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Minova MAI Self Drilling SystemsInstallation Manual
THE EARTH. UNDER CONTROL.
2© 2017 MINOVA GLOBAL. ALL RIGHTS RESERVED
Preface Please read this installation manual carefully before using this product to ensure a safe and successful installation of the Minova MAI Self Drilling Systems and any applicable accessories (collectively, the “Prod-ucts”). Every person involved in the installation and assembly must strictly observe not only this manual and operating instructions but also the safety and accident prevention rules and regulations valid at the place of use.
DANGER! Incorrect storage, assembly, installation or use of the Products may endanger life and limb of the operator, support personnel and third parties or cause damage to the drill rig or other important auxiliary equipment. It could also potentially result in negative effects on the stability of the entire structure.
Warranty and Liability
• Our General Terms and Conditions apply to all Product sales and set forth Minova’s warranty and limit its liability. At the latest the purchaser will receive a copy upon conclusion of the sales contract. • Please note that the manufacturer’s warranty is no longer valid if the Products are not used in compliance with these instructions. Among others, any of the following will invalidate the warranty:
• Improper storage • Incorrect installation • Useofanycomponentpartoranyaccessorywhichisnotidentifiedasagenuine Minova Product or which is not included in the Minova Products delivery • Failure to observe the instructions of this manual • Insufficientmonitoringofdrillingrigcomponentssubjecttowear • Unauthorized structural changes to the product, including welding, cutting, bending and/or application of any coating method (e.g. galvanization) • Unforeseendisastersduetoexternalinfluencesorforcemajeure • The installation or use of any Product that is obviously damaged or in poor condition
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Safety instructionsAny failure to follow this manual and applicable safety regulations could compromise safety and Product performanceandmustberectifiedimmediately.Usershouldkeepacopyofthisinstallationmanualavailable on site at all times.
Operating personnel
1.Qualification:Mentalandphysicalfitness,abletoresponsiblyandreliablyperformtheassignedtasks.Proofoftherequiredcapabilitiesandtheexplicitpermissionbytheimplementingcompanytocarryoutthework.Theminimumageofmachineoperatorsis18years.
2.Onlytrained,instructedandexperiencedpersonnelmayworkwiththeProducts.Thepersonor persons responsible for assembly, installation and installation procedures must be clearly definedbeforecommencingwork.
3.PersonnelintrainingmayonlyworkwiththeProductsunderthesupervisionofexperiencedspecialized personnel.
General safety instructions
1.Alwayswearapprovedpersonalprotectiveequipmentforhands,feet,eyesandears(“PPE“) whenworkingwiththeProductsoranydrillrigorinitsvicinity.Theuserwhoisassembling andinstallingtheProductsmustensureallinvolvedhaveandusetherequiredandappropriate PPE.Allexistingsafetydevicesassociatedwiththedrillrigmustberegularlycheckedandtested in order to ensure their correct function. 2.DonottouchanyrotatingpartsoraccessoriesduringtheinstallationoftheProducts.Make sure that the drill hammer cannot be accidentally started during assembly and installation of the Products. 3.Ensurethattheflushingandgroutinghosesarelaidoutwithoutkinksanddonotrunover sharp edges. For changes in direction, the bending radius must be at least six times the outer hose diameter.
WARNING! Injectionpumpsarehigh-pressurepumps–useonlyreinforcedhoses and a manometer!
4.Priortocommencingwork,theusermustmakesurethataworkablegroutmixisreadyforuse,thatthehoseiscompletelyleak-freegivingspecialnoticetotheconnections,andthattheinsi-deofthehoseissufficientlymoist.
5.Priortolooseninganyconnectionswithinthegroutingandflushingsystem,e.g.pumps,hosesetc., ensure that these have been depressurized.
6.Donotoperateanyflushingorgroutingpumpwithoutamanometer.
4© 2017 MINOVA GLOBAL. ALL RIGHTS RESERVED
Introduction CAUTION! - Please note!
Before installing or using the Products, carefully read the section “Safety Instructions” on the preceding page of this manual so as not to endanger life and limb of the operator, support personnel or any third party,aswellastopreventdamagetothedrillingrigorotherauxiliaryequipment.
Theinstallationmanualassumesthattheoperatorhasasolidunderstandingandworkingknowledgeofdrilling and grouting operations.
