the pump, or disconnect from grout tube in the hole.

4.3.2 When grouting, use the proper PPE:

 Long latex gloves
 Long latex sleeves (optional)
 Hood to protect head and neck
 Rubber apron
 Respiratory protection
 Eye protection (goggles / full face shield)
 Ensure an eye wash is readily available at the work site and in the refuge station.
 Have a supply of neutralite on hand. Mixed neutralite is good for six months
 Advise people downwind of the requirement for dust mask/respiratory protection, and of the
potential for chemical burns to exposed skin.

4.3.3 Mix one batch at a time. CONTINUOUS MIXING IS UNACCEPTABLE.

For MS grout, mix a maximum of 120 kg of grout at one time (six 20 kg bags).
Grout Water
20 kg 5.0 litres CRITICAL
80 kg
120 kg
20 litres
30 litres
!
 Measure proper quantity of water in clean 20 litre pails. Introduce water into mixer.
 Add MS Cable Grout slowly while operating the mixer at medium speed.
 Increase mixer speed and continue mixing at high speed for 3 to 5 minutes.
 Decrease mixer speed to low and continue mixing while placing the grout.
 The time between mixing and pumping of the batch should not exceed 15 minutes.
4.3.4 Ensure there are no air leaks at the pump.
4.3.5 Using vice grips, attach the grout hose from the pump to the black grout hose installed in the hole.
Clamp the hose connection firmly.
4.3.6 Set a pail of water at least two rings away from where grouting will take place. Put the end of the
breather tube into the pail of water.

