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By Nan Zhou, Jixiong Zhang, Qiang Zhang

"Mining activities under hard roof could easily induce rock burst. Based on the geological conditions of widespread hard roof in China, this paper discusses the type, mechanism of occurrence and prevention of rock burst caused by hard roof from energy evolution point of view. It analyzed the interaction between the solid backfilled body and roof under different backfilling ratios. And by establishing and applying the mechanical model, the deformation of hard roof and energy evolution of the panel under different backfilling ratios were determined, revealing the control effect of solid backfilling on disaster-causing energy. As a result, an innovative method using the solid backfilling method was proposed as a solution to the hard-roof-induced rock burst hazards. Moreover, mine trial was conducted in Panel 6304-1 of Jisan Mine. The result shows that the stress concentration factor of the front abutment stress was only 1.44; the coal dusts in drill holes didn’t exceed the limits and microseism of large energy didn’t occur during mining mining, indicating that solid backfilling mining could be applied as an effective method for preventing rock burst caused by hard roof.INTRODUCTIONSHard roof refers to the thick strata above the coal seam or thin immediate roof. It is strong with poor joint development. After mining, instead of immediate caving, it will overhang for a large area in the gob, resulting in high stress in front of the face and difficulty in gas dispersion. As a result, the face spalls, the roof exposes and the gas accumulates in the gob. With the continuing advance of the face and increase in area of overhang, the stress in the hard roof will eventually exceed its ultimate strength and cause a large area of caving, followed by quick release of energy concentrated in the roof and coal seam, which may cause rock bursts and other dynamic disasters in the mine as well as serious equipment damage and casualties. Therefore, the hard roof becomes one of the main factors causing rock bursts at the face.Hard roofs in China varies in conditions. It ranges from dozens of meters to hundreds of meters in thickness. However, coal reserve under hard roofs accounts for about 1/3 of the total reserve; moreover, nearly 40% of the fully-mechanized coal mining panels are those with hard roofs and more than 50% of the mining areas are associated with problems of hard roofs. Aiming at this problem, researchers at home and abroad have proposed many solutions, e.g. coal pillar support, strength weakening and forced caving, to prevent rock bursts caused by hard roof. These solutions have been employed in some cases with good results. However, due to the variability in geological conditions of mining and hard roofs, the application of the above solutions is limited."

Jan 1, 2015

By Shuren Wang, Wenbing Guo, Paul C. Hagan, Yanhai Zhao

"The overlying strata is often destroyed in large scale during shallow coal seam mining, and the sliding instability of the caved roof seriously threatens the safety of the mining field. The typical shallow coal mining in Shendong Mining Area in China was used as engineering background; the load distribution characteristics of the overlying strata were analyzed based on the monitoring data of the support resistance. Through theoretical analysis and numerical simulation, the formation and changing process of the pressure-arch in the overlying strata were studied, and the instability mechanism of the overlying strata was revealed by focusing on the accumulation and release law of the elastic energy in the pressure-arch. The results show that the continuous pressure-arch was formed when the horizontal stress exceeded the primary vertical stress of the mining field, and the elastic energy of the roof was released by the mining unloading effect. The elastic energy was accumulated in the pressure-arch, and the energy arrived the highest at the front arch foot. The accumulated energy at the arch foot was released by coal mining, and the shear zone could be formed. Therefore, the sliding of the caved zone along the shear zone induced strong roof weighting. The concentrated stress and the released energy during each mining increased with the panel advancing, and the height of the shear zone also increased. The conclusions obtained in the study are of important theoretical value to direct similar engineering practice.INTRODUCTIONThe instability of overlying strata during shallow coal mining, such as the large-scale roof falling and step-like ground subsidence, is a key problem that can restrict the safety mining in the mines (Ju and Xu, 2015). The self-bearing structure of the pressure-arch can form in the overlying strata after coal mining, and this structure can support the load of the upper strata and soil layer, so the weighting intensity of the panel is determined by the caved rock in the unloading zone under the inner boundary of the pressure-arch. A large amount of elastic energy is accumulated in the pressure-arch under the concentrated stress, and the released energy for mining is the internal cause of rock failure (Wang et al., 2017). It is an important problem to reveal the distribution characteristics of the stress and energy fields in the mine and to analyze the stability of the overlying strata during shallow coal mining based on the evolution characteristics of the pressure-arch."

Jan 1, 2018

By Rajendra Singh

Considering the importance of a fully mechanized depillaring operation, the Indian coal mining industry has introduced a number of such depillaring operations at depths of cover ranging from 60 m to 377 m. The overlying strata of these depillaring faces vary widely from highly laminated, weak and easily caveable to massive, strong and difficult to cave. Most of these mechanized depillaring operations were carried out in difficult site conditions, however, performance monitoring in the field has showed good production, productivity and safety results. Field studies have shown that the use of roof bolts as breaker line support for this technology worked well for moderate strength overlying roof strata, but experienced difficulties for both extremely weak and strong/massive overlying roof strata. It is observed that the performance of a breaker line support along the goaf edge deteriorated with an increase in depth of cover of the depillaring face. Practice of a straight line of extraction (single row of pillars) during the mechanized depillaring below competent roof strata experienced a considerably large hanging area inside the goaf, which needs to be managed either by induced caving of the roof strata or through an increase in width of the excavation. Observations of good performance of a fully mechanized depillaring face under highly laminated and weak strata at a shallow cover is mainly due to a faster rate of extraction. However, the mechanized depillaring underneath laminated and weak roof strata for a deep-seated coal seam was forced to go for partial extraction mainly due to strata control problems. Discussing the implications of main technical and operational differences between the conventional (semi-mechanized) and fully mechanized depillaring, this paper presents results of different strata control studies conducted at different mechanized depillaring sites with varying geo-mining conditions.