Misuse or improper installation or use of the Products will invalidate all waranties and release Minova of any liability.
Proper use
For layout, assembly and installation of the Products, the standards and regulations valid at the place of use apply. All structures must be so designed to provide redundancy.
Soil and rock nailing
SoilandrocknailingisaconstructionmethodusedtomaintainorenhancethestabilityofsoilorrockmassesbyinstallingSoilorRockNails(anchors)inaccordancewiththeprovisionsoftheexecutionofgeotechnicalworks.Anchorages(sometimesincombinationwithotherelementssuchasshotcrete,drainagesystems,retainingwallsetc.)createasupportingstructureofreinforcedsoil/rockmasses,whoseanchorsareprimarilysubjectedtotensilestress.Inaddition,theymayalsobesubjectedtobendingandshear stress.
ThegeneralpriniciplesfortheexecutionofsoilnailingarespecifiedinEN14490.
The Minova MAI Self Drilling System may be used for:
• TemporarySoilandRockNails:Servicelifeofupto2years• PermanentSoilandRockNails*:Servicelifeofupto50yearsandmore,dependentontheground
conditions with or without additional corrosion protection
Typicalsoilorrocknailingapplicationsinclude:
• Stabilization of slopes and construction pits• Tunnelling (forepoling, spiling, face bolting, radial bolting)
The system comprises the following dimensions and types:
*InordertoreducethecorrosionrateMinovaMAISelfDrillingSystemsarealsoavailablewithhot-dipgalvanizationorTwinCoat coating. For additional information, please refer to the Minova MAI Product Catalogue and the Minova MAI Design Guide.
Dimensions TypesR25 R25NR32 R32L, R32N und R32SR38 R38NR51 R51L und R51N
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Micropiles
Micropiles are load-bearing elements transferring tensile, compressive or alternating loads into the ground.Inaddition,theymayalsobesubjectedtobucklingloads,inparticularinsoftground.
ThegeneralprinciplesfortheexecutionofmicropilesarespecifiedinEN14199.
The Minova MAI Self Drilling System may be used as Self Drilling Micropiles for:
• Temporary micropiles: Service life up to 2 years • Permanentmicropiles*:Servicelifeofupto50yearsandmore,dependentontheground
conditions with or without additional corrosion protection.
Typical micropile applications include:
• Foundation of new structures • Underpinning of existing foundations • Buoyancy control for structures below ground water level • Root piles in tunnelling
The system comprises the following dimensions and types:
*InordertoreducethecorrosionrateMinovaMAISelfDrillingSystemsarealsoavailablewithhot-dipgalvanization or TwinCoat coating. For additional information, please refer to the Minova MAI Product Catalogue and the Minova MAI Design Guide.
Dimensions TypesR32 R32N und R32SR38 R38NR51 R51L und R51NT51 T51ST63 T63NT76 T76N und T76ST111 T111L und T111N
6© 2017 MINOVA GLOBAL. ALL RIGHTS RESERVED
The Minova MAI Self Drilling System can be used bothasSelfDrillingSoilandRockNail(SRN)orSelf Drilling Micropile (MIP). It offers reinforcement solutions for unstable ground conditions such as sand, gravel, silt, clay and soft to medium hard and fracturedrock.Forprojectsfacingsuchgroundconditions, the Minova MAI Self Drilling System pro-videsanefficientandcost-effectivereinforcementsolution.
The system features a hollow bar, which is used as adrillstringfordrillingeitherwithwaterflush,airflushorcementgroutflush.Thehollowbarisfittedwith a left-hand or right-hand R-thread or T-thread for easy extension and connection to conventional rockdrillingequipment.
The hollow bar is manufactured from seamless or welded steel tubes. The R-thread according to ISO standards and the T-thread according to factory standard are formed in a cold rolling process.
The hollow bars can be extended using couplers. Our patented standard couplers ensure a safe connection of the hollow bars to optimally transfer the impact energy from the drill hammer to the drill bit.Asealingringinthecentrestopminimizesflushspillage during drilling.
The nuts are manufactured with a spherical cap on at least one end to compensate for deviations of the borehole angle with respect to the plate surface.
Thedomedorflatplatesfeatureachamferedboretoensurefirmseatingofthenut.
All system components are rigorously tested ac-cordingtostringentfactorystandardsandISO9001toensurethatthespecificationsaremet.
