Rock bolt and its manufacturing method

Abstract

To provide a lock bolt that makes it possible to eliminate work of removing a nut and re-tightening in performing a pull-out test, to easily perform the pull-out test, and to prevent a waterproof sheet from being damaged.SOLUTION: A lock bolt 1 comprises an approximately semi-spherical head 13 formed on a rear side in an installation direction of a shaft 11, the head 13 having a front end surface 14 provided so as to be capable of pressing a bearing plate 2 to be externally inserted to the shaft 11, the head 13 having a female screw part 15 into which a tension rod 62 can be screwed from the rear end side so as to be coaxial with the shaft 11.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a rock bolt used, for example, for supporting a tunnel space, and a manufacturing method thereof. [Background technology]

[0002] In a typical tunnel, as shown in Figures 10 and 11, shotcrete 102 is poured along the tunnel excavation surface 101, and rock bolts 104 are cast radially from the shotcrete 102 into the surrounding natural ground 103. Each rock bolt 104 is fixed to the natural ground 103 with an anchoring material 105, and a nut 108 is fitted onto a male thread 107 at the rear end so that an inserted bearing plate 106 is in close contact with the shotcrete 102. The tunnel space 110 is supported by an arch structure 109 constructed in the natural ground 103 surrounding the tunnel by the rock bolts 104 cast radially.

[0003] The rock bolts 104 driven into and fixed in the natural ground 103 support the arch structure 109 so as not to break by resisting the force F that the natural ground 103 tries to push out with the axial force T in the tensile direction generated in the rock bolts 104. In order for the rock bolts 104 to perform this function, it is important that the rock bolts 104 are firmly fixed in the natural ground 103 in a state where they have the required pull-out resistance. Furthermore, it is also necessary that the rock bolts 104 do not break and that the nuts are tightened on the rock bolts 104 so that the support plate 106 is in close contact with the sprayed concrete 102.

[0004] Patent Document 1 also proposes a rock bolt in which a plate fixing member made of a circular flat steel plate is integrally joined to the rear end of the rock bolt, and a bearing plate is inserted into the shaft of the rock bolt. This rock bolt is installed by pushing it into an insertion hole in the ground, and the plate fixing member presses down on the bearing plate, and the rock bolt is installed in the ground. Therefore, it is possible to omit the work of attaching the bearing plate by tightening a nut when installing the rock bolt. Furthermore, the rock bolt in Patent Document 1 is said to be able to prevent damage to the waterproof sheet laid to cover the bearing plate, since the thickness of the plate fixing member protruding from the bearing plate to the inside of the tunnel is small. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2005-314993 A Summary of the Invention [Problem to be solved by the invention]

[0006] In the meantime, in order to confirm that the rock bolt 104 driven into the natural ground 103 as described above has been driven in a state in which it has the required pull-out strength, a pull-out test is performed according to the specifications for construction management. In the pull-out test for the nut-tightened rock bolt 104, the nut 108 pressing the support plate 106 is removed, a tension bar is connected to the male thread 107 at the rear end of the rock bolt 104 via a coupling, and the tension bar is inserted into the center hole ram and loaded with a hydraulic jack to apply a tensile force to the rock bolt, thereby measuring whether it will come out until the specified pull-out strength is reached. After confirming that it will not come out until the specified pull-out test, the test device consisting of the coupling, tension bar, center hole ram, and hydraulic jack is removed from the rock bolt 104, and the nut 108 pressing the support plate 106 is re-tightened to the male thread 107 of the rock bolt 104.

[0007] Such a pull-out test is usually performed on a sample of all rock bolts 104 driven into the natural ground 103, but even if it is performed on sampled rock bolts 104, it takes a lot of time to remove the nuts 108 from the rock bolts 104 and retighten them to return them to their original state. Furthermore, in a configuration in which the male threads 107 at the rear ends of the rock bolts 104 protrude into the inside of the tunnel, if a waterproof sheet is laid inside the tunnel to cover the bearing plate 106, there is a risk that the waterproof sheet will be damaged, or it will be necessary to take separate measures to prevent damage.