Jan 1, 2014

By Michael Murphy, Khaled M. Mohamed, Berk Tulu

"Failures of coal ribs are major hazards in underground coal mines. For the period of 2010 to 2014, rib falls were the leading cause of groundfall fatalities and accounted for 35% of all groundfall-related fatalities. Currently, the National Institute for Occupational Safety and Health (NIOSH) is conducting a research project to develop an engineering-based design methodology for rib control in underground coal mines to reduce rib fall accidents and fatalities. Numerical models can be used as part of the design methodology provided the models are appropriately calibrated and verified.This paper presents a coal rib model to simulate the mechanism of coal deformation and fracturing that can lead to stress-driven rib falls. The proposed coal rib model was calibrated against published data from an instrumented rib site at the West Cliff Mine in Australia. Fracturing of the coal rib was defined by critical VALUES (of plastic shear strain of the coal material and rib displacement. A critical plastic shear strain of 2.8% and a sudden increase of rib displacement of 30 to 45 mm were sufficient to develop a fracture plane in the rib model. Accordingly, a discontinuous rib deformation was achieved and it compared favorably against field monitoring data.INTRODUCTIONCoal ribs are the vertical walls of coal formed when entries are developed in a coal bed. Failures of coal ribs are a major hazard in underground coal mines. Furthermore, failing ribs can contribute indirectly to roof and floor instability by increasing opening widths across intersections and entryways. Over the last 18 years, there has been a continual occurrence of injuries and fatalities in underground coal mines due to rib falls. For the period of 2010 to 2014, rib falls (excluding longwall face failure and bursts) were the leading cause of ground fall fatalities and accounted for 35% of all groundfall-related fatalities (MSHA, 2015)."

Jan 1, 2016

By Timothy Batchler

"Pumpable roof supports are currently being used to provide a safe working environment for longwall mining. Because different pumpable supports are visually similar and installed fundamentally in the same manner as other supports, there is a tendency to believe they all perform the same way. However, there are several design parameters that can affect their performance, including the cementitious material properties and the bag construction practices that influence the degree of confinement provided. A full understanding of the impact of these design parameters is necessary to optimize the support application and to provide a foundation for making further improvements in the support performance.This paper evaluates the impact of various support design parameters by examining full-scale performance tests conducted using the National Institute for Occupational Safety and Health (NIOSH) Mine Roof Simulator (MRS) as part of manufactures' developmental and quality control testing. These tests were analyzed to identify correlations between the support design parameters and the resulting performance. Based on more than 160 tests over 7 years, quantifiable patterns were examined to assess the correlation between the support dimensions, cementitious material type, wire pitch, and single-wall vs dual-walled bag designs to the support capacity, stiffuess, load shedding events, and yield characteristics.INTRODUCTIONDeveloped in the 1990s, the first major use of pumpable supports systems in U.S. longwall operations was in the support of bleeder entries (Barczak, Tadolini, 2008). Since then, they have been utilized as yieldable concrete supports to provide a safe working environment for longwall mining gateroads, bleeders, and emergency escapeways while also maintaining adequate ventilation pathways. The basic structure of pumpable roof supports has remained unchanged over the years. Formed in place with a twopart fast-setting grout, the support material can be pumped into a containment bag from several thousand feet away often through surface boreholes. The containment bag then acts as a form to fill the support and provides confinement to the grout during loading and after failure. Pumpable roof supports provide full contact with the mine roof and floor, which eliminates the need for secondary material to establish proper roof contact (see Figure 1). They provide a high peak load capacity and a sustained, confinement controlled yield behavior while maintaining stable ground conditions, which is essential to underground mining operations."