Thesacrificialdrillbitsignificantlyenhancestheproductivity of the installation process. In order to improveperformanceandcost-effectiveness,proj-ect data are being collected from around the world. Continuous optimization of our drill bits is a primary concern to further improve the penetration rate and bitqualitywhileatthesametimereducingmanufac-turing costs.
For an improved corrosion resistance, Minova MAI Self Drilling System components are either hot dip galvanizedorfittedwithaTwinCoatcoating(hot-dipgalvanization with an additional dual epoxy coating). Product lines with and without technical approvals are available.
Minova MAI Self Drilling Soil and Rock Nail and Micropile Systems
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© HABAU Hoch- und Tiefbau Gesellschaft mbH
The system consists of the following components:
Nutsforanchoringandlocking
Flat plates or domed plates for connection to the structure
Protection tube
Hollow bars of various diameters with rolled continuous left-hand
or right-hand threads, available in standard lengths of 1m, 2m, 3m, 4m
and 6m
Couplers to connect and extend the hollow bars, with a centre stop
for improved load transfer and sealing
Spacers
Grout or cement
Drill bits of various diameters and typestofittherespectiveground
conditions
Soil Nail Micropile
8© 2017 MINOVA GLOBAL. ALL RIGHTS RESERVED
CE-certifiedsystems(withEuropeantechnicalassessments)
SoilandRockNails• EuropeanTechnicalAssessmentETA-08/0277
Micropiles• EuropeanTechnicalAssessmentETA-11/0134
Value systems (without technical approvals)
• Systems with R-threads (typically used as Soil andRockNails)
• Systems with T-threads (typically used as Micropiles)
National technical approvals
SoilandRockNailsAustria• BMVIT-327.120/0014-IV/IVVS2/2016
Micropiles Austria• BMVIT-327.120/0015-IV/IVVS2/2016
SoilandRockNailsGermany• National Technical Approval for temporary soil
androcknailsDlBtZ-34.713-080277
SoilandRockNails,MicropilesPoland• AT/2016-02-3278
©Geomek
Our product range of Self Drilling Systems comprises the following product lines:
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Minova MAI Self Drilling Soil and Rock Nails SRN
MinovaMAISelfDrillingSoilandRockNailsconsistofaself-drillinghollowbarwitharolledcontinuousthread as load-bearing element embedded within a grout body.
Theyarepredominantlysubjectedtotensilestress,butmayalsobesubjectedtobendingandshearloads.
Ingeotechnicalengineering,SoilandRockNailsareusedtostabilizenaturalorartificialslopesortosupport structures e.g. retaining walls.
Inordertofurtherstabilizethesurfaceoftheslopeorrock,varioussupportsystemse.g.flexiblereinforcingmeshes or geotextiles may be installed that are held in place by the head plates of the nails.
Inundergroundapplications,SoilandRockNailsarepredominantlyusedforforepoling,spiling,facebolting and radial bolting.
Inbothcases,theMinovaMAISelfDrillingSystemsprovideidealsolutions.SoilandRockNailsaretypically grouted along their entire length.
©SST-SchusterSprengtechnikGmbH © GEOS Spezialbau GmbH
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Minova MAI Self Drilling Micropiles MIP
Micropilesaresmalldiametergroutedpiles(typicallylessthan300mm)transferringcompressive,tensileoralternatingloadsintothesurroundingground.Inaddition,theymayalsobesubjectedtobucklingloadsin particular in soft ground.
Minova MAI Self Drilling Micropiles consist of a self-drilling hollow bar with a rolled continuous thread as load-bearing element that is embedded within a grout body. Dependent on the ground conditions, Self Drilling Micropiles are designed either as end-bearing or friction piles.
The main areas of application include:
• Foundation of new structures• Underpinning of existing foundations • Minimizing settlements• Buoyancy control for structures below groundwater level
Self Drilling Micropiles are typically installed via simultaneous drilling and grouting using cement grout as theflushingmedium.Particularlyincohesionlessorunstablegroundconditionse.g.sand,clayorgravel,thisisthefastestandmostefficientinstallationmethodformicropilesystems.Comparedtoothermethods,smallerdrillingequipmentcanbeused.ThusSelfDrillingMicropilesareideallysuitedforprojectswithlimit-edaccess,confinedspacesorlowheadroomconditions.