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4.3.7 Start pumping the grout at a slow to moderate speed. Bubbles will be seen in the water as the grout
fills the hole and displaces the air.
4.3.8 When the bubbles stop, the hole is full OR the hose could be blocked. (Rule of thumb: a 10 m long
hole should take at least 30 kg of grout which is about ¼ of a tank if 120 kg was mixed.)
 If the bubbles stop prematurely, continue to pump until you hear the
pump start to labor. This audible change in the pump indicates that pressure is CRITICAL
building up - shut down the pump. Identify the problematic hole by ring and
hole number, and location, on your cable bolt shift report. Ground Control will !
arrange for a pull test once reports are reviewed
 If the hole is full (correct grout amount, bubbles ceased, grout in breather tube), turn off the pump.
4.3.9 Immediately bend back and kink the grout tube to ensure no grout can escape. Secure the bend with
electrical tape, tie wraps, or cable bands.
4.3.10 Disconnect the pump hose from the grout tube. Exercise caution, as the grout can be under pressure,
and it can spray as the hose is disconnected. The hoses can also whip.
4.3.11 Repeat the grout cycle (steps 4.3.5 to 4.3.10) on all adjacent holes in the ring. Ensure every hole is
grouted on a ring prior to moving to the next ring. Ensure every hole is grouted.
4.3.12 If grout begins to leak from cracks, or around the collar of a hole, or from other holes nearby, stop the
pump, crimp the grout hose to prevent leakage, and disconnect the hose from the pump. Continue
grouting other holes in the area, while waiting for ten (10) minutes to allow the grout to settle in the
leaking hole before attempting to pump again. Mark the location of the leaking hole by ring and hole
number on your cable bolt shift report. After waiting for the grout to settle, attempt to grout the hole
again, and continue to monitor for leakage. It may take several attempts to seal the cracks until the
hole can be fully grouted. Spray foam can be used if necessary to establish a proper seal.
4.3.13 If the hole cannot be properly grouted due to leakage, or the leakage is severe:
 Disconnect the grout tube and let all grout drain from the tube and the hole. The grout that has
reached the cracks will depressurize, set, and may allow the hole to be pumped later.
 Flag the hole so that is readily visible. Use paint, flagging tape or any other highly visible
markings. Red tag the cable bolt explaining the problem.
 Mark the hole information on the cable bolt shift report.
 Notify your supervisor.
 Prior to leaving the job site, and after a minimum of 8 hours curing time, attempt to grout the hole
again, following Steps 4.3.5 to 4.3.12 as necessary. If the hole cannot be grouted, notify your
Supervisor, clearly identify the hole on your shift report, and red tag the cable. The cable may
need to be removed from the hole and replaced by a Super Swellex bolt at the discretion of
Ground Control, or it may need to be fish plated (see Steps 4.3.18 and 4.3.19).
4.3.14 Prepare test cylinders – Grout samples must be taken for EVERY cable bolt installation site.
 Mark six (6) 10 cm by 25 cm test cylinders with the date, shift, work location, and the initials of
the person preparing the cylinders. Have one additional cylinder available to hold extra grout to
top off cylinders later in the process if necessary.
 Fill the six (6) test cylinders with grout half way to the top of the mold.
 Gently tap them on the side 10-15 times to release air bubbles, and then fill the cylinders to the
top, slightly overfilling as necessary. Repeat the tapping to release air bubbles.
 Close the attached cylinder covers, and wipe the outside of the cylinders clean. Relabel if
required.
 If possible, transport the cylinders to the closest Refuge Station, as soon as possible after casting
so that the grout does not have time to set before they are placed in a position to cure. IF they
cannot be transported immediately, find a safe, secure level place where the cylinders can be left
to cure, and where they are unlikely to be disturbed by blasting.
 Place the cylinders upright and level in a location within the Refuge Station (or at the job site)
where they will be not disturbed for at least an hour, and preferably 4 hours.
 Open the lids and ensure that the top surface of the grout is level with the top of the cylinders, and
that the grout has not stuck to the lid. Top up the cylinders with extra grout as necessary and clean
the inside of the lid. Close the lids once the grout is confirmed level with the top of the cylinder.
Do not move the cylinders again until the grout has hardened.
 Clearly state on the cable bolt shift report that test cylinders are to be picked up, including the
location of the cylinders either at the job site or in the Refuge Station. (Cable bolt shift reports are
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used by the Ground Control department; they will pick up the test cylinders or arrange to have
them moved to the Paste Plant lab within 3 days of them being cast).
4.3.15 Disassemble and clean up the grout pump and mixer. Remove all grout; flush system (including pump
and hoses) with water; spray with form oil.
4.3.16 Collect all garbage and dispose of it in a garbage bin.
4.3.17 Wrap empty grout bags with plastic. Exercise caution as dry cement can cause chemical burns. Wear
all PPE. Bring the empty bags wrapped in plastic to the Shaft Station. Hose down bags to suppress any
dust.
4.3.18 If a cable bolt fails during tensioning, or cannot be completely grouted and has to be removed from the
hole, follow the steps outlined below (or see Section 4.3.19 for installing a fish plate);
 Remove un-necessary personnel from the job site and isolate with barricades
 Slide a plate over the cable bolt (standard swellex plate, cable bolt plate)
 Install a barrel grip and wedge, OR install wedges in a standard cable bolt plate.
 Obtain a long 5/16” chain, and clevises, and attach the chain to the cable bolt ABOVE the plate,
being careful not to allow the weight of the chain and plate to pull the cable out of the hole
 Use a clevis to attach the other end of the chain to the scissor deck or other piece of suitable
mobile equipment.
 Remove personnel from the deck, and personnel not required to operate the mobile equipment
are to retreat a safe distance away, longer than the length of the installed cable
 The equipment operator, working from the seat at the front of the unit, will slowly lower the
deck, to pull on the cable and drop it onto the deck.
 Once the deck is fully lowered, raise the mobile equipment leveling jacks, then slowly drive the
unit away from the cable ring until the entire length of the cable is safely out of the hole
 Check the back and adjacent holes for any other hazards (hanging grout tubes, torn screen,
loose), then from a safe position, cut the removed cable into manageable pieces, following all
appropriate procedures (Hot work permit, Portable Grinders Guideline, etc.).
 Wet the area down, use heat gun or other devices and ensure no hot spots remain which could
ignite flammable refuse.
4.3.19 If a cable cannot be removed from an un-grouted hole, and Ground Control confirms that a Super
Swellex bolt does not have to be installed, install fish plates on any holes that have not been grouted
(as identified in step 4.3.13).
 Ensure wedge and foam are still supporting cable.
 Drill two holes into solid ground, the proper distance apart for the fish plate being used.
 Cut the grout and breather tubes at the collar, and then cut the safety rope off.
 Carefully cut the cable bolts as close as possible to the collar of the hole, staying out of the line
of fire should the cables unexpectedly fall out.
 Install the fish plate with eye bolts. If eyebolts are unable to reach solid ground, use rebar.

