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By Revendra Awasthi

The application of a horizontal inclinometer and a tiltmeter to measure tilt, curvature, and deformations of shallow footings during mine subsidence is described. The measurements were taken during mining of a longwall panel in Southern Illinois and were supplemented with precision level survey data. Monitoring was conducted under a cooperative agreement between the Institute for Geotechnology at The University of Tennessee, Knoxville, the U.S. Bureau of Mines, the National Science Foundation, the Illinois Mine Subsidence Insurance Fund, and Old Ben Coal Company. Six different footings were constructed and instrumented at two sites; one above the panel centerline, and the second inside the edge of the panel in the anticipated zone of maximum tension. A brief description of the inclinometer casing and tiltplate installation is described, and the results obtained from the two instruments on a plain concrete footing compared. Observations of footing deformations and curvatures calculated from the inclinometer and tiltmeter data are also presented, and the results compared with observed structural damage.

Jan 1, 1990

By Ross W. Seedsman

The in situ behaviour of claystone floors associated with the Wallarah, Great Northern and Fassifem Seams has been studied using a comprehensive suite of stress and displacement monitors. The instrumentation was supplemented by in situ and laboratory testing of the claystone materials. The instrumentation demonstrated that the presence of claystone floors is associated with floor heave, extra rib spall, and settlement of the pillar into the floor. Horizontal floor extensometers showed that the depth of extrusion of clay was limited to 1-2 in. A pore pressure transducer installed in a claystone floor demonstrated the possible existence of short-term undrained behaviour of the claystone. Long term swelling of destressed claystone was also documented. Settlement of pillars into claystone floors can be analysed using simple elastic theory. The assumption of plane strain is valid for most claystone thickness/pillar width aspect ratios. Floor heave can be analysed using bearing capacity concepts. However, it is considered that heave is the result of local bearing capacity failure in the rib spall zone. The advantage of this model is that the bearing capacity equation can be applied without resort to unrealistically high factors of safety.

Jan 1, 1992

By Yunqing Zhang

Roof failure occurs much more frequently at intersections than entries and crosscuts. Using a commercial finite element package, four-way and three-way intersections reinforced with the tensioned bolts are modeled. The 3-D model considers bolt pre-tension, bolt installation procedure, bedding planes and in-situ horizontal stresses. The modeling results from both four-way and three-way intersections are analyzed with regard to the intersection stability. The mechanisms of tensioned bolting at the intersections are investigated and some tensioned bolting guidelines for intersections are given. Based on this study, a better way to enhance intersection stability is to use longer bolts than entries or crosscuts and increase the bolt density near the intersection corners.

Jan 1, 2003

This paper describes the experiences with the application of the Coal Mining Roof Rating (CMRR) System to South African strata conditions. Roof classification studies using the CMRR system were undertaken as part of a SIMRAC investigation into falls of ground in South Mean collieries. Colliery roof rating exercises were undertaking in a range of geotechnical conditions from shallow level coal seams under flat topography to workings with cover depths of greater than 300m A comparison is made between the CMRR and other Rock Mass Rating systems used to classify different roof geotechnical conditions. The need for geological discontinuity orientation, blasting and rockmass stress adjustments to the CMRR is discussed. The effects of acid mine water on strata weatherability and the need to incorporate immersion tests using acid mine water are also detailed. In addition limited correlation is given between CMRR values and other geotechnical factors such as joint trace length, joint shear strength, joint orientation, weatherability and roof damage due to horizontal stress. Taking cognizance of these observations, a concept of stress induced roof damage triggering is discussed.

Jan 1, 2001

By Herryal Anwar

The application of roof bolting technology to control the stability of roadways in coal mining within weak strata or under high ground pressure has improved progressively. One of several factors that affect the design of rock bolting is the immediate roof characteristics of the roadway. On the competent rocks, the mining conditions may indicate a high level of stability and a low density of bolting patterns may be adequate to control the ground stability. However, at a weak strata, the roadway will be affected by both horizontal and vertical stresses that may generate a high level of deformation in the immediate roof. This sensitivity of the roadway will require a mine plan design which consider the pillar sizes and sequences of extraction as well as a conservative reinforcement to maintain the integrity of the deforming weak roof strata. Rock bolting technology has been used to maintain the stability of roadways in Indonesia and Japan for a few years. In this paper the overview of the application of rock bolting reinforcement in Ombilin Coal Mine, Indonesia and Miike Coal Mine, Japan is given.