Jan 1, 2016

By Eric C. Poeck, Ryan Garvey, Ugur Ozbay, Kun Zhang

"A coal bump is characterized by the sudden failure of one or more pillars and an associated release of kinetic energy. Although the geologic conditions surrounding coal bumps are often similar, their occurrence and magnitude are difficult to predict. This paper presents the development of an approach to assess the potential for coal bumps in room and pillar mines through the use of energy concepts and special consideration of the interface properties between the coal and overlying rock. Back analyses were performed on the widespread collapse of a room and pillar mine with an associated 3.9 local magnitude seismic event. Pillar and mine-scale models were constructed using the distinct element method to simulate the mining stages leading up to the collapse. A variety of loading conditions, material properties, and interface properties were evaluated for their effect on unstable failure of single pillars, and the mine-scale model was used to study the evolution of failure during progressive mining. The extent of unstable failure was quantified in these models by calculating the total kinetic energy released during each mining stage. Through the parametric analysis of single pillar models, it was found that softening parameters in either the coal or the coal/ rock interface can individually facilitate unstable failure of pillars, but the combination of the two in a single model produced a much higher release of energy during failure. The results of the minescale model further illustrated the trend as the combination of softening parameters in the coal and coal/rock interface produced a series of failures that most accurately reflected the collapse event at the mine. The method of room and pillar stability analysis demonstrated in this study effectively explores the potential for large coal bumps.IntroductionThe analysis of coal pillar behavior is challenging because natural variability in geologic conditions requires estimation of material strengths and predicted loads for a given mining situation. Large width-to-height (w/h) ratio pillars and deep overburden present an additional challenge, as the failure behavior of such pillars is more complex and may involve unstable, sudden collapse. Empirical methods have improved the success of coal pillar design for a wide range of conditions, but, for deep cover and squat pillar (w/h > 10) geometries, pillar performance predictions are not as accurate (Mark, 2000). As with any empirical approach, more back analysis and the consideration of new variables may help improve understanding and accuracy of future designs."

Jan 1, 2015

By James D. Pile

Following a methane ignition in the active panel of a longwall coal mine, the affected panel was successfully isolated from the rest of the mine. This allowed for the remainder of the mine to return to regular operation, and the conventional practice of having to seal the portals for a defined period of time was avoided. After the affected panel had remained isolated for a regulatorily mandated period of time, it was reopened in preparation for longwall face recovery. As it was not possible to move the shields from their existing positions to facilitate the installation of recovery mesh prior to shield recovery, alternative methods had to be considered to stabilise the gob and minimise flushing, thereby improving operator safety. The objective of the paper is to show how stabilisation of the gob was achieved during shield recovery, thereby minimising flushing, and improving operator safety. Phenolic foam was chosen and injected from between the shields into the gob behind them. This is a technique that has been used to great effect in Germany, to a lesser extent in Australia, but not knowingly to date in the United States. To ensure nothing was left to chance and thereby guarantee the project?s success, the procedure used in Germany was employed, down to the application of equivalent hardware, which was sourced through the North American supplier.

Jan 1, 2013

By Peter Zhang, Dan Neilans, Scott Peterson, Scott Wade, Joe Pugh, Ryan Mcgrady

"A coal outburst is a severe safety hazard in room-and-pillar mining under deep cover. It is more likely to occur during pillar retreating. Multi-seam mining dramatically increases the risk of coal outburst within the influence zones created by remnant pillars and gob-solid boundaries. Though coal outburst is generally associated with heavy loading of coal pillars, its occurrence is difficult to predict. Risk management provides a proactive tool to minimize coal outburst in room-and-pillar mining under deep cover. Risk assessment is the first step in identifying and quantifying outburst risk factors. The primary risk factors for coal outburst are overburden depth, roof and floor strength, geological anomalies, mining type, multi-seam mining, and panel width. A risk assessment chart can be used to proactively screen out mining sections with high risk of coal outburst for further analysis. Gob-solid boundaries and remnant pillars are critical factors in evaluation of the coal outburst risk of multi-seam mining. Risk identification, risk assessment, geologic influence mapping, geotechnical evaluation, risk analysis, risk mitigation, and monitoring are essential elements of coal outburst risk management process. Training is an integral part of risk management for risk identification and communication between all the stakeholders including management, technical and safety personnel, and miners.INTRODUCTIONA coal outburst is a sudden violent burst of coal from a pillar with broken coal or blocks of coal forcibly ejected into open entries. A coal outburst is a severe safety hazard as the mining crew is highly exposed at the site when the event occurs. Though deep cover and strong roof and floor are underlying geologic conditions of a potential burst incident, its real occurrence is also the result of additional mining factors. In room-and-pillar mining, a coal outburst could occur during both development and pillar retreating, but the latter greatly increases the risk of outburst. The other risk factors of coal outburst also include mining layout, multi-seam mining, presence of adjacent gob, cutting sequence, and local abnormal geologic conditions. Over the years, the cases of coal outbursts have been studied by many researchers and mining practitioners(Peng, 2008; Newman, 2008; Iannacchione and Tadolini, 2008; Gauna and Phillipson, 2008; Hoelle, 2008; and Newman, 2002). It is commonly believed that the coal outburst is the result of a sudden release of elastic strain energy stored in coal pillars and is highly associated with cutting into heavily loaded coal pillars, but its occurrence is a rare event and is difficult to predict. A number of engineering controls have been recommended to mitigate outburst potential. For room-and-pillar mining, sufficient pillar sizes have been the primary control for coal outburst prevention. The pillar design tools such as ARMPS and AMSS developed by NIOSH have played an important role in the design of stable pillars to prevent pillar collapse and squeezing as well as coal outbursts. In fact, with the implementation of pillar design using proper stability factors, pillar collapse and squeezing have been almost eliminated, and the number of coal outbursts has been greatly reduced in the US over the past decade. However, after a few outbursts occurred during pillar retreating in the US over the past a few years (MSHA, 1996; MSHA, 2014; MSHA, 2013), it has been realized that sufficient pillar size is still not enough to prevent coal outbursts. The investigations of the incidents showed that other factors such as multi-seam mining, panel layout, cutting sequence, and local geologic factors also seemed critical in causing the events. Therefore, it has become imperative that additional proactive measures beyond proper pillar design be implemented to prevent coal outbursts."

