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Tag: Bolting

New Routing

If you follow Rock & Sun on Facebook, Instagram or via our Newsletter, you would have seen a few posts this year about the new routes we developed in the Costa Blanca during the Corona pandemic. Here we will describe what it entails to make them, what we love about new-routing, plus we’ll give the overview of all the new routes as most of them were developed just after the new Costa Blanca guidebook by Roberto Lopez was published. We also aim to answer the questions you’ve been asking us about developing new routes. If you have more questions after reading this blog, please send us a message and we will add it to this blog.

New-routing during Covid-19

International borders being closed for tourists for most of the time between March 2020 and May 2021 meant that we had a lot of time on our hands in the last year or so. Once the initial and very strict lockdown in Spain ended and we were slowly gaining more freedom again, we at first felt it could be considered too ‘frivolent’ to start climbing for fun again. But we considered going to the crag to create new climbs a justified reason to go to the crag. The first routes we started to work on were the 4 routes ‘in the trees’ in sector Alejandria of Pena Roja (see the full overview of new routes at the bottom of this blog). Trev had his eye on this sector mainly because of the easy angled rock and the fact that it is protected from the sun by the trees. If we could create some routes here, that would allow us to climb at Pena Roja all day; starting in Alejandria-riverbed in the morning, then move into the trees, and finish the day at the original wall of Pena Roja.

What is your motivation for developing routes?

A question we get asked quite regularly, as most climbers ‘just’ climb and never put up a route in their whole life. Routesetters can be quite invisible, and unless you get to see someone developing a route, you may never really think about how and why those bolts got there.

There are several reasons why we like to get involved in bolting routes. One is because we are well aware of the fact that as Rock & Sun we use the Costa Blanca for our Sport Climbing Holidays and Performance Coaching Courses. We climb routes that have been equipped by others, we bring more climbers to this area. We therefore find it important to do something back. Not only by maintaining existing routes or sectors (we for instance replaced 10 anchors at Sierra de Toix Oeste with titanium glue in anchors), but also by creating more routes. This will give the locals something new to climb, and it will give climbers from other areas something to come back to the Costa Blanca for, and it means that on busy days at popular crags, people can spread over a greater number of routes without having to wait for one another.

Another important reason to develop new routes is so that when we are working with our groups, we can organise our climbing days in a different way and thereby offer our clients better climbing experiences. By for instance creating routes that are in the shade around midday, it means that when it’s hot we can climb in the shade all day, moving from one sector to the next, instead of having to go back to the villa for a two or three hour break before heading out to the crag again. And it also means our regular clients will have something new to try on their next trip. Finally, the routes we set tend to lend themselves really well for climbing coaching; they are good routes to practice route-finding and/or work on technical movement patterns.

The whole creative process from spotting to bolting new lines is our third motivation. We all have a different creative outlet; some of us sing, make music, love cooking, painting or making furniture. For us, it is new routing that ‘ticks us’. Trevor is naturally looking for new route potential at any crag we go to, even at any crag or piece of rock we drive past. He is always spotting natural lines or striking features that would be amazing to climb. Those of which that are on shady crags, with a potential grade range from 4s to 6s are the top of our list to have a closer look at and decide to start working on. What Desiree loves most about this creative process, are first, the uniqueness of climbing an unclimbed piece of rock and the freedom to decide where it climbs best, and second, the removing of loose rock, vegetation and mud, behind which you often find beautiful handholds.

These cleaning activities naturally lead us to our final motivation of new-routing: it is a great way to get fit. After 2,5 months in total lockdown, having drunk and eaten more than we could burn off, we had some kilos to lose and muscles to regain. Hanging in the harness all day, jumarring up the fixed line, using a crow-bar to get body-size blocks of rock off, hammering other loose rock off, drilling and brushing provides a quite intense full-body workout.

The rock scars as well as rocks at base of the crag show the amount of rock we removed (sector Estado de Alarma, Cuarentena, Corona)

Do you need permission or a qualification to make new routes?

There is no qualification for route-setting. It is a skill that is often passed on from an experienced route-setter to an ‘assistant’ to learn all the ins and outs involved with doing a good job at it.