Jan 1, 1999

By Anil Mahyera

Under contract to the Bureau of Mines, a roofbolting machine has been developed which will: control torque on the bolthead to within 4 percent of a set point, control thrust to a low level (150 lbf), and implement a tightening method to minimize variability due to bolt tension decay of a group of bolts caused by differing anchor creep rates. This bolter was used to determine bolthead and thread friction factors, and to determine the effect of adding a hardened washer to the bolt assembly on the uniformity of bolt tension in the laboratory and field. Recommendations for torquing speed, bolt lubrication, use of hardened washers, and thrust level on the bolthead are made. The relationship of this system to Improved roof control is discussed, along with additional work that remains to be performed. Patent Notice Patents are pending which protect the hardware and methods of controlling tension decay as discussed in this paper.

Jan 1, 1981

By Michael Kelly

Current research in longwall mining in CSIRO Exploration & Mining is focused within five major projects and several minor projects. The major projects are: 1 3D Aspects of Longwall Geomechanics. This was reported to the conference last year and a final report will be available by mid-2001. 2 Mine Gas Control. This just completed project centred on Dartbrook Colliery which has a longwall gas make of more than 8 cubic metres per second. 3 Rapid Roadway Development This includes the construction of an autonomous conveying and bolting module (ACBM) that sits between the miner and haulage system. 4 Top Coal Caving In conjunction with the YanKuang group in China, CSIRO and the University of NSW are conducting a prefeasibility study of the Top Coal Caving method in Australian conditions. 5 Longwall Automation. In partnership with the Cooperative Research Centre for Mining Technology and Equipment (CMTE), the CSIRO has conducted a scoping study on this issue and will commence an initial three-year demonstration project in July this year. This paper describes these protects in more detail with particular focus on the last three in the above list.

Jan 1, 2001

By Bruce Hebblewhite

An ACARP-funded industry research project in Australia recently investigated the problem of premature rock bolt failures in underground coal mines. The project carried out limited sampling from 9 different collieries in NSW and Queensland, followed by a more comprehensive, controlled sampling from one colliery. Over 50 broken bolts were collected and subjected to metallurgical analysis at UNSW to determine both the steel composition and to analyse the fracture surfaces. Prior to this study, there had been anecdotal evidence of similar bolt failures from a number of sites within the industry. The sampling and analysis conducted by this project - whilst being below a statistically representative sample of the entire industry bolt population - highlighted the fact that bolt failures were continuing to occur at a number of sites, in both older and recently installed bolts. The failures were almost entirely attributable to stress corrosion cracking (SCC). It appears that a combination of factors - including steel composition, bolt manufacturing process, loading environment, geological and hydrological environment, bacterial corrosion - can all contribute to this problem. There is no simple solution, however, as with similar research findings from the UK, it appears that steels with higher values of fracture toughness, or Charpy Index, are less susceptible to SCC. Testing to date has been limited to bolt failures below the resin encapsulation horizon. A real concern is the potential extent of the problem at higher horizons, within the encapsulation. These may require some form of non-destructive testing (NDT) for detection. Initial trials in Australia of the ultrasonic device developed by DMT in Germany have proved encouraging. Further testing using this device is anticipated in future research. This paper describes the outcomes of the project, completed in 2002.

Jan 1, 2003

By Maynard O. Serbousek

The mechanics of load transfer of fully-grouted roof bolts in coal mines has been investigated in laboratory and analytical studies. The purpose of this research is to increase the understanding and better interpret data from pull tests which are routinely performed in the field. Laboratory work includes variation of bolt length, hole diameter and grout type in pull tests. Four-foot bolts were tested in holes of 1- and 1-3/8-inch diameters. Both polyester resins and inorganic grouts were used as the anchorage medium. The bolts were strain gauged at six locations to observe the rate of load transfer from the bolt to the rock mass when a force was applied at the bolt end using standard Jack pull testing procedures and equipment. Analytical studies using closed form solutions and finite-element techniques were compared to experimental results. The models are for the elastic regime only but do include slip elements. A detailed analysis of the load transfer mechanisms from the bolts through the grout to the rock mass is presented.

Jan 1, 1984

By Deren Zhu

The principle of roof control in longwall mining is to control main roof fractures so as to reduce roof weighting, plus reasonable and effective design of supports to reduce the convergence and premature caving of the immediate roof. This paper introduces a comprehensive test for better roof control based on the geological conditions of coal seam No. 16 in Zaozhuan Colliery, China.