[0008] In addition, the rock bolt in Patent Document 1 has a flat steel plate fixing member that holds down the bearing plate joined integrally to its rear end, making it difficult to carry out a pull-out test. Furthermore, if a bent portion is formed at the corner of the bearing plate by bending it toward the ground as in the second embodiment of Patent Document 1, there is a risk that if the rock bolt were to protrude into the inside of the tunnel, the bent portion would get caught on the waterproof sheet laid to cover the bearing plate, damaging the waterproof sheet.

[0009] The present invention has been proposed in consideration of the above-mentioned problems, and aims to provide a lock bolt and a manufacturing method thereof that can eliminate the need to remove and retighten the nut when performing a pull-out test, allowing the pull-out test to be performed easily while preventing damage to the waterproof sheet. [Means for solving the problem]

[0010] The rock bolt of the present invention has a substantially hemispherical head on the rear side of the shaft in the driving direction. The shaft is integrally formed by hot forging. Formed, A hot forging process is performed on the head portion to form a continuous grain flow from the shaft portion, The front end surface of the head portion is provided so as to be able to press a support plate that is fitted onto the shaft portion, The female thread portion can be used to screw in a tension rod for pull-out testing. The head is attached coaxially to the shaft from the rear end side. In the shape It is characterized by being constructed in such a way that According to this, when performing a pull-out test on a rock bolt, a tension rod can be screwed into the female thread of the roughly hemispherical head, which eliminates the need to remove and re-tighten the nut, making it easy to perform a pull-out test on the rock bolt. In addition, since the bolt can be installed simply by pushing it into the ground without the need for nut tightening, the labor required for driving the rock bolt can be reduced. In addition, since the head of the rock bolt is roughly hemispherical, damage to the waterproof sheet that is laid to directly or indirectly cover the head of the rock bolt can be prevented.

[0011] The rock bolt structure of the present invention is characterized in that a bearing plate is fitted onto the shaft portion of the rock bolt of the present invention, and the corners of the bearing plate are chamfered with a radius. According to this, by forming the corners of the support plate with a radiused chamfer, damage to the waterproof sheet that is laid to directly or indirectly cover the head of the rock bolt and the support plate can be more reliably prevented.

[0012] The manufacturing method of the lockbolt of the present invention is a method of manufacturing a lockbolt of the present invention, characterized in that the approximately hemispherical head is formed by hot forging at one end of a steel bar having the outer shape and outer peripheral size of the shaft portion. This allows the roughly hemispherical head to be made from the same material as the shaft, and also allows the roughly hemispherical head to have a continuous grain flow from hot forging that is continuous with the shaft, resulting in a material structure with a homogenous internal structure and a tougher material structure with increased viscosity. This makes it possible to obtain a rock bolt that exhibits high strength and high yield strength over its entire length. Furthermore, the hot forging process allows the rock bolt of the present invention to be manufactured quickly and inexpensively.

[0013] The method of installing a rock bolt of the present invention is a method of installing a rock bolt of the present invention, characterized in that it comprises a first step of extrapolating a support plate from the tip side of the shaft portion of the rock bolt, and a second step of driving the rock bolt into the ground by pressing the support plate against the ground with the front end surface of the head. This eliminates the need to tighten the nuts until the support plate is in close contact with the ground or sprayed concrete, and the rock bolt can be installed simply by moving it in a pushing motion, making construction work easier.

[0014] The ground reinforcement structure of the present invention is a ground reinforcement structure in which a rock bolt of the present invention is driven, characterized in that the rock bolt is driven into the ground with the support plate extrapolated to the shaft portion being interposed between the front end surface of the approximately hemispherical head and the ground or the surface to be poured of sprayed concrete, and a waterproof sheet is laid so as to directly or indirectly cover the approximately hemispherical head. According to this, by attaching a tension rod to the head of a rock bolt that is driven into a natural ground reinforcement structure and abutting against the bearing plate, a pull-out test of the rock bolt can be easily performed without removing and re-tightening the nut. In addition, since the bolt can be installed simply by pushing it into the natural ground without the need for tightening the nut, the labor required for driving the rock bolt can be reduced. In addition, since the head of the rock bolt is approximately hemispherical, damage to the waterproof sheet that is laid to directly or indirectly cover the head of the rock bolt can be prevented.