Jan 1, 2015

By Xinzhi (Thomas) Du

"In order to monitor the overburden strata deformation over a longwall mining area in the Pittsburgh Coal Seam, three boreholes were drilled across the longwall panel. Each borehole employed multiple-point borehole extensometers (MBE) to monitor overburden strata movement during and after the longwall face passed under the study area. The longwall face in the study area was 1,428 ft wide and 4,000 ft long. The average mining height was about 7 ft. The overburden depth ranged from 550 ft to 650 ft with an average of 600 ft. The final extensometer readings indicated that overburden strata initially showed sign of movement when the longwall face was 700 ft inby the MBE. The rate of strata movement accelerated when the face was 300 ft inby MBE. When the face was directly under MBE, a sudden anchor displacement occurred, indicating rapid strata movement once under-mined gob. The readings showed insignificant strata movement after the longwall face was 400–700 ft outby MBE.INTRODUCTIONThe longwall mining method is an efficient mining method of underground mining. Surface and subsurface strata are inevitably disturbed above the longwall mined out gob. Figure 1 shows the four zones of disturbance in the overburden strata in response to longwall mining.A longwall shear cuts the coal seam and allows the immediate roof strata to cave into irregular blocky material to fill the void. This is called the caved zone. The caved zone extends from the mining horizon to six or eight times the mining height, depending on the bulk factor of each caving strata layer. The fractured zone is located above the caved zone, in which the strata breaks into regular blocks by vertical or sub-vertical fractures caused by bending forces due to the weight of the underlying strata. The surface soil and rock crack zone extends to approximately 50 ft below the surface. The surface cracking is caused by downward movement of the surface. Between the fractured zone and surface crack zone is the continuous deformation zone. The strata in this zone deforms gently without causing any major cracks that extend long enough to cut through the thickness of the strata, as in the fractured zone (Peng, 2006).The objective of this project is to provide fundamental rock mechanics research about overburden strata movement response to longwall-related activity. The findings aid in better understanding pillar stability, gas well subsidence management, hydraulic impacts, and numerical modeling."

Jan 1, 2018

By Hongwei Wang, Hao Zhang, Panshi Xie, Xicai Gao, Youfu Zeng, Yongping Wu, Juan Dou

"The reserves and production of steep coal seams account for approximately 15–20% of the total coal reserves in China and 5–10% of the total annual coal production. More than 50% of the coal is high-quality coking coal and anthracite, based on reviews of steeply dipping seam mining at home and abroad. Fully mechanized mining is considered to be the only safe and efficient way to mine steeply dipping seams. To achieve fully mechanized longwall mining, four issues must be addressed: ground control, equipment stability control, development of complete sets of equipment, and safety. Engineers must focus on many factors of steeply dipping seams, such as the following: stope, roof asymmetrical structure, stability control, “roof-support-floor” system dynamics control, multi-region big-range ground control technology, adjustment false-inclined method, nonlinear layout method, control technology, safety, and development of complete sets of equipment. Engineering practices in China introduce these concepts systematically: fully mechanized mining of medium-thickness seams, fully mechanized high mining of thick seams, fully mechanized caving of extremely thick coal seams, fully mechanized mining of coal seams, roadway support, and so on. A steeply dipping seam is one with a dipping angle in the range of 35°–55°. This accounts for about 15%–20% of the total coal reserves in China. Because of the environment, more than 50% of the coal is high-quality coking coal and anthracite. Mining steeply dipping coal seams is known to be difficult in the mining industry. After the study conducted by Germany, Poland, and the former Soviet Union in the1970s–1980s, the fully mechanized mining basic theory, core technology, and key equipment research have not been a breakthrough. Being fully mechanized is a technological “restricted area” at home and abroad. A lot of steeply dipping seams are excavated by non-mechanized mining, leading to harsh job environments, labor-intensive work, low productivity, frequent accidents, and significant security hazards. The death rate per million tons of coal reaches above 4.0 and is far higher than slow inclined coal seam mining. Making steeply dipping seam mining safe and efficient is a global problem that urgently needs to be solved. Fully mechanized mining is the only way to overcome these problems (Wu, 2003; Wu, Yun, and Zhou, 2000). The realization of fully mechanized coal seam mining must solve four problems. (1) Examine the disaster mechanisms induced by overburden “key strata” mutation under steeply dipping seams as a basis for ground control methods and technical problems. (2) Work to solve the dynamic stability control technical problems of thousands of tons of complete sets of equipment under the steeply dipping seams. (3) Complete sets of equipment must be developed to adapt to the conditions of steeply dipping seams. (4) Overcome the steeply dipping face safety protection technical problems. In the last two decades, a number of universities, research institutes, and enterprises have realized the importance of safety and efficiency of steeply dipping seams in China. This is especially true of Professor Wu Yongping’s “hard coal layer safe and efficient mining” team at Xi’an University of Science and Technology. After several generations’ research and technical work, the team puts forward China’s longwall mechanized coal mining of steeply dipping seams strata control basic theory. This paper puts forth a series of key technologies of fully mechanized mining, develops and manufactures complete sets of equipment by independent innovation, and establishes a perfect face security system, forming a theory and technology system for fully mechanized longwall mining of steeply dipping seams."