©Geomek© HABAU Hoch- und Tiefbau Gesellschaft mbH
© 2017 MINOVA GLOBAL. ALL RIGHTS RESERVED
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Minova MAI offers two product lines, the CE-line or nationally approved products and the Value-line.
The CE-line is based on the European Technical AssessmentsforSoilandRockNails(ETA-08/277)andMicropiles(ETA-11/0134).Inaddition,anumberof national technical approvals have also been granted. For more detailed information, please refer tothechapter“Certification”sectiononpages23and 24.
TheValue-linemeetsrequirementsatareasonableprice. The products of the Value-line do not have technical approvals. Both product lines are produced in compliance withtheregulationsofISO9001.Inbothlines,thecouplersandnutstransfertheloadsspecifiedforthe respective system.
Hollow barsThe system consists of one or several coupled hollowbarsfordrillingwithwaterorairflushorfor simultaneous drilling and grouting. The hollow bar features a left-hand or right-hand R-thread (rope thread) or T-thread (trapezoidal thread) for easy extension and connection to all conventional drill rigs. It is manufactured from seamless or welded steel tubes. The R-thread according to ISO standards and T-thread according to factory standard are both cold formed.
CE-line and approved systems: Only seamless tubes are used. We purchase the tubes from European suppliers approved according toETAG013.
Value-linie: For the Value-line, seamless or welded tubes are used. The material is purchased exclusively from carefully selected suppliers with proven expertise in quality.
Extension couplersThe couplers are used to extend the hollow bars. Therequiredlengthoftheload-bearingelementcan thus be achieved also in cases of limited drill rig feed lengths or low headroom conditions. All couplers are so designed as to safely transfer the specifiedsystemload,withthefacesofthehollowbars bearing against each other to ensure safe energy transfer between the hollow bars and the drill bit without affecting the couplers mechanically.
CE-line and approved systems: Only seamless tubes are used. We purchase the tubes from European suppliers approved according toETAG013.ThecouplersarefittedwithanR-thread or T-thread to ensure safe connection of the hollow bars.
Value-line: For the Value-line, seamless or welded tubes are used. The material is purchased exclusively from carefully selected suppliers with proven expertise in quality.
Minova MAI Self Drilling Systems - Components© GEOS Spezialbau GmbH
12© 2017 MINOVA GLOBAL. ALL RIGHTS RESERVED
For the Value-line, the designer/customer is free to choose between two options:
• Standard couplers with an R-thread or T-thread dependent on the thread of the bar used
• Anewthreaddesignallowstosignificantlyreduce the length of the coupler for R-threads thus offering improved economy without impairingthespecifiedsystemperformance(LCcoupler).
PlatesThe steel plates feature a chamfered bore allowing an angle of deviation of 5 degrees in all directions.
CE-line and approved systems: The technical approvals prescribe the use of specificplatesforeachhollowbartypedependentonitsuseasSoilandRockNailorMicropile.
Value-line: The designer/customer is free to choose from among a variety of plates dependent on the requirementsofthespecificproject.
NutsThe nuts transfer the load from the plate into the hollow bar. They feature a spherical cap on at least one end to compensate for angle deviations. All nuts are so designed as to ensure safe transfer of the specifiedsystemload.
CE-line and approved systems: The technical approvals prescribe the use of specificnutsforeachhollowbartype.Thenutsfeature an R-thread or T-thread to securely connect to the hollow bars.
Value-line: The material is purchased exclusively from carefully selectedsupplierswithprovenexpertiseinquality.For the Standard-line, the designer/customer is free to choose between two options:
• Standard nuts with R-thread or T-thread dependent on the thread of the bar used.
• A new thread design enables nuts for R-threads to be produced more economically without impairingthespecifiedsystemperformance(LCnut).
Nail and pile neck protection tube• Protectiontubesforsoilandrocknails(plastic
tubes)areavailableuponrequest.
• Pileneckprotectiontubes(plasticorsteeltubes)areavailableuponrequest.
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Minova MAI Self Drilling Systems - AccessoriesSacrifi cial drill bitThe correct selection of the drill bit dependent on the geological conditions on site is essential to ensuring a productive and cost-effective installation of the Self Drilling System.