[0015] The pull-out test method of the present invention is a pull-out test method for the rock bolt driven into the ground reinforcement structure of the present invention, and is characterized by comprising a first step of screwing a tension rod into the female threaded portion of the head of the rock bolt in the driven state, and a second step of applying a force in the pull-out direction to the head via the tension rod to determine the pull-out strength of the rock bolt. According to this, in a rock bolt driven in a natural ground reinforcement structure, a tension rod is screwed and attached to the head part that abuts against the bearing plate, so that a pull-out test of the rock bolt can be easily performed without removing and re-tightening the nut. In addition, after the pull-out test is completed, the original state can be easily restored by simply removing the tension rod from the head part of the rock bolt, making it unnecessary to re-tighten the nut. Effect of the Invention

[0016] The lock bolt of the present invention eliminates the need to remove and retighten the nut when performing a pull-out test, making it possible to easily perform the pull-out test while preventing damage to the waterproof sheet. [Brief description of the drawings]

[0017] [Figure 1] FIG. 2 is a perspective view of a state in which a bearing plate is extrapolated onto a rock bolt according to an embodiment of the present invention. [Diagram 2] FIG. 2A is a front view showing the periphery of a head portion of a lock bolt according to an embodiment, and FIG. 2B is a partial cross-sectional explanatory view showing the periphery of the head portion of a lock bolt according to an embodiment. [Diagram 3] 1A is a plan view of a bearing plate that is extrapolated to a rock bolt of an embodiment, and FIG. [Figure 4] 5A to 5E are process explanatory views illustrating a manufacturing process of the rock bolt according to the embodiment. [Diagram 5] 4A to 4D are process explanatory diagrams illustrating the installation process of the rock bolt according to the embodiment. [Figure 6] FIG. 1 is a schematic explanatory diagram of a tunnel constructed with a natural ground reinforcement structure having rock bolts installed according to an embodiment of the present invention. [Figure 7] FIG. 8 is an explanatory diagram illustrating a fixing mechanism of a rock bolt according to an embodiment in the example of the tunnel in FIG. 7. [Figure 8] FIG. 4A is an explanatory diagram illustrating how force is applied to a rock bolt in an embodiment of a natural ground reinforcement structure, and FIG. 4B is an explanatory diagram illustrating how a tensile load is applied to the head of the rock bolt in the embodiment. [Figure 9] FIG. 2 is a partial cross-sectional view illustrating a pull-out test on a rock bolt in a natural ground reinforcement structure in which the rock bolt of the embodiment is driven. [Figure 10] A schematic diagram of a typical tunnel under construction. [Figure 11] FIG. 2 is an explanatory diagram illustrating a typical fixing mechanism of a rock bolt. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] [Lock bolt of embodiment] A rock bolt 1 according to an embodiment of the present invention is made of a deformed steel bar, which is a metal material or a steel bar material, and as shown in Figures 1 and 2, a substantially conical point 12 is formed at the tip in the driving direction of a shaft 11 which is in the shape of a deformed steel bar. A substantially hemispherical head 13 is formed on the rear side in the driving direction of the shaft 11, and the head 13 is provided so as to protrude outward from the outer periphery of the shaft 11 in a substantially flange-like shape.

[0019] The head 13 is provided so that a front end surface 14 at the tip thereof can press the support plate 2 (described later) that is fitted onto the shaft portion 11, and the outer diameter of the head 13 is larger than the insertion hole 21 of the shaft portion 11 formed in the support plate 2. In this embodiment, the front end surface 14 of the head 13 is a flat surface. The head 13 is also formed with a female thread portion 15 consisting of a female threaded hole from the rear side, and the axis of the female thread portion 15 is formed so as to be coaxial with the axis of the shaft portion 11.