Jan 1, 2017

By Peter Zhang, Gary Deemer, Rod Lawrence, Scott Peterson, Scott Wade, Mike Mishra, Rick Smith, Robert Bottegal, Ed Zeglen

"Thinly-laminated silty shale that falls like ""stack rock"" is always difficult to support in underground coal mines. With thin laminations of 2.5 to 52 mm (0.1 to 2 in) thick and weak bonding between laminations, the roof is much weaker under horizontal stress than under vertical load. Buckling of thin laminations and cutters are common signs of initial failure for this type of roof. When a roof fall occurs, it is mostly above the primary bolted horizon with a fiat top and steep breaking angle above the pillar ribs. Because silty shale is brittle, roof falls mostly develop without significant roof sagging. With thick, laminated silty shale, it is difficult to build a strong solid beam with short primary bolts. Longer bolts, straps, and supplementary cable bolts are required. Since installation of longer primary bolts in low seam mining is operationally inefficient, supplementary bolting is important to maintain overall roof stability. The bolting plan should also be chosen based on the geologic hazard map, which indicates the distribution and thickness of laminated silty shale, as well as the transition areas.To effectively support the thinly-laminated silty shale roof, an area with the same type of roof in a low seam mine was monitored for approximately four months. The mine had experienced roof falls while using different bolting systems and mine orientations in past years. The roof support in the area was studied through geologic mapping, roof scoping, and testing of different bolting plans. This paper presents the roof failure characteristics of the thinly-laminated silty shale, the correlation between failure and geologic condition, an evaluation of different bolting plans, and the requirements for primary and supplementary bolting for the silty shale roof.INTRODUCTIONThinly-laminated silty shale that falls like ""stack rock"" is always difficult to support in underground coal mines (Peng, 2007). With thin laminations of 2.5 to 52 mm (0.1 to 2 in) thick and weak bonding between laminations, the roof is much weaker under horizontal stress than under vertical load. Buckling of thin laminations and cutters are common signs of initial failure for this type of roof. When a roof fall occurs, it is mostly above the primary bolted horizon with a fiat top and steep breaking angle above the pillar ribs. Because silty shale is brittle, roof falls mostly develop without significant roof sagging. In low seam mining, it is difficult to install longer primary bolts, so supplementary bolts have to be installed to maintain overall roof stability. To effectively support the thinly-laminated silty shale roof, an area with the same type of roof in a low seam mine in western Pennsylvania was studied for approximately four months."

Jan 1, 2010

By Tom Blevins, Roland Walker, Jinsheng Chen

"The Dywidag-Systems International DSI Tandem Anchor bolt, with an improved expansion shell-washer design, can substantially reduce potential entry roof falls caused by twisted or deformed expansion shells of the traditional mechanical anchor bolts during installation. In addition, the improved anchorage system can also ensure that a consistent and high installed load is achieved, which is critical for effective beam building under thinly laminated or layered roof conditions. This paper discusses the genesis and anchorage performance of the Tandem Anchor bolt, and analyzes the tension/torque relationship of different mechanical shell anchors using data obtained from both lab and field tests. It also discusses roof bolting mechanisms, roof bolting systems, and factors influencing effective beam building. Finally, numerical modeling was used to analyze the effect of bolt pretension magnitude on entry roof stability.INTRODUCTIONThroughout the history of underground mining, keeping the roof from uncontrollable collapse has been the greatest concern of the miner. Tremendous strides have been made in better understanding, predicting, and supporting the mine roof. This conference has spent the last twenty-eight years sharing information and distributing it to the mining community. A paraphrased statement from former Secretary of Defense Donald Rumsfeld adequately describes the challenges to the mining engineer as it pertains to roof control: it is a study of known knowns, known unknowns, and unknown unknowns. It is the hope of the authors to address some of these unknowns.The paper discusses the development of bolt anchorage systems from dry shells to shells with resin-assisted anchorage. It looks at some of the issues faced with the anchorage shells being used when introducing the insertion pressures caused by resin cartridges. The rationale behind the shell design changes was to compensate for this resin induced stresses.An improved expansion shell assembly (a slotted expansion shell base, a tapered cramming plug, and a novel support nut with tapered top) for mine roof bolts makes up the Tandem Anchor (U.S. Pat. No. 6742966); this minimizes the possibility of twisting seen with traditional mechanical shells and thus prevents springy bolts and shell leaves from breaking. A fully grouted Tandem Anchor bolting system has the advantages of both the pure mechanical point-anchor and the non-pretention fully grouted bolting systems. Once installed, the installed load or pretension will be locked in and never bleed off. Compared with the fully-grouted (2-speed resin) tension rebar bolting system, the fully-grouted Tandem Anchor bolting system can (a) reduce bolting cycle time (about 15 seconds per bolt), boosting coal production and productivity; (b) provide a greater installed load or pretention; and (c) achieve a consistent tension/torque ratio, which gives better bolting quality control. Therefore, a fully grouted Tandem Anchor bolting system is the most effective means to reinforce a weak rock mass intrinsically by the theory of beam building. For thinly laminated or layered roof conditions, a higher installed load or pretention (50% or more of the bolt's yield strength) can make a roof bolting system much stiffer, which results in less roof movement. Numerical modeling results show that the magnitude of the roof's tensile stress and relaxation zone can be substantially reduced under a higher installed load or pretention."