Whether permission is needed completely depends on where we want to develop new routes. If the land is privately owned then of course we’d need permission from the land owner. As it happens though, on more than once occasion it has been the other way around, and Trevor has been asked if he would please come to have a look at a limestone wall and develop routes there. These instances were in Thailand, where the owners see the potential of building bungalows and a restaurant to accommodate the climbers, once the routes have been developed. A win-win situation.

If the crag is on public land, we ask around among local climbers to see if permission would be needed from the forestry commission and/or from the municipality. For the past year we have wanted to start developing this untouched, north-facing crag, not far from where we live. We explored it on a few occasions and see great potential, but after talking to some local climbers we decided that now is not the right time to ask permission from the local government. So we will save that crag for another time in the future.

On existing crags, we use the following logic. If it is an established crag where there haven’t been new additions for a while, then we assume that the original route developers have finished the lines that they want to put up. And that they would not be against us developing more routes. Most local developers are, A: not interested in removing tons of loose rock or vegetation, and are B: not interested in bolting low 6s, 5s or 4s. Whereas those grades are of great interest to us. The routes at the Alejandria sector in the trees for example, from Estado de Alarma till Distanciamiento Social, took a lot of effort to get cleaned. We spent multiple days up there with a crowbar and lump hammer to make this area safe for climbing. And possibly more surprisingly, the sector at Alcalali from Artmosphere till The Baker was never developed before because the rock was invisible behind the trees and bushes that were growing on its ledges. Once we cut those down, a beautiful compact slab appeared with four striking lines. We opened this sector in November 2020, and with Alcalali being the perfect winter crag in the Costa Blanca, these routes were popular right from the start.

Finally, if the crag we have spotted a line on is still in development, which was the case for Murlali, we ask the people who are bolting there whether they are planning to bolt the line that we have seen. For “Cuando termine el cierre” we were given permission to go ahead and develop that route. The last thing you want of course when you are aiming to contribute to a climbing area is to upset the other developers and climbers in that area.

Selfies (5) was donated and named by Ross and Ness Self

How much does a route cost?

This depends on the materials used. Titanium bolts that need to be glued in with a special waterproof glue (Hilti RE500, see our blog on placing titanium bolts) are more expensive than 12mm expansion bolts, which are more expensive than 10mm expansion bolts. And expansion bolts come in different alloys that vary in cost and durability. It also depends on the length of the route, or more precisely, how many bolts are needed to protect the route. Besides the material going into the route itself, there are the associated costs of the tools and protective equipment: a cordless battery-powered hammer drill (we use the Hilti Te4-A22), drill bits, ropes, saws, brushes, etc.

We estimate that on average a route costs £75.

Is there a bolt fund? How can I contribute?

In the Costa Blanca there is no bolt fund. We feel it is our obligation to contribute to the maintenance and development of this area and have been investing in it using our own funds. We do of course welcome contributions and have set up a donation page in the Rock & Sun Shop. For a £75 donation you get to name the route. Climbers visiting us in the Costa Blanca can contribute by buying a Rock & Sun t-shirt or renting our climbing shoes, harnesses, or helmets; all this income goes towards route development and route maintenance in the Costa Blanca.

How many days does it take to make a route?

On average it takes 2 days to develop a route. This however completely depends on whether it is the first route on a sector and we need to get access to the top of the crag, or whether we are creating a new route next to an existing one, in which case we can simply traverse across from the existing anchor. Besides the ease or difficulty of getting access to the top, the time it takes to make a new line also depends on the amount of vegetation and loose rock that needs to be removed.

Trevor on the first ascent of Tiger Balm (6A+)

What is the process of making a new route?

First we need access to the top of the crag. Sometimes it is possible to walk to the top of crag and set up a temporary anchor there, using trees and or trad gear. When that is not possible and it is also not possible to traverse across from an existing anchor, then Trevor will trad climb up a route from the ground and make a trad anchor at the top. This anchor is not necessarily in the spot where the final anchor will be but can be used during the routesetting process. Once a line is fixed, we can haul the drill up and drill 12mm holes to place Petzl removable bolts and take out the trad gear.