[0020] Furthermore, in the lock bolt 1 of this embodiment, the head 13 and the shaft 11 are integrally formed, and for example, a high-tensile deformed steel bar specified in JIS G3112 is used, and the head 13 is integrally formed by hot forging on the rear side of the shaft 11. That is, in the lock bolt 1 of this embodiment, the head 13 and the shaft 11 are integrally formed from the same high-tensile metal material.

[0021] 1 and 3, the support plate 2, which is inserted onto the shaft 11 of the rock bolt 1 and constitutes the rock bolt structure together with the rock bolt 1, is a generally rectangular plate with chamfered corners 22. An insertion hole 21 into which the shaft 11 of the rock bolt 2 is inserted is formed in the approximate center of the support plate 2 in a plan view, and the diameter of the insertion hole 21 is larger than the outer diameter of the shaft 11 and smaller than the outer diameter of the head 13.

[0022] In the case of manufacturing the rock bolt 1 of this embodiment in which the substantially hemispherical head 13 is integrally formed by hot forging on the rear side of the shaft 11, a rod-shaped metal material or steel bar material having the outer shape and outer circumferential size of the shaft 11 is used as a raw material, for example, the deformed steel bar 1m shown in Fig. 4(a) is used. The deformed steel bar 1m is preferably a high-tensile deformed steel bar, and more preferably a high-tensile deformed steel bar specified in JIS G3112.

[0023] When processing this deformed steel bar 1m by hot forging, the deformed steel bar 1m heated to a high temperature is inserted between chucks 31, 32 that can be opened and closed in the radial direction up to a position where it hits a stopper 35, and one end of the deformed steel bar 1m is positioned in a state where it protrudes by a predetermined length L1 on the side opposite the insertion side relative to the chucks 31, 32, and is firmly clamped by the chucks 31, 32 (see FIG. 4(a)). The protruding length L1 of this deformed steel bar 1m is designed to be the same for each processing in order to form the shape of the head 13 from the deformed steel bar 1m by hot forging.

[0024] When the protruding length L1 of the deformed steel bar 1m from the chucks 31 and 32 is thus determined, the stopper 35 is withdrawn laterally from the axis of the deformed steel bar 1m, and then the first die 34 is pressed against the protruding portion of the deformed steel bar 1m so as to abut against the chucks 31 and 32 firmly holding the deformed steel bar 1m, and hot forging is performed to form the first stage head 13m1. Inside the first die 34, an intermediate shape internal space 33 for forming the end of the deformed steel bar 1m into the head 13 shape is formed as a closed space, and the deformed steel bar 1m of the predetermined length L1 is forced into the internal space 33 to form the intermediate shape head 13m1 (see FIG. 4(b)). After the head 13m1 is formed, the first die 34 is withdrawn.

[0025] Next, while the deformed steel bar 1m is firmly clamped between the chucks 31, 32, a second mold 38 having an internal mold space 37 having a shape corresponding to the approximately hemispherical head 13 is placed on the axis of the deformed steel bar 1m, and the second mold 38 is pressed into the head 13m1 of the deformed steel bar 1m, which has been heated to a high temperature, until it is in contact with the chucks 31, 32, thereby performing hot forging, and a head 13m2 having the same outer shape and size as the approximately hemispherical head 13 is integrally formed at the rear of the shaft portion 11m of the deformed steel bar 1m (see Figures 4(c) and (d)).

[0026] After the head 13m2 is formed, the second die 38 is withdrawn and the chucks 31 and 32 are opened to remove the deformed steel bar 1m with the head 13m2 formed thereon, and unnecessary burrs are removed as necessary from the deformed steel bar 1m with the head 13m2 formed thereon. Then, a tap 39 is used to thread the head 13m2 of the deformed steel bar 1m from the rear side to form a female threaded portion 15 consisting of a bottomed female threaded hole (see Figs. 4(d) and (e)). Then, a substantially conical tip portion 12 is separately formed at the tip of the deformed steel bar 1m, and the lock bolt 1 of this embodiment is obtained. Note that the hot forging when forming the lock bolt 1 of this embodiment by hot forging may be any appropriate method within the scope of the present invention, and it is also possible to use free forging hot forging without using a forging die, for example.

