Axial Load Transfer Mechanisms in Fully Grouted Fibreglass Rock Bolts: Experimental and Numerical Investigations

Fully grouted rock bolts play a vital role in stabilising underground excavations, particularly in corrosive environments where material properties, geometric configuration, and installation conditions influence their load transfer performance. Although the practical importance of fully grouted fibreglass rock bolts is well recognised, quantitative evidence on their axial load transfer mechanisms remains limited. Prior work has primarily centred on steel rock bolts, with few studies on how embedment length, grout stiffness, interface roughness and confining stress govern bond mobilisation in fully grouted fibreglass rock bolts, indicating a clear need for further scientific investigation. This study examines the axial load transfer and shear behaviour of fully grouted fibreglass rock bolts, focusing on the effects of embedment length (EL), grout properties, and boundary conditions. A comprehensive series of laboratory pull-out tests were conducted on two widely used Australian glass fibre reinforced polymer (GFRP) rock bolts, TD22 and TD25, with diameters of 22 mm and 25 mm, respectively, under varying ELs and grout curing times to evaluate their axial performance. Additionally, single shear tests and uniaxial compressive strength (UCS) tests were conducted to assess the shear behaviour of the rock bolts and the mechanical properties of the grout. The results showed that increased EL, bolt diameter, and grout curing time generally enhance axial capacity. With grout curing from day 7 to the day 28, the influence of embedment length became increasingly pronounced, as the axial peak load rose from 35 kN (TD22-50, 7 days) to 116 kN (TD22-150, 28 days) and from 39 kN (TD25-50, 7 days) to 115 kN (TD25-150, 28 days), confirming that both longer bonded lengths and extended curing significantly enhance the axial load-bearing capacity of fully grouted GFRP rock bolts. However, the TD22 rock bolts exhibited superior shear strength and ductility compared to the TD25 rock bolts. Also, a calibrated distinct element model (DEM) was developed in 3DEC to simulate axial load transfer mechanisms and validated against experimental results. Parametric studies revealed that increasing the grout stiffness from 5 e7 N/m to 5 e8 N/m increased the peak load from 45 kN to 205 kN (approximately 350%), while reducing the peak displacement, indicating a shift toward a more brittle response. Similarly, increasing the grout-bolt interface roughness boosted the peak load by 150% (from 60 kN to 150 kN) and enhanced residual stability, raising the residual load from 12 kN to 93.5 kN. In contrast, confining stress (up to 5 MPa) did not affect the 110 kN peak load but reduced the residual load by up to 60% in isotropic conditions. These quantitative findings provide critical insights into the performance of GFRP bolts and support their optimised design for underground reinforcement applications.