Construction begins with rotary or rotary-percussion drilling of a borehole that passes through the unstable surface zone and seats well into competent rock behind the potential failure surface. Hole diameter is typically 1.5 to 3 inches, sized to suit the bar diameter and required grout cover. The bar, typically a Grade 60 to Grade 150 deformed bar, threaded rod, or hollow self-drilling element, is inserted with centralizers to maintain consistent grout cover around its full length.
Anchorage develops by one of three mechanisms. Mechanical anchorage uses an expansion shell at the toe of the bar, which clamps against the borehole wall when the bolt is torqued, providing immediate load capacity for tensioning. Grouted anchorage uses neat cement or polyester resin pumped into the annular space, developing bond between the bar and the grout, and between the grout and the rock. Combination systems use a mechanical anchor for immediate load and follow with full-column grouting for long-term corrosion protection and full-length bond.
Once the anchorage is set, a steel bearing plate is seated against the rock face and a nut is run down the threaded end of the bar. For tensioned bolts, the nut is torqued to a calibrated preload, typically 50 to 75 percent of the bar yield, applying immediate clamping force across the jointed rock. For passive bolts, the nut is hand-tight and the bolt develops tension only as joints try to open. Load transfers from the loose surface blocks into the bearing plate, through the bar in tension or shear, and into the competent anchor zone behind the failure surface. Bolt spacing and length are sized using rock mass classification frameworks such as Bieniawski's RMR or Barton's Q-system.
1
Geological Mapping
Drill holes into targeted rock zones based on geological mapping and engineering design.
2
Bolt Insertion
Insert steel rock bolts (mechanical, resin-grouted, cement-grouted, or tensioned bolts).
3
Grouting & Tensioning
Grout or tension the bolt, creating anchorage within competent rock.
4
Plate Installation
Install plates and nuts to clamp the rock face and reinforce surface stability.
5
System Integration
Integrate with mesh or shotcrete where containment or additional surface control is required.