[0027] As an example of a rock bolt 1 in which a roughly hemispherical head 13 is integrally formed by hot forging on the rear side of the shaft 11, a rock bolt 1 made of 1m of D25 high tensile deformed steel bar SD345 specified in JIS G3112 with a nominal diameter of 25 mm will break at the base of the head 13, i.e., the side closer to the shaft 11m, when a tensile load is applied, and the breaking strength is 213.3kN. On the other hand, a D25 deformed steel bar rock bolt made of SD345 material using a conventional nut fastening method has a standard value of tensile strength of 120kN because the threaded portion restricts the tensile strength and yield point and becomes a bottleneck. For this reason, according to the rock bolt 1 of the present invention, even if a D22 deformed steel bar material with a nominal diameter of 22 mm is used, it is possible to clear the standard value equivalent to the conventional D25, allowing the use of a smaller diameter and lighter rock bolt, and also making it possible to reduce the drilling diameter for drilling the rock bolt when driving it, thereby facilitating the construction work of driving the rock bolt.

[0028] Next, the construction process of the rock bolt 1 of this embodiment will be described. When constructing the rock bolt 1, as shown in Figures 5(a) and (b), the bearing plate 2 having the insertion hole 21 is inserted from the tip side in the casting direction onto the shaft 11 of the rock bolt 1. The process of inserting the shaft 11 of the rock bolt 1 into the insertion hole 21 of the bearing plate 2 can be performed in an appropriate manner. For example, it is preferable to hold the bearing plate 2 at the tip of the guide cell 41 of the rock bolt driving device using a holding mechanism provided near the tip of the guide cell 41, and hold the rear end of the rock bolt 1 with a push-in type driving machine 42 that slides along the guide cell 41 as described later, and move the driving machine 42 forward to insert the shaft 11 of the rock bolt 1 into the insertion hole 21 of the bearing plate 2 held in a predetermined position by the holding mechanism (see Figures 5(a) to (c)). Incidentally, the bearing plate 2 does not have to be moved so as to approach the head 13 of the rock bolt 1, and the bearing plate 2 is positioned in a state of being extrapolated by being positioned near the tip of the shaft portion 11. Also, drill holes 52 are formed in advance in the natural ground 50, or in the natural ground 50 and sprayed concrete 51, and fixing material 53 such as mortar is injected into the drill holes 52 in advance (see FIG. 7).

[0029] Then, as shown by the bold arrow in Figure 5(c), the rear end of the rock bolt 1 is held by a push-type driving machine 42 that slides along a guide cell 41, and the driving machine 42 is advanced toward the natural ground 50, pushing the rock bolt 1 from the tip side where the point 12 is formed into the drilled hole 52 into which the fixing material has been injected. The rock bolt 1 is pushed in until the front end face 14 of the head 13 presses against the bearing plate 2, and the rock bolt 1 is driven into the natural ground 50 with the bearing plate 3 interposed between the front end face 14 of the head 13 and the natural ground 50 or the surface to be poured of the sprayed concrete 51 (the surface of the natural ground 50 or the surface of the sprayed concrete 51) (see Figure 5(d)). In the ground reinforcement structure constructed by this construction process, the bearing plate 2 inserted onto the shaft 11 is interposed between the front end surface 14 of the approximately hemispherical head 13 and the ground 50 or the surface to be poured of sprayed concrete 51, and the rock bolt 1 is driven into the ground 10 in a state in which the bearing plate 2 can withstand the pushing force when the ground 50 pushes out.

[0030] An example of a tunnel having a natural ground reinforcement structure constructed by the above construction process is shown in Figures 6 and 7. In this example, shotcrete 51 is poured along the excavation surface 54 of the tunnel, and rock bolts 1 are cast radially from the shotcrete 51 into the surrounding natural ground 50. Each rock bolt 1 is fixed to the natural ground 50 with an anchoring material 53, and the front end surface 14 of the approximately hemispherical head 13 is pressed against the bearing plate 2 so that the inserted bearing plate 2 is in close contact with the shotcrete 51. The tunnel space 56 is supported by an arch structure 55 constructed in the natural ground 50 around the tunnel by the radially cast rock bolts 1.