Jan 1, 2010

By Thomas M. Barczak

The performance characteristics of Mobile Roof Supports (MRS's) were evaluated through full-scale testing in the Strategic Structures Testing Laboratory at the National Institute for Occupational Safety and Health, Pittsburgh Research Center. Safety issues pertaining to the operation and design of these supports for pillar extraction during retreat mining are examined. A unique load frame, called the mine roof simulator, provided a realistic simulation of mining conditions by inducing vertical, horizontal, and lateral loading on the support. The purpose of these experiments was to determine the capabilities and limitations of the supports and to investigate factors that influence the measurement of loading and loading rate. An evaluation of the support design and load conditions that can cause support failure or loss of support capacity are discussed relative to the laboratory tests. In general, lateral loading perpendicular to the longitudinal axis of the canopy is most severe, although horizontal loading in the direction of the long axis of the canopy can also produce critical loading in some cases. The experiments indicate that both setting force and leg pressure measurements are influenced by the staging of the leg cylinders. The implications of these factors on load rate measurement are evaluated. A comparison of MRS capacity and stiffness characteristics is made to conventional timber supports.

Jan 1, 1997

By Jim Sandford

The South Bulga Colliery longwall operation, owned and operated by Cyprus Coal Australia. Oakbridge Pty. Ltd., and located near Singleton, NSW, is currently operating under an average 80-ft-thick (24-nt) sandstone unit residing immediately above the coal seam, resulting in sudden and severe face weightings. To date, nine severe weightings have occurred at the property (within Panels 3, 4. and 5), three of which resulted in face closures accompanied by significant equipment damage and several weeks of downtime. The remaining six events nearly resulted in face closures, incurring single-pass vertical convergence of up to 8 in (200 mm) along the pan line. In an effort to mitigate and/or eliminate the occurrence of these severe weighting events, mine management has established an in-house program to immediately address the geotechnical and operational mechanisms underlying rapid weightings, as well as specific measures to mitigate these events on future panels. In support of this in-house effort. NSA Engineering Pty. Ltd., is assisting the engineering staff at South Bulga in developing a more aggressive face monitoring program. The aim of this program is to provide weighting occurrence predictions sufficiently ahead of time to ensure that operational controls are optimized prior to attempting to mine through potential weighting areas. This paper reviews the occurrence of weightings to date at the South Bulga Colliery as well as the latest developments in shield monitoring technologies to forecast these events in near-real time.

Jan 1, 1999

By Kanchan Mondal, Anthony (Sam) Spearing, Gopi Bylapudi, Joseph C. Hirschi

"The U.S. coal mining industry uses about 100 million rock anchors per year. ASTM F432 specifies the requirements for rock bolts on mines but does not address corrosion. Corrosion has been found to be an issue in Australian coal mines (Hebblewhite et al., 2003 and Villaescusa et al., 2007), where the problem has been researched and stress corrosion has been found to be a significant cause of rock falls. Corrosion is also a major concern for underground civil construction in the U.S. but has not been considered an issue or adequately researched in coal mines. Underground conditions are conducive to corrosion mainly because of water quality and humid conditions. There is a perception, however, that when bolts are fully grouted, adequate corrosion protection is offered to the steel. Research has shown that this is not necessarily the case, due to the formation of micro-cracks as the resin sets and with subsequent rock movement shearing the resin column. This paper outlines a method to determine the corrosion potential of bolts used in long-term excavations and suggests ways to mitigate such effects based on research conducted in the lab and on three mines.INTRODUCTIONResearch on rock anchor corrosion in mines has not been extensive enough in the past, and the effects of several factors in the mine atmosphere and waters are not clearly understood. One probable reason for this lack of research may be attributed to the time required for gathering meaningful data, which makes the study of corrosion quite challenging.Almost all the rock bolts used in coal mines are made from steel, hence the corrosion of iron needs to be understood. The corrosion of iron is an electrochemical phenomenon with the overall equation"