Using the temporary anchor, we set up a toprope. Both of us climb the ‘line’ at least twice. Do we choose similar ways to climb this unclimbed piece of rock? Does it go where we thought it would when we were looking at it from the ground? Is it a worthwhile route that we can make safe and fun to climb?

Once agreed on where the route goes (more or less) we climb it again to mark where the bolts go. This is a very interactive process between climber and belayer, and a lot of thought goes into it. Ultimately we want the bolts to 1) be in solid rock, 2) protect the climbing, 3) be in comfortable clipping positions for short and tall people, 4) allow the rope to run more or less in a straight line. Other considerations are that the bolt should not interfere with hand-or footholds, that the quickdraw should be hanging ‘free’ in the bolt (not pressed against or over the rock below the bolt). We both climb it several times, marking, erasing and re-marking bolts until we are happy that the bolts are marked where we would like them to be.

Depending on the amount of vegetation and loose rock, the route is either being cleaned before marking the bolts – if there is a lot of cleaning to be done, or afterwards – if the cleaning is more or less ‘cosmetic’. Desiree usually does the cleaning jumarring up a fixed line, instead of a toprope, so we can both work at the same time. Trevor can for instance be on a fixed line next to it and drill the bolts on the next route.

Trevor sometimes starts with the first bolt from the ground, working his way up to the anchor. Other times he starts at the top and works his way down. Before drilling the hole, the quality of the rock is assessed once again with the hammer to make sure it is in good quality rock. It is not always possible to put the bolt exactly where you would like it to be.

Once the bolts have been placed, we do a final clean of the route: blow off the drill dust, brushing the holds. Sometimes we reinforce holds with glue, to make the route safer (we did this for Cuarentena and Corona), or to make sure that the crux hold won’t break off (we did this on Tiger Balm).

Then one of us gets the privilege of the official “first ascent”. Climbing the route on lead for the first time, helps us to get a better idea of what the grade might be.

Trevor on the first ascent of Golden Jugs (6A)

Final Words

The good thing the Pandemic has brought us, is time. It has been great to invest in the climbing in the Costa Blanca by developing new lines. We love the process from spotting a line on the rock, to cleaning the vegetation and loose rock, to deciding where the bolts should be, and having the first ascent.

That is when the next bit of the fun starts – introducing the route to other climbers and watching them climb it. Do they go ‘the right’ way? Do they more or less get the difficulty they were expecting based on the grade we gave it? And most of all, are they enjoying it?

As the Pandemic is nearing its end, and international travel being allowed again, we are very much looking forward to our clients returning and allowing them to have a variety of new climbing experiences.

 

Full Overview of routes bolted by Trevor and Desiree during the Covid-19 Pandemic[i]

 CragRoute NameGradeDonated and named by (if applicable)Finished around
1Alejandria (in the trees) – Pena Roja, LLiberBarney Rubble6cAug 2020
2Yabba Dabba Doo !!!6cApril 2021
3The Flintstones6cAug 2020
4Estado de Alarma6bJune 2020
5Cuarentena4-5+June 2020
6Corona4+June 2020
7Distanciamiento Social6a+June 2020
8Alejandria (riverbed) – Pena Roja, LLiberDenise Denise4June 2020
9Awesome5+June 2020
10Rainbow Feet6b+Feb 2021
11Golden Jugs6aAlan BrittonFeb 2021
12Voltarol6cMarch 2021
13Tiger Balm6a+Feb 2021
14Selfies5Ross and Vanessa SelfFeb 2021
15Take is not a safe word6b+Blanka NoriMarch 2021
16AlcalaliEpidemiology5Paul CookeJan 2021
17Viva Colombia5+Mark WeeninkJan 2021
18Artmosphere6a+Rianne VerbeekNov 2020
19Rocky6aSteve CoxNov 2020
20Gene6b+Nov 2020
21The Baker6a+Nov 2020
22MurlaliBen & Jerry’s6cMark HaworthFeb 2021
23Cuando Termine el Cierre6c/+Stewart RobertsonFeb 2021

 

[i] Multiple routes at the same crag are described from left to right when facing the crag

*Alcalali and Murlali are temporarily closed for climbing due to a discovery of ancient cave paintings. Once these have been analysed and protected by the researchers of Alicante University we expect these crags to be opened up to climbers again.*

Placing Titanium Bolts

In the previous issue I looked at the lessons learned over the years from bolt placements and the advantages of titanium bolts over stainless steel glue-in bolts. Glue-in anchors that flex or deform can crack the resin, thus creating a crevice. Corrosion loves a crevice and this is therefore likely to shorten the working life of a plated steel or stainless steel anchor.