[0031] Furthermore, in this example, a sheet-like cushioning material 57 such as nonwoven fabric is laid to cover the approximately hemispherical head 13 of the rock bolt 1 protruding into the tunnel inside and the bearing plate 2, and a waterproof sheet 58 is laid so as to be layered inside the cushioning material 72, and the waterproof sheet 58 is laid so as to indirectly cover the approximately hemispherical head 13. The cushioning material 57 and the waterproof sheet 58 are laid, for example, by fixing the cushioning material 57 to the sprayed concrete 51 with fasteners 571 such as anchors or nails and laying it along the inner surface of the sprayed concrete 51, and by fixing the cushioning material 57, the waterproof sheet 58 fixed to the cushioning material 57 at the scattered fixing parts and laid over the cushioning material 57 is laid along the inner surface of the sprayed concrete 51. 59 shown in the figure is a lining concrete.

[0032] In this natural ground reinforcement structure with waterproof sheet 58 laid, the bearing plate 2 installed on the natural ground 50 protrudes from the surface of the shotcrete 51 by a thickness of, for example, 9 to 12 mm, and furthermore, the approximately hemispherical head 13 protrudes from the inner surface of the bearing plate 2 by a height of, for example, about 30 mm, and the buffer material 57 and waterproof sheet 58 are laid to cover these, but since the installation pitch of the rock bolts 1 in the circumferential direction of the tunnel is 1 mm or more apart, the actual buffer material 57 and waterproof sheet 58 are laid in a state with less unevenness than in the schematic example of Figure 6. It is also possible to lay the waterproof sheet 58 so as to directly cover the approximately hemispherical head 13 and bearing plate 2 without laying the buffer material 57.

[0033] In this way, in a natural ground reinforcement structure for a tunnel equipped with rock bolt 1 driven and fixed into the natural ground 50 and bearing plate 2, the force F that the natural ground 50 tries to push out is supported by the bearing plate 2, and is resisted by the axial force T in the tensile direction generated in the rock bolt 1, thereby supporting the arch structure 55 so as not to break (see Fig. 7 and Fig. 8(a)). At this time, since a tensile load is applied to the approximately hemispherical head 13 of the rock bolt 1 in the vertical direction to the outer circumferential side surface 161v of the virtually extracted circular truncated cone 16v shown in Fig. 8(b), it is advisable to set the breaking load obtained by multiplying the tensile strength of the material of the approximately hemispherical head 13 by the area S of the outer circumferential side surface 161v so as to exceed the required value.

[0034] Next, a pull-out test for the rock bolt 1 of this embodiment will be described. When a pull-out test is performed on the rock bolt 1 in a state where it has been cast in a natural ground reinforcement structure, for example as shown in Fig. 9, in a ground reinforcement structure in which shotcrete 51 is cast along the surface of the natural ground 50, the rock bolt 1 is cast into a borehole 52 drilled in the shotcrete 51 and the natural ground 50, and the rock bolt 1 is fixed by an anchoring material 53 in the borehole 52, a tension rod 62 is screwed into the female thread portion 15 of the approximately hemispherical head 13 of the cast rock bolt 1. In the illustrated example, a roughly cap-shaped base plate 611 of a pull-out test reaction base 61 is provided so as to be placed on the support plate 2, whose front end surface 14 of the head 13 of the rock bolt 1 is in contact with the sprayed concrete 51, and inside the pull-out test reaction base 61, the male threaded portion 621 at the tip of a tension rod 62 inserted through a through hole in the pull-out test reaction base 61 is screwed into the female threaded portion 15 of the head 13 of the rock bolt 1.

[0035] A center hole jack 63 and a pull-out test measuring plate 64 are extrapolated to the part of the tension rod 62 protruding from the pull-out test reaction base 61 on the side opposite the ground 50, and a pull-out test retaining nut 65 is screwed onto the tension rod 62 to restrict movement of the pull-out test measuring plate 64 on the side opposite the ground 50.