Conventional drill bits are designed for longevity. Drill bits for the Minova MAI Self Drilling System mustmeetthefollowingrequirements:• The stability of the drill bits enables safe drilling
oftheboreholedowntotherequireddepth.• Since the drill bit is used for one borehole only
(sacrificialdrillbit),theservicelifeshouldmeetbutnotsignificantlyexceedtherequirementssoas to ensure cost-effectiveness.
• The drill bit type used and, in particular, the inserts are dependent on the geological conditions on site.
• The drill bit diameter is dependent on the design requirementsandthespecificationsdefinedinthe approvals.
Minova MAI offers a wide range of drill bits suitable for diverse geological conditions.
Drill bit adaptersDrillbitadaptersincreaseflexibilitybyallowingthe use of drill bits designed for other hollow bar dimensions.
SpacerSpacers are used to centre the hollow bars within the borehole and to ensure the correct grout cover of the load-bearing element according to therelevantstandardsandasspecifiedintheapprovals.
Coupling boxesCoupling boxes (crossover couplers) must be installedbetweentheshankadapterandthehollow bar. Since this section of the drill string is directlyandcontinuouslysubjectedtotheimpactenergy of the drill hammer, our coupling boxes are manufactured from hardened steel and intended for multiple use.
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All coupling boxes feature a centre stop to ensure the direct transfer of the impact energy to the face ofthehollowbaraswellasflatsforeasylooseningof the connection. Extension couplers may not be usedascouplingboxes,sinceadamagedshankadapter thread can cause damage to the thread in the extension coupler and negatively affect the load-bearing capacity of the system.
Grout swivelsThe grout swivels consist of a grout body and a swivelshaftandareattachedtotheshankadapter.A large variety of grout swivels for all standard types ofshankadaptersisavailable.Thegroutswivelsare suitable for simultaneous drilling and grouting.
Pull test equipmentA CE-approved pull tester is available to test the self-drilling nails and piles after installation of the system and curing of the grout body.
MAI M400NT und M440GE grout pumpsMinovaMAIrecommendstheuseoftheM400NTgrout pump or, for geotechnical applications, M400GEtoproduceagroutmixturewithacontrolled water/cement ratio.
TheM400NTpumpisgloballythemostwidelyusedpump in tunnel construction.
• Proven technology for a long service life• Easy handling and maintenance• User-friendly operation• Rugged design
TheM400GEgroutpumpistheresultofdecadesof experience and sets new standards in process security.
• Multi-purpose machine• Intelligent control system• Innovative water and dry material management
© 2017 MINOVA GLOBAL. ALL RIGHTS RESERVED
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Product specifi cation and caracteristic load-bearing capacities of the hollow bar system
Line ParameterType R Type T
R25 R32L R32N R32S R38N R51L R51N T51S T63N T76N T76S T111L T111N
1 Nominal diameter Da, nom
mm 25 32 32 32 38 51 51 51 63 76 76 111 111
2 Outer diameter Da mm 24.7 31.3 31.3 31.3 38.0 50.0 50.0 51.9 64.9 75.4 75.4 111.0 111.0
3 Inner diameter Di 1) mm 14.0 20.6 18.5 15.0 19.0 33.3 30.2 26.6 40.6 51.0 44.0 85.0 75.5
4Nominal cross sectional erea S0
2)mm2 300 350 430 520 750 900 1070 1325 1720 1870 2400 3185 4395
5 Nominal mass m 3) kg/m 2.35 2.75 3.4 4.1 5.9 7.05 8.4 10.4 13.5 14.7 18.85 25.0 34.5
6 Relative rib area fR - 0.12 0.24
7 Nominal yiel load Fp0.2,nom
kN 150 160 230 280 400 450 630 750 900 1200 1500 2000 2750
8Nominal tensile load-bearing capacity Fm, nom
4)kN 200 210 280 360 500 550 800 1050 1400 1600 1900 2640 3650