Here is some guidance for placing titanium bolts, gained from placing thousands over the years. At the time of writing the certified 8mm Eterna bolt (from Titan Climbing) appears to me to provide the best and most permanent solution, but the same placement principles apply to other ring bolts.

 

How to place titanium bolts – step 1

Before drilling, check that the intended bolt position is in good rock by listening for a solid ringing sound when it’s hit with a hammer. Choose a position that is a good distance away from cracks and edges. It is also worth considering how the gate on the bottom and top of the quick draw will sit against the rock.

 

How to place titanium bolts – step 2

To place the Eterna bolt, use a 14mm drill bit to drill a 10mm deep hole where you want the top shaft of the bolt to be. Then drill a series of holes as close as possible to each other, directly below. Each hole should be drilled a few mm less deep than the previous hole. A total of three pilot holes should be sufficient with a 14mm bit to spread along a 45mm line. Return to the original pilot hole and angle the drill bit onto the bottom lip of the hole then drill down at an angle, drilling out the gap between each hole until you are left with one vertical trench. The angle of the trench should suit the curve on the eye of the bolt.
Trenching/recessing the vertical back bar of the eye of the bolt can greatly increase both strength and performance. Martin Roberts of Titan carried out tests on trenched and non-trenched bolts. The results showed that the yield strength (load at which the bolt permanently deforms) increased by around 50% for bolts that were trenched i.e. from around 10~11kN to 15~16kN. The bolts deformed elastically (flexed under load and sprung back to their original shape when the load was relieved) at a low load around 4kN when not recessed but when recessed this load increased greatly to around 12~13kN. The typical service load is below those figures, so this greatly reduces the potential problem of fatigue.

 

How to place titanium bolts – step 3

Once the trench is finished, drill your hole for the shaft of the bolt at the top (where your original pilot hole was). The hole should be drilled at a 90 degree angle to the rock face. In normal circumstances this hole can be over-drilled by about 5 to 10mm.

On steep rock, over drilling can be problematic as the bolt can slide out of the hole. The Eterna bolt has a special design feature that allows for easier installation on steep rock:
Tape the drill bit at 9.5cm and stop drilling when the tape is flush with the edge of the trench, flush with the rock. When placing the bolt gently tap it with a suitable hammer for the last 15mm for a tight interference fit. The last 15mm of the bolt is slightly over 15mm in diameter but will squeeze down then try to spring back once tapped into the 14mm hole, improving the grip.
Do not use a normal steel hammer as it will leave iron deposits on the titanium bolt and the iron will rust, which may cause corrosion issues with the titanium anchor itself. Either use a proper stainless steel climbing hammer, or a rubber or wooden mallet.

 

How to place titanium bolts – step 4

Check that the bolt fits easily into the hole: the vertical shoulder of the bolt should fit neatly into the trench. If any extra length is necessary, this can be achieved by drilling down on the bottom lip of the trench. The reason for the slot is to semi-recess the eye of the bolt to help ensure the strongest possible bolt installation for the given position. It also greatly reduces the effects of fatigue during normal use due to the increased stiffness. I always carry three bolts with me and check each one to allow for any slight variation in size.

 

How to place titanium bolts – step 5

It is vitally important that the hole and trench are clean, and free of any rock dust before proceeding any further. I use a Hilti wire hole brush (a Metolius brush or a shaved down hard tooth brush with the bristles cut short can also work well) and a manual Hilti blow pump for alternate brushing and blowing. Alternate between brushing and blowing until dust is no longer visible.