4.4. Clean Up
4.4.1 Clean up usually is done during the next shift. However, it can start at a minimum of 45 minutes after
grouting has been completed on the last hole, if the grout is set on the first hole. As a precaution, all
PPE must be worn to reduce the risk of chemical burns.
4.4.2 Cut 1.5 metres (5 feet) off of the end of the grout hose, beginning with the hole which was grouted
first, and retreating towards the hole that was grouted last. Ensure that the grout hose is full of cement
and that the grout is hard and does not run out of the hose.
 If grout leaks from the hose, stay out of the “line of fire”, and while avoiding contact with the
grout, immediately crimp the hose to prevent any further spill, and do not cut any other grout
tubes until the grout has been allowed to set fully, fence off the area and notify your Supervisor.
Report any leakage of grout on the Cable Bolt Shift Report, including ring and hole number.
 If the hose is empty, it was probably never grouted. Attempt to grout the hole, starting at Step
4.3.1. If the hole cannot be grouted, notify your Supervisor, and report that the hole could not be
grouted on the Cable Bolt Shift Report, including ring and hole number.
 If the hose is full of hardened grout, cut the breather tube and grout hose as close to the collar as
possible. The grout hose may be cut in 1.5 metre lengths to help with garbage removal.
4.4.3 Leave any cables to be tensioned as they were installed, and remove the wooden wedges, or cut them
flush with the collar to ensure that they do not interfere with proper tensioning
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OR
If the cables do not require tensioning, any cable within 2.5 metres of the floor is to be cut flush with
the collar. Cables higher than 2.5 metres from the floor should be cut 8 to 10 cm from the collar to
allow the cables to be monitored for load (pig tails or unbraiding of the cable).
4.4.4 Collect all garbage including unsalvageable grout hoses, and dispose of it in a garbage bin. Wet down
any surface or container that may have come in contact with either dry cement powder, or with mixed
grout, and any flammable material in the bin which could come into contact with hot slag or cable
ends.
4.4.5 Wash down work area.

4.5. Strapping the Cables

4.5.1. Follow KMN-08-GC-PRO-00806 – Strap Installation Procedure and any specific instructions
contained in the installation prints. Ensure that the underlying screen is intact prior to installing straps,
and replace the mesh if required. If placing new screen or straps, ensure that the cables are passed
through the appropriate hole(s) in the screen so that the screen will meet the back or wall without
stretching or distortion, and to ensure that the cables are not bent or trapped behind the screen,
preventing proper tensioning.

4.6. Tensioning the Cables

4.6.1. Ensure the wooden wedges used to temporarily hold the cables in the
hole have been removed/cut, and that the cable tails are free to be
separated to the full width of the collar of the hole. This may require
some of the spray foam to be cut or scaled out of the way.
4.6.2. Install tensioning block and grips onto the cable. One cable runs through
each hole in the block. Slide grips onto each cable. Push the block
firmly into contact with the screen, straps (if installed) and rock. Snug
wedges with 1” diameter pipe until they are pushed tightly into the block. DSI’s CTS cable bolting jack
4.6.3. Slide the cable tensioner on the cable tails sequentially. manual Figure 8
4.6.4. Tension EACH cable to a maximum of 2.5 tons per cable strand (5
tonnes for the hole) using the designated pressure for the jack being used.
4.6.5. If the block moves unevenly, repeat tensioning each cable until the block is tight to the back or wall and
both cables are equally loaded. Ensure that the jack is not at “full stroke” when the final tension is
reached, as the cable may NOT be tensioned. Reset the jack by retracting the ram and repositioning it on
the cable, and confirm that the proper tension has been achieved between the jack and the underlying
rock, not between the plate and the jack, or jack and wedge.
4.6.6. Report any issues including cables which pull out of the hole during the tensioning process on shift end
reports, to your Supervisor, and ensure that they are documented in the Ground Control log book in
CPCR.
4.6.7. Cut the cables no closer than 10 cm (4 inches) from the grips, and no further than 15 cm (6 inches) from
the block. Cutting the cables too close to the grip could result in a premature failure of the system
under load. Do not heat the grips with the torch – they could slip. Follow KMN-08-CT-PRO-00301 Hot
Work Procedure, including wetting down if using torches. Use a heat gun or thermal imaging camera to
check for hot spots, and follow proper fire watch processes.
4.6.8. Collect all garbage and dispose of it in a garbage bin. Wet down the bin if there is any flammable
material in the bin which could come into contact with hot slag or cable ends, or if there is any risk of
coming in contact with dry cement powder, or fresh grout.
4.6.9. Remove the barricade(s).

5. Related Documents
None

6. Reference Documents

KMN-08-CT-PRO-00301 Hot Work Procedure

KMN-08-GC-GDL-00801 Ground Support Guidelines
KMN-08-GC-PRO-00806 Strap Installation Procedure
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 Installation of Cable Bolts in Up Holes Procedure

KMN-08-GC-PRO-00818 Extensometer Installation Procedure

KMN-08-GC-PRO-00827 Installation of Cable Bolts In Down Holes
KMN-08-GC-PRO-00828 Installation of Cable Reels into Cassettes
KMN-08-GC-SWI-00001 Ground Stability Assessment Standard Work Instruction
KOP-SAF-STD-00002 Barricades Standard
KOP-SAF-GDL-00004 Portable Power Tools Guideline
KOP-SAF-GDL-00006 Hand Held Grinders Guideline

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