9 Yield strength Rp0.2 5) N/mm2 500 460 530 530 530 500 590 570 520 640 630 630 630
10 Tensile strength Rm 5) N/mm2 670 600 650 690 660 610 750 790 810 860 790 830 830
11 Rm / Rp0.26) - ≥1.15
12 Total elongation at maximum load Agt
% ≥2.5 ≥5.0
13 Fatiquestrength2σa 7) N/mm2 ≥120 ≥100
14Notch effect according to EN 1993-1-9
N/mm2 90 70
15 Bond strength tak8)
N/mm2 ≥2.8 ≥5.3
16 Moment of inertia I 9) mm4 11200 25800 29800 33300 75700 179000 211000 215000 480000 863000 977000 3580000 4110000
17 Thread - ISO10208 ISO1720 Factory Standard
Legend1) Mean value2) Calculated based on nominal mass m, S0=103m/7.853)Allowabledeviation-3%to+9%4) Characteristic value as 5% fractile5) Calculated based on nominal force and nominal cross sectional area, rounded value6)Characteristicvalueas10%fractile
ModulusofelasticityE≈205000N/mm2
7) DeterminedatanupperloadofFup=0.7*Fp0.2,nom forthehollowbar,couplerandanchorage80N/mm2
8)Characteristic value, determined in pull-out tests. The valuesarebasedonameanvaluewithaslipof0.01,0.1and1.0mmandacylindercompressivestrengthofcementgroutof≥40N/mm29) Determined in bending test. Relative to a modulus of elasticityof205000N/mm2 and reduction by 5% to takeintoaccountdeviationsinthemasstolerances
Technical Data of the approved systems
takeintoaccountdeviationsinthemasstolerances
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16© 2017 MINOVA GLOBAL. ALL RIGHTS RESERVED
Couplers and nuts
Type R
Type T
Type R - LC Coupling and nuts
1) Locknutsofhalftheheightmaybedesigned2) Hexagonal nut3) Ringnutø160mmwith4flats
ComponentType R
R25N R32L R32N R32S R38N R51L R51N
Coupler
Outer diamter mm 33.7 42.4 42.4 42.4 51.0 63.5 63.5
Length mm 150 145 145 190 220 170 220
Minimum torque Nm 300 500
Nut
Height 1) mm 35 45 45 45 60 85 85
Width across �ats AF mm 462) 462) 462) 462) 502) 752) 752)
Minimum torque Nm 300 500
ComponentType T
T51S T63N T76N+S T111L+N
Coupler
Outer diameter mm 70 84 95 140
Length mm 160 180 220 250
Minimum torque Nm 500
Nut
Height 1) mm 70 75 80 120
Width across �ats AF mm 752) 902) 1002) 1503)
Minimum torque Nm 500
ComponentType R - LC
R25N R32L R32N R32S R38N R51L R51N
Coupler
Outer diameter mm 33.7 42.4 42.4 42.4 51.0 63.5 63.5
Length mm 90 90 90 110 100 120 140
Minimum torque Nm 300 500
Nut
Height 1) mm 35 45 45 45 60 85 85
Width across �ats AF mm 462) 462) 462) 462) 502) 752) 752)
Minimum torque Nm 300 500
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Plates
Type R
Type T
ComponentType R
R25N R32L R32N R32S R38N R51L R51N
Domed plate
A mm 150 150 200 200 300 - -
B mm 8 8 8 10 12 - -
ø C mm 30 35 35 35 41 - -
D mm 25 25 28 28 28 - -
Flat plate
A mm - - 95 120 140 150 180
B mm - - 25 30 35 40 45
ø C mm - - 35 35 41 56 56
ComponentType T
T51S T63N T76N T76S T111L T111N
Flat plate
A mm 200 230 250 250 300 350
B mm 50 55 60 60 80 90
ø C mm 60 80 90 90 130 130
A
D
ø C ø C
A
A
B B
A
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Protection tubes
Soil and rock nails
Micropiles
Component DimensionType R
25 32 38 51
Plastic tube (smooth or corrugated)
Outer diamteterA mm >32 >32 >38 >51
Wall thickness d mm 0.8 0.8 1 1
Length L mm >200 >200 >200 >200
Component DimensionType R Type T
32 38 51 51 63 76 111
Steel tube
Outer diameter A mm 76.1 76.1 88.9 88.9 108 114.3 159
Wall thickness d1) mm 2.9 2.9 3.2 3.2 3.6 4.5 4.5
Length L mm 420 480 610 450 500 630 650
Plastic tube (smooth or corrugated)
Outer diameter A mm ≥63 ≥75 ≥ 80 ≥ 80 ≥ 90 ≥ 100 ≥ 160
Wall thickness d mm ≥ 1 ≥ 1 ≥ 1.5 ≥ 1.5 ≥ 1.5 ≥ 1.5 ≥ 2.0
Length L mm 300 300 300 300 300 300 300
1) For temporary micropile applications, the wall thickness of the steel tube may be reduced by 1.0 mm.