 

How to place titanium bolts – step 6

Use the epoxy resin as per the manufacturer’s instructions. I recommend the tried and tested Hilti HIT RE-500. Pure epoxy resin is often as hard if not harder than the rock it is being placed in, so the more glue you use the better. It will also provide a greater chance of a good seal from the rock and increased adhesion to the bolt.

It is important to express and discard three full trigger pumps as a precaution before gluing your first bolt. I usually express the three full-trigger pulls into a plastic bag on the ground and then make three test beads somewhere on the ground or on the rock. This allows you to check how the glue has cured when you return the next day. If the beads are soft there was a problem with the mix. (If starting a new tube high up, one pull of the trigger for each bead.) The guns have an automated puncture system and one of the tubes is usually punctured slightly before the other leading to an uneven mix at the start.
There is a balance between speed of curing vs. “going-off” within the nozzle, and times vary depending on temperature. In hot climates, you should have a good 20mins prior to the resin going off in the nozzle.

 

How to place titanium bolts – step 7

Insert the nozzle fully into the hole. Almost fill the hole with resin by pulling on the trigger gently while slowly withdrawing. Try to avoid creating any air pockets by only withdrawing the nozzle while resin is being expressed. Insert the bolt, slowly rotating it as you do so. If you feel any resistance it will be an air pocket, this is best solved by withdrawing the bolt 1-2cm and inserting again, you may hear a small popping sound when the airlock is broken.

 

How to place titanium bolts – step 8

Continue inserting the bolt until it sits neatly in the trench. Having an ice-lolly-type stick is useful for dealing with any glue that oozes from the hole (a good excuse for a Magnum!). This can be used to backfill the trench and tidy up at the end. You can also use them to scrape excess glue from the nozzle.

 

How to place titanium bolts – step 9

It is important that the bolt is not recessed so far that larger snapgates do not fit. I test this while drilling with a solid gate on the bolt before gluing. The inside of the bolt eye should be flush with the rock surface.

 

How to place titanium bolts – step 10

You should leave at least 24 hours before loading even in a hot climate, although the glue should be cured within 12hrs, this is also where the test beads you made before gluing are helpful. Hit them with a hammer; if they’re completely dry, hard and brittle, then the bolts will be good.

 

Trevor Massiah is a Mountaineering Instructor based in Spain and is the owner operator of Rock and Sun which runs climbing and bouldering courses and holidays in many parts of the world. He has been working in the outdoors for 33 years and has climbed extensively around the world. His favourite crags are Pembroke, Taipan wall and the Needles California. He has put up many routes – both trad and sport – in the UK, Thailand, Australia, China and India, and is currently involved in rebolting existing routes and developing new routes in Thailand and the Costa Blanca.

 

by Trevor Massiah

Published in Professional Mountaineer Summer 2017

The Case For Resin Bolts

This article will look at why the use of resin bolts and anchors might be the best choice for sport climbing. It will also look at what might be the best materials to use and hope to share greater understanding of how they work and the choices available. Much of this has been learned through trial and error in addition to extensive research.

 

What are the advantages of resin anchors over expansion bolts?
  • No Spinning hangers.
  • No stress on rock due to expansion.
  • Better performance in softer rock types.
  • Less stress on bolt during installation. This reduces risk of stress corrosion cracking (SCC).
  • Expansion bolts are easy to over torque, which can result in premature failure. This can happen during installation or when a well-meaning climber attempts to tighten a loose or spinning hanger without a torque wrench.
  • Single component: this greatly reduces the risk of crevice and galvanic corrosion.
  • Reduces risk of hanger theft.
  • In the building industry, expansion bolt anchors are regarded as temporary fixings, with resin anchor bolts being used where a permanent fixing is required.

 

Having been involved in new routeing in Thailand since 1993 I’ve seen it go through some major changes, from rapid development into one of the world’s most popular sport climbing destinations in the early 90’s, to a dramatic slowdown as bolts started failing catastrophically. What were thought to be the best marine grade stainless steel expansion bolts would sometimes break under body weight less than a year after being placed!