Jan 1, 2010

By Andre Zingano, Anderson Weiss

"The objective of this paper is to study the behavior of a low thick and low depth coal seam and the overburden rock mass. The mining method is room and pillar in retreat and partial pillar recovery. The excavation method is conventional drill and blast because of the small production. The partial pillar recovery is about 30% of the previous pillar size, 7m x 7m. The roof displacement was monitored during retreat operation; the surface movement was also monitored. The effect of the blasting vibration on the final pillar strength had been considered. Due to blasting, the pillar reduced about 20%. The consequence is more pillar deformation and roof vertical displacement. The pillar retreat and ground movement were simulated in a three-dimensional numerical model. This model was created to predict the surface subsidence and compare to the subsidence measured. This study showed that the remaining pillar and low seam reduce the subsidence that was predicted with conventional methods.INTRODUCTIONMining low coal seams (less than 1 meter) with the room-and-pillar mining method implies the excavation of part of the roof or floor to maintain adequate entry height for equipment and compliance with labor regulations with respect to ergonomic issues. The direct consequence of this is an increase in coal contamination and the increased cost of transportation and preparation at the plant. Traditional room-and-pillar mining only uses a development operation, even with a continuous miner or drill-and-blasting. Therefore, all the run of mine (ROM) coal is carried out with part of the roof or floor. However, if the retreat mining method were to be considered, the quality of the coal could increase because only the coal seam is excavated from the pillar recovery. The quality of ROM coal will increase, and the cost will decrease proportionally to the amount of coal produced from the retreat operation.However, the retreat mining with partial or total pillar recovery implies greater subsidence. This is particularly true if the coal seam depth is shallow, under 100m depth. Subsidence prediction in room-and-pillar retreat mining is complex; it depends upon the remaining pillar (stump pillar) size, as well as the pillar height, and the behavior of the pillar after retreat. This is related to the strength of the remaining pillar, which is related to the excavated method (drill-and-blast or mechanical)."

Jan 1, 2018

By Jun Lu

This paper presents the evaluation, enhancement and comparison of two hydraulic fracturing techniques which were employed to mitigate the impact of a massive sandstone channel on two successive longwall faces. The hydraulic fracturing technique and Longwall Visual Analysis (LVA) software were initially employed to mitigate the impact of thick, massive sandstoneroof during mining of longwall Panel 21. Improved longwall face conditions and productivity were observed as Panel 21 mined through the sandstone channel. However, moderate sandstone fractures and falls at the face were still present in areas where hydraulic fracture influence was not present. Such adverse conditions caused two to three weeks of production delays due to large face cavities, jammed face conveyor and subsequent face gluing. Based on the mining experience in Panel 21, and site-specific roof geology in Panel 22, a modified and more effective hydraulic fracturing program was employed. Fewer well-placed holes were drilled, and larger volume of water was pumped into each hole in order to propagate the individual horizontal pancake fractures over a larger area, thereby enhancing caving and relieving face pressure caused by overhang of the massive sandstone. Longwall Visual Analysis (LVA) software was also employed at Panel 22 to predict the cavity risk index and guide the longwall face crew in double-pulling shields behind the shearer drum. This helped to reduce the tip-to-face distance at the critical spots along the longwall face, which helped mitigate the formation of the roof cavities and failure of massive sandstone onto the face conveyor. Underground observations, face advance rate and face rock delay analysis confirmed that longwall face conditions and advance rate in Panel 22were significantly improved compared to those of Panel 21. Consequently, safety and productivity were improved.

Jan 1, 2014

By Ted Klemetti, Gabriel Esterhuizen, John L. Ellenberger

"Advanced numerical models can be used to evaluate entry support systems in coal mines. However, these methods require specialized software and specialized skills to create the models and evaluate the results. Practicing support design engineers require a method to rapidly assess a proposed support system for a given geotechnical scenario. A prediction equation that can be used to assess roof support systems has been developed from the results of hundreds of FLAC3D analyses that were conducted during recent research. These models were validated against field cases and empirical design approaches and were found to adequately predict entry stability in coal mines. The understanding developed from the model outcomes was used to develop an equation to predict entry roof stability against large roof falls. Least-squares error analysis was conducted to find appropriate parameters for the nonlinear equation. The developed equation can be solved using spreadsheet software, allowing for rapid assessment of alternative support system performance in variable geological conditions. The performance of the prediction equation is evaluated against empirical design methods and against selected case histories of support practices at currently operating mines. Examples are presented that demonstrate the performance of the equation in variable geological settings. The stability factor (SF) prediction equation can be used as an assessment tool to assist in the design of coal mine roof support systems.IntroductionGround falls represent a significant proportion of injuries and fatalities in underground coal mines in the US. During 2013, ground falls were responsible for 4 of the 14 fatalities and 16.6 % of the 1,577 reportable lost-time injuries (MSHA, 2015). In addition, each year about 400 to 500 large roof falls are reported that can extend up to or above the bolted horizon. Large roof falls and associated ground fall hazards can be mitigated through improved support design.The research presented here particularly addresses the problem of large roof falls that extend more than 90 cm (3 ft) above the roof line of an entry and may extend above the bolted horizon. Smaller roof falls that fall out between supports or extend less than 90 cm (3 ft) above the roof line are excluded. These smaller roof falls can be controlled by appropriate surface support such as roof screen or other skin control methods. Also excluded are roof falls that are associated with an individual geological structure such as a slip of fault. Structure-related instabilities can be controlled by strategically locating individual roof bolts or other supports appropriate for the local situation."