© 2017 MINOVA GLOBAL. ALL RIGHTS RESERVED
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Installation of Minova MAI Self Drilling Systems
Inunstablegroundconditions,conventionalsoilandrocknailsandmicropilesaretypicallyinstalledusingcasing drilling whereby the casing is retrieved during grouting.
MinovaMAISelfDrillingSystemsofferamoreefficientalternative,particularlyinunstablegroundconditions. The hollow bars serve as drill strings and after drilling as supporting elements. The hollow bars canbedrilledusingwaterorairflushorbymeansofsimultaneousdrillingandgrouting.
SoilandRockNailsaretypicallydrilledusingwaterorairflushandgroutedafterinstallation(postgrouting).
Micropilesaretypicallyinstalledusingsimultaneousdrillingandgroutingwiththegroutservingasaflushingmediumthatimmediatelystabilizesthesurroundinggroundbyfillingvoidsandcracks.Afterreachingthefinaldepth,thewater-cementratioisdecreasedinordertofilltheannularspacebetweenthehollowbarand borehole wall thus ensuring optimal load transfer.
Manual, mechanical and automated installation methods are available.
• The selection of the suitable drill bit is dependent on the planned length of the nail or micropile, expectedgeologicalconditionsonsiteandintendedgroutcover.Ifrequired,anexpertpossessing therequiredknow-howandexperiencemustbeconsultedorloadtestsonsample nails or micropiles must be carried out.
• The corrosive effect of the ground on metallic materials must be evaluated and assessed in the designinadvanceinordertoprovidetherequiredcorrosionprotection(groutcover,corrosion allowance, hot-dip galvanization or TwinCoat. Combinations of the aforementioned alternatives are possible).
• Using the selected drill bit, the hollow bar is installed by means of rotary or rotary percussive drillingusingacouplingboxbetweentheshankadapterandhollowbar.Air,waterorgroutmaybe usedasdrillflush.Thehollowbarcanbeextendedusinganextensioncouplerscrewedonbyhand. Thetorqueisappliedviatheinstallationprocess.Guidevaluesfortorqueandimpactenergyare listedonpages20and21as50%valuepairs,thepathsareshownintorque-impactenergy diagrams.
• Simultaneously to drilling the nail or micropile, the annular space around the hollow bar may be filledwithcementorcementgroutcreatingagroutbodyusingarotaryinjectionadapter(grout swivel).Postgroutingmaybecarriedoutusinganinjectionadapteriftheboreholeisofsufficient stability.
• A plastic or steel protection tube, dependent on the type of loading acting on the soil nail or micropileandonthetypeofjoint,mustbeinstalledintothestillflowablegrout.Forsoilnails,the protectiontubeprotrudes200mmbeyondthenailshaft,formicropilesatleast100mmintothe foundationbody.Theannularspacebetweenhollowbarandprotectiontubemustbefilled withcementgrout.Therequireddimensionsoftheprotectiontubesarelistedonpage18.
• The anchorage is installed after the grout or cement grout has set. Dependent on the type of loading, the head plate must be tightened via the load-bearing nut (in the case of micropiles also via thelocknut),theminimumtorqueis500Nm.
• Duetotheriskofmacro-elementformation,anelectricallyconductivecontactbetweenthe reinforcement of the foundation body and the micropile must be prevented by installing suitable insulation. The exact design of the anchor head is carried out during the planning and design of the structure.
reinforcement of the foundation body and the micropile must be prevented by installing suitable insulation. The exact design of the anchor head is carried out during the planning
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Torque Mt and impact energy Es during the installation process
Duringinstallation,theimpactenergyEsandtorqueMtmustbelimitedtothespecifiedvaluepairs.Forapplicationsbeyondthesespecifications,thetorque-impactenergydiagramsmustalsobetakenintocon-sideration.