A great deal has been written already about the tropical or marine environment and bolt corrosion. I do not intend to go into this in any great detail here but have included some links for those that are interested in gaining a better understanding of why and how certain rock types and environments can have a more aggressive corrosive effect on stainless steel, alloys and other metals than others than would be considered normal.

The tropical paradise of Thailand can be seen as a testing ground for climbing anchors. There does not seem to be a harsher environment for bolts than this one: if bolts can last in Thailand then they’ll work pretty much anywhere!

Once it had become apparent that even marine grade stainless steel expansion bolts would not work in Thailand, new route developers turned to glue-in bolts hoping that isolating the bolt from the rock and the greater surface area of the bolts versus that of a hanger would solve the problem. The results were mixed. A large variety of stainless steel glue-in bolts were used to rebolt existing routes and create new ones. It would take much longer for them to show signs of corrosion but in time even the best quality stainless glue-in bolts started to show worrying signs of corrosion and then failures started to occur. Unfortunately, the first round of rebolting was carried out with Hilti’s recommended RE-100 glue epoxy, but unbeknown to Hilti the cliffs in most Tropical locations suffer from a great deal of seepage during the monsoon season. RE-100epoxy is porous and not flexible enough. The ensuing cracking and shrinkage allowed water seeping through the rock to come into contact with the bolt. By the time we realised that the glue was a problematic weak link, hundreds of bolts had already been placed. When made aware of the problem, Hilti suggested using the RE-500. It is waterproof, can be used under water so also in wet conditions with minimal shrinkage, it is incredibly strong and should be good for 50 years or more. It is by far the best resin I’ve ever used.

At about the same time, an affordable source for titanium bolts had been discovered. Now there is much debate about other metals being as suitable for tropical or marine environments and it is not for me to suggest that anything other than titanium would be irresponsible but titanium bolts have been used in the Grand Cayman for more than 16 years and Thailand for a little over 13 years and are showing no signs of corrosion. The UIAA recently carried out some extensive research that led to the UIAA Safety commission recommending only the use of Titanium and high end ‘HRC’ alloys (6% Molybdenum stainless steel such as 1.4529, 254SMO) in these environments. They have also suggested that the expected life time of fixed protection in any environment should be a minimum of 50 years. It seems that the titanium bolts in combination with the RE-500 have the best chance of lasting a lifetime.

So where does this information leave us?

We have whole crags in places like Kalymnos being rebolted with stainless steel glue-in bolts less than 10 years after being developed. There is a reasonable chance that these routes will need rebolting again in 10 or 15 years. We have seen recent stainless steel glue-in bolt failures in Sardinia, multiple bodyweight failures in Taiwan of Petzl Collinox glued using RE-500 after less than 10 years, and Fixe anchor chain failures in the Costa Blanca. Some anchor failures and weld cracking have occurred at indoor and outdoor walls in both Germany and the UK. Perhaps we should take a longer term approach to equipping sport routes?

Maybe the pace of new route development will be slower due to increased cost, but the savings in rebolting could be enormous. Certified titanium bolts are now available from around £6.50 to £9 from Titan climbing, a Sheffield based company. This is not cheap when compared to expansion bolts, but they will probably last a lifetime if placed properly and with the correct glue. Pure epoxy resin can be purchased direct from Hilti or Titan climbing at a cost of around £16 per tube, which is enough to place about 25 bolts. A single pitch would cost approximately £75-£100 – even ignoring the safety advantages, surely at £2/year for a route anything else is a false economy?

In the next installment, I will share some of the lessons we have learned from placing thousands of bolts.

Trevor Massiah is a Mountaineering Instructor based in Spain and is the owner operator of Rock and Sun which runs climbing and bouldering courses and holidays in many parts of the world. He has been working in the outdoors for 33 years and has climbed extensively around the world. His favourite crags are Pembroke, Taipan wall and the Needles California. He has put up many routes – both trad and sport – in the UK, Thailand, Australia, China and India, and is currently involved in rebolting existing routes and developing new routes in Thailand and the Costa Blanca.

Further information

 

 

by Trevor Massiah

Published in The Professional Mountaineer – Spring 2017