[0036] Then, by applying pressure in the extension direction of the center hole jack 63, a pull-out force is applied to the tension rod 62 via the pull-out test measuring plate 64 and the pull-out test retaining nut 65. As a result, a reaction force is obtained from the pull-out test reaction force base 61, and a force in the pull-out direction is applied to the rock bolt 1 from the head 13 via the tension rod 62. By applying a pull-out force to the rock bolt 1 in this way, the axial force applied to the rock bolt 1 is calculated from the applied load, and the displacement of the pull-out test measuring plate 64 is measured, thereby recognizing the elongation of the rock bolt 1 and recognizing the pull-out strength and elongation of the rock bolt 1. It is preferable that the pull-out strength and elongation of the rock bolt 1 are calculated by a computer device such as a personal computer, smartphone, or dedicated terminal that stores mutual correspondence data in a memory unit, and output from an output unit.

[0037] According to this embodiment, the pull-out test of the rock bolt 1 can be performed by screwing the tension rod 62 into the female thread portion 15 of the approximately hemispherical head 13, which eliminates the need to remove and re-tighten the nut during the pull-out test, making it easy to perform the pull-out test of the rock bolt 1. In addition, since the rock bolt 1 can be installed by simply pushing it into the ground 50 without the need for nut tightening, the labor required for the installation work of the rock bolt 1 can be reduced. In addition, since the head 13 of the rock bolt 1 is approximately hemispherical, damage to the waterproof sheet 58 laid so as to directly or indirectly cover the head 13 of the rock bolt 1 can be prevented. Furthermore, by forming the corner portion 22 of the support plate 2 with a chamfered radius, damage to the waterproof sheet 58 laid so as to directly or indirectly cover the head 13 of the rock bolt 1 and the support plate 2 can be more reliably prevented.

[0038] Furthermore, when manufacturing rock bolt 1 by forming a substantially hemispherical head 13 by hot forging at one end of a steel bar having the outer shape and outer circumferential size of shaft 11 of rock bolt 1, not only can the substantially hemispherical head 13 be formed from the same material as shaft 11, but also the substantially hemispherical head 13 can have a material structure with a homogenous internal structure and high toughness with increased viscosity, in which grain flows are formed in the substantially hemispherical head 13 by hot forging that continues from shaft 11. Therefore, it is possible to obtain rock bolt 1 that exhibits high strength and high yield strength over its entire length. Furthermore, the rock bolt 1 can be manufactured quickly and inexpensively by manufacturing by hot forging.

[0039] Furthermore, in the installation method of the rock bolt 1 of this embodiment, there is no need to tighten the nuts until the support plate 2 is in close contact with the ground 50 or sprayed concrete 51, and the rock bolt 1 can be installed simply by moving it in a pushing motion, thereby simplifying the installation work.

[0040] Furthermore, in a pull-out test of the rock bolt 1 in a ground reinforcement structure in which the rock bolt 1 has been driven, the pull-out test can be easily performed by simply screwing and attaching the tension rod 62 to the head 13 that abuts against the bearing plate 2, without the need to remove and retighten the nut. After the pull-out test is completed, the original state can be easily restored by simply removing the tension rod 62 from the head 13 of the rock bolt 1, making it unnecessary to retighten the nut.

[0041] [Scope of the invention disclosed herein] The inventions disclosed in this specification include, in addition to the inventions and embodiments listed as inventions, those specified by changing partial contents of these to other contents disclosed in this specification, those specified by adding other contents disclosed in this specification to these contents, or those specified by deleting partial contents of these to the extent that partial effects can be obtained, and specifying them as a higher-level concept. The inventions disclosed in this specification also include the following contents and modifications.