Type R
Type T
Range ParamterType R
R25N R32L R32N R32S R38N R51L R51N
Es, max2
Es Joule 90 80 130 160 230 220 380
Mt Nm 350 500 700 750 1300 1850 2500
Mt, max2
Es Joule 130 120 200 250 330 320 550
Mt Nm 250 400 500 550 950 1350 1800
Range ParamterType T
T51S T63N T76N T76S T111L T111N
Es, max2
Es Joule 395 460 500 680 320 730
Mt Nm 3550 6050 8950 10000 14800 21500
Mt, max2
Es Joule 555 615 690 950 400 970
Mt Nm 2700 4750 7000 7700 12300 17600
© 2017 MINOVA GLOBAL. ALL RIGHTS RESERVED
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22© 2017 MINOVA GLOBAL. ALL RIGHTS RESERVED
Packaging, transport and storage of Minova MAI Self Drilling SystemsPackaging sizes
MinovaMAISelfDrillingSystemsarepackedindifferenttypesofpackagingforeasyhandling:• Hollow bars in bundles• Couplers, nuts and drill bits in cardboard boxes on pallets (R25 - T63)• Couplers, nuts and drill bits in wooden crates on pallets (T76 - T111)• Plates on pallets
Hollow bars
R25 50 bars per bundle
R32 L, N, S 50 bars per bundle
R38 N 50 bars per bundle
R51 L, N 25 bars per bundle
T51 S 25 bars per bundle
T63 N 25 bars per bundle
T76 N, S 10 bars per bundle
T111 L, N 5 bars per bundle
Nuts
R25 100 nuts per carton
R32 L, N, S 65 nuts per carton
R38 N 48 nuts per carton
R51 L, N 12 nuts per carton
T51 S 12 nuts per carton
T63 N loose
T76 N, S 8 nuts per carton
T111 L, N loose
Couplers
R25 40 to 60 couplers per carton
R32 L, N 30 couplers per carton
R32 S 25 couplers per carton
R38 N 12 couplers per carton
R51 L 12 couplers per carton
R51 N 12 couplers per carton
T51 S 9 couplers per carton
T63 N loose
T76 N, S loose
T111 L, N loose
Drill bits and plates
Drill bits Up to 90 drill bits per carton
Plates Up to max. 800 kg per pallet
Transport and storage
A. Deliver the components (hollow bars, couplers, nuts, drill bits and head plates) to the construction site inundamagedmanufacturerpackaging–includingtheinstallationinstructions. B. Use suitable lifting means, hoists and transportation.
C. StoreProductssuchthattheyareeasilyaccessibilityforinspectionandidentificationpurposes.
D. Store the Products such that they are safeguarded against mechanical damage.
E. Safeguardallsteelpartsandpackedmaterialsagainstcorrosion.Storethemclearoftheground, covered and protected against weather and soiling.
F. StoreProductssuchthatthedeliverysequenceisobservedinordertoreducetheriskofcorrosion (Firstin–Firstout).
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Certifi cationISO certifi cationProductioniscertifiedaccordingto:• ISO9001QualityManagementSystems• ISO14001EnvironmentalManagementSystems• OHSAS18001OperationalSafetyandHealth
Management Systems.
European technical assessments, CE certifi cationETA-08/0277SelfDrillingSoilandRockNailsETA-11/0134SelfDrillingMicropilesTheEuropeanTechnicalAssessmentsconfirmthetechnical performance in the assessment documents andpermitthecomponentstobeartheCEmarking.IfCEcertifiedmaterialisrequiredthishastobere-questedintheorder.TheCEcertificationisonlyvalidincombinationwiththeCEcertificateandtheDecla-rationofPerformanceforthespecificorder.TheCEcertificationincludesfrequentexternalqualitycontroland audits, both of Minova MAI and its suppliers.
German technical approvalDIBtZ-34.713-080277NationalTechnicalApprovalfortemporarySoilandRockNails
24© 2017 MINOVA GLOBAL. ALL RIGHTS RESERVED
Legal disclaimer:This installation manual replaces and supersedes all prior manuals. It provides basic information only. Technical data and information provided herein may be changed without prior notice. Minova MAI does not assume any liability for damage or losses attributed to the use of this technical data or any improper use of the products. For further information on our products please contact Minova MAI directly.
Issue2017-01
Austrian technical approvalsBMVIT-327.120/0014-IV/IVVS2/2016SelfDrillingSoilandRockNailBMVIT-327.120/0015-IV/IVVS2/2016Self Drilling Micropile
Polish technical approvalAT/2016-02-3278SelfDrillingSoilandRockNailandMicropile
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Minova MAI GmbHWerkstrasse17
9710Feistritz/Drau,AustriaT.+434245651660
www.minovaglobal.com