Jan 1, 2015

By Long Fan, Shimin Liu, Guijie Sang

"Weak shale roof falls have long been the main cause for fatalities in underground coal mines. Moisture-induced swelling is one of the root causes for the degradation of roof shales. In this study, slake durability tests are conducted on shale samples collected from Illinois basin coal mines, and different levels of durability are analyzed according to Gamble slake durability classification. There are two main mechanisms influencing the shape of retained fragments after two cycles of wetting and drying: mechanical abrasion and swelling pressure. A prototype optically based shale swelling apparatus is designed and manufactured for the shale free-swelling measurement. The experimental results suggest that swelling pressure tends to deteriorate shale laminations. Moisture-induced swelling of the No. 6 roof shale from Bear Run Mine was measured under 100% relative humidity condition. The measured swelling strain normal to beddings is ~5 to 7 times greater than the swelling strain parallel to beddings. This suggests that interlayer expansion plays a key role in moisture-induced swelling. Cracks induced by swelling pressure tend to occur along the bedding plane and lead to shale deterioration. INTRODUCTION Background Ground falls have long been the cause for nearly 50% of all fatalities in underground coal mines and continue to be one of the greatest safety hazards in underground spaces. Among the various ground fall hazards, roof failure takes up 23% of total fatalities in underground coal mines, of which 13% are due to skin failure and 10% are due to massive roof falls (Mark, Pappas, and Barczak, 2011). Roof failures associated with weak shales are summarized in previous studies (Molinda and Mark, 2010; Aughenbaugh and Bruzewski, 1973; Bajpayee, Pappas, and Ellenberger, 2014; Murphy, 2016). For mine roof instability and failure, two aspects can explain the failure mechanism of weak roofs. One is the elevated stress concentration in lateral direction due to the mining-induced excavation and its stress redistribution around the mine opening (Song and Stankus, 1997; Fan and Liu, 2017; Hill, 1986). The other mechanism is the passive stress-relief due to the strength weakening induced by the ambient moisture and temperature fluctuations during a period of time. Shale is moisture sensitive and presents a lower durability if it is exposed to a highly humid environment for a long time, thus leading to roof deterioration and instability in underground coal mines (Aughenbaugh and Bruzewski, 1976; Stateham and Radcliffe, 1978; Chugh and Missavage, 1981; Klemetti, Oyler, and Molinda, 2009). It is well known that shale is a clay-bearing sedimentary rock and that clay minerals are water sensitive. The moisture uptake for shale will induce the micro-deformation of a shale matrix, thus the structure and strength of shale is a function of time and intensity of moisture exposure. All mine engineers notice moisture-induced shale deterioration; however, the underlying mechanism(s) are still not fully understood due to the complexity of geophysical-chemical water-shale interactions (Huang, Aughenbaugh, and Rockaway, 1986; Hensen and Smit, 2002; Diaz-Perez, Cortés-Monroy, and Roegiers, 2007). The coal mining industry is still in the process of finding a technically sound, cost-effective technology to prevent this unexpected and unpredictable shale roof failure. Therefore, understanding how the moisture-sensitive shale responses to various ambient moisture and what role exposure duration plays in shale roof failure is key to prevent unexpected roof incidents, which will lay the foundation for the long-term roof support design and ground control management."

Jan 1, 2017

By Filippo Vallianatos, Michael Verigakis, Vasili Saltas, Kosta Kaklis, Stelio Mavrigiannakis, Zach Agioutantis

"Development of failure in brittle materials is associated with microcracks, which release energy in the form of elastic waves called acoustic emissions. This paper presents results from acoustic emission measurements obtained during three-point bending tests on Nestos marble under laboratory conditions. Acoustic emission activity was monitored using piezoelectric acoustic emission sensors, and the potential for accurate prediction of rock damage based on acoustic emission data was investigated. Damage localization determined based on acoustic emissions evident in the critically stressed region in the form of scattered events or stresses below and close to the strength of the material.IntroductionNon-destructive testing (NDT) has gained popularity in recent years due to commonly available sensors, devices and software tools. Although the majority of such testing still occurs under laboratory conditions, the ultimate goal is a direct field application, especially in the case of underground mining. NDT, if properly applied, may be used to directly provide material property values and characteristics that can be used to determine rock mass or soil mass behavior, with a direct impact to mine design (Iannacchione et al., 2003).AE is generally defined as the high-frequency transient elastic waves originating from the sudden release of energy at localized points within a loaded material (Nomikos et al., 2010). The field of Acoustic Emissions (AE) due to compressive, tensile or other types of loads is a promising research area due to its wide application. The accurate identification of failure precursors stemming from AE is still an open research topic (Lei et al., 2004).Rock is a typically inhomogeneous and anisotropic material that contains several natural defects with various scales such as grain boundaries, microcracks, pores and joint inclusions (Jing, 2003; Read, 2004). Damage induced by microcracks is an essential mechanism in many brittle rocks subjected to stresses. An applied stress induces microcrack growth and damage is distributed uniformly throughout the sample. Finally, the microcracks coalesce and the damage is localized to a shear band, leading to strain softening and macro-scoping failure (Dragon et al, 2000)."

Jan 1, 2015