[0042] For example, the rock bolt of the present invention is preferably configured such that the head 13 is integrally formed with the shaft portion 11 by hot forging as in the above embodiment, but it is also preferable to use a material that is stronger than the high tensile material of the shaft portion 11 for the roughly hemispherical head 13 on which the female thread portion 15 is formed, and to frictionally weld the head 13 of a different material to the rear side of the shaft portion 11. Furthermore, rock bolts formed by manufacturing methods other than these are also included within the spirit and scope of the present invention, and it is possible to use, for example, a rock bolt configured such that the roughly hemispherical head 13 is welded to one end face of a steel bar material that has the same shape and size as the shaft portion 11, or a rock bolt configured such that the roughly hemispherical head 13 is integrally formed with the shaft portion 11 by a method other than hot forging, such as cold forging.

[0043] In addition, in installing the rock bolt 1 in the above embodiment, the rock bolt 1, which presses the front end surface 14 of the approximately hemispherical head 13 against the support plate 2, is preferably installed by automatically pushing the rock bolt 1 in using a driving machine 42 or the like, but it is also possible to manually push the rock bolt 1 in and install it. [Industrial Applicability]

[0044] The present invention can be used, for example, for rock bolts to be driven into tunnels, rock bolts to be driven into slopes, etc. [Explanation of symbols]

[0045] 1...Rock bolt 11...Shaft 12...Tip 13...Head 14...Front end surface 15...Female thread 16v...Truncated cone 161v...Outer periphery side 1m...Deformed steel bar 11m...Shaft 13m1, 13m2...Head 2...Support plate 21...Insertion hole 22...Corner 31, 32...Chuck, 33...Space inside mold 34...First mold, 35...Stopper, 37...Space inside mold 38...Second mold 39...Tap 41...Guide cell 42...Pouring machine 50...Natural ground 51...Sprayed concrete 52...Drilling 53...Anchoring material 54...Excavation surface 55...Arch structure 56...Tunnel space 57...Buffer material 571...Fastener 58...Waterproof sheet 59...Lining concrete 61...Reaction base for pull-out test 611...Base plate 62...Tension rod 621...Male threaded portion 63...Center hole jack 64...Measuring plate for pull-out test 65...Retaining nut T...Axial force F...Force exerted by the ground S...Area of ​​the outer side surface of the truncated cone 101...Tunnel excavation surface 102...Sprayed concrete 103...Ground 104...Rock bolt 105...Anchor material 106...Support plate 107...Male thread 108...Nut 109...Arch structure 110...Tunnel space

Claims

1. A substantially hemispherical head is formed integrally with the shaft portion by hot forging on the rear side in the casting direction of the shaft portion, A hot forging process is performed on the head portion to form a continuous grain flow from the shaft portion, The front end surface of the head portion is provided so as to be able to press a support plate that is fitted onto the shaft portion, A lock bolt characterized in that a female threaded portion into which a tension rod for a pull-out test can be screwed is formed in the head from the rear end side so as to be coaxial with the shaft portion.

2. A bearing plate is fitted onto the shaft portion of the rock bolt according to claim 1, A rock bolt structure characterized in that the corners of the support plate are chamfered with a radius.

3. A method for manufacturing a rock bolt according to claim 1, A method for manufacturing a lock bolt, comprising the steps of: forming the approximately hemispherical head by hot forging at one end of a steel bar having the outer shape and outer peripheral size of the shaft portion.

4. A method for installing a rock bolt according to claim 1, A first step of inserting a bearing plate from a tip side of the shaft portion of the rock bolt; A rock bolt installation method comprising a second step of driving the rock bolt into the ground by pressing the front end surface of the head of the support plate against the ground.

5. A ground reinforcement structure in which the rock bolt according to claim 1 is driven, The rock bolt is driven into the ground with the bearing plate inserted into the shaft portion between the front end surface of the substantially hemispherical head portion and the ground or the surface of the sprayed concrete to be poured, A ground reinforcement structure characterized in that a waterproof sheet is laid so as to directly or indirectly cover the approximately hemispherical head.

6. A method for performing a pull-out test on the rock bolts installed in the natural ground reinforcement structure according to claim 5, A first step of screwing a tension rod into the female thread portion of the head of the rock bolt in a driven state; A pull-out test method comprising a second step of applying a force in a pull-out direction to the head via the tension rod and determining the pull-out strength of the rock bolt.

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