Jan 1, 1990

By N. P. Kripakov

This paper presents a brief overview of current bump mechanics theories and pillar design methodologies, and relates these concepts to experiences at two mines located in a north-central Utah coalfield where different pillar designs were used to control mountain bumps. Experiences gained at the first mine demonstrated the successful implementation of a two-entry, 9.8 m (32 ft)-wide, yield-pillar design. A U.S. Bureau of Mines field study quantified the timing of chain pillar yielding and resulting load transfer from the gateroad. In-mine pillar response, although apparently sensitive to site-specific conditions, compared favorably to estimates derived using two yield-pillar design methods. A second study conducted at another mine located in the same district, but subjected to different geologic conditions, documents the unsuccessful attempts to employ progressively narrower three-entry pillar designs based on successes achieved at the first mine site. This second mine never achieved a true yield-pillar design. Use of pillar widths ranging between 9.1 m (30 ft) and 27.4 m (90 ft) always resulted in violent bumps in the tailgate pillars. The pillars were either too large to yield, or too small to support peak operational loads. Hypothetical gateroad systems were evaluated using both analytical and empirical approaches for configurations comprised of two rows of conventional pillars, and systems incorporating both yield and abutment pillars. Analysis concluded that yield pillars less than 6.1 m (20 ft) wide and abutment pillars ranging between 30.5 m (100 ft) and 39.6 m (130 ft) square would be required to achieve a stable gateroad design. However, results of a field study conducted on a two-entry, 36.6 m (120 ft)-wide abutment pillar concluded that abutment pressures from the first panel overrode the pillar, and that a still larger pillar may be required to preclude bumps in the tailgate during second panel mining. Without the benefit of a demonstrated in-mine success, it is not clear which design would ensure elimination of gateroad bumps.

Jan 1, 1992

By Ben Mirabile, Alan Campoli, Rodney Poland

"The majority of U.S. underground coal mines use some form of cable bolt as supplemental support to a primary roof bolting system. Many coal operators employ the high load capacity of non-tensioned cable bolts, cable roof trusses, or solid bar trusses in an attempt to suspend the primary bolted horizon to overlying strata. However, in cases where many discontinuities exist in the roof strata or where pre-existing fractures are present, these passive supplemental support systems often cannot adequately control roof deflection. This paper examines the application of tensioned cable systems to minimize roof deflection in very laminated and fractured strata. Three underground case studies are presented to demonstrate the application of tensioned cable bolts. The first case study involves the rehabilitation of a longwall head gate in the Eagle Seam with highly laminated and fractured sandstone. The second case study examines the recovery of a longwall face in the Alma Seam. The final case study addresses rehabilitation of a longwall head gate in the Pittsburgh No. 8 Seam that was developed in a sandstone channel margin area and subjected to horizontal stress concentration.INTRODUCTIONDuring the previous decade, Jennmar Corporation has recognized coal operators' increasing interest in tensioned cable bolts. The majority of these tensioned cable bolt systems have been applied in adverse roof conditions including broken ground, high horizontal stress areas, and highly laminated roof strata. In most cases, qualitative data on roof conditions after application of tensioned cable bolt support indicate successful implementation of these systems. The qualitative evidence suggests that the combination of high load' capacity and applied tension provides superior supplemental roof support in adverse roof conditions. This research aims to quantify the effects of applied tension to cable bolts. This paper will review the types and installation of tensioned cable bolt systems, present initial laboratory test data, discuss successful case studies, and propose an instrumentation system for quantification of tensioned cable bolt performance."

Jan 1, 2010

By Nielen van der Merwe

The data base of failed pillar cases as used by Salamon and Munro (1967) in their original analysis to determine the strength of coal pillars empirically, has been updated for this study. It is shown that the Vaal Basin and Klip River coal fields exhibit similar behaviour, i.e. failure at high safety factors within a short period of time after their creation. Those collapse cases have been omitted from the new data base. New failures that occurred after 1967 have been added, except for those that occurred in the Vaal Basin and Klip River coal fields. (1967) a technique to minimise the area of overlap between the populations of failed and intact pillar cases, the new data base was re-analysed in conjunction with the original Salamon and Munro (1967) data base of intact pillar cases. It was found that a linear formula reduced the overlap area by 22%. The new formula predicts higher strength for pillars with a width-to-height ratio greater than approximately 2S and a lower strength for smaller pillars. For most current South African coal mining conditions, using the new formula for pillar strength will result in leaving smaller pillars without sacrificing stability. The reason for this is that the Salamon and Munro (1967) formula underestimated the strength of larger pillars and overestimated the strength of smaller pillars. The potential benefit for the South African coal mining industry amounts to saving reserves equal to the total production of two large mines per year.

Jan 1, 2002

By Tom Denton

The bolt design criteria, since it was first published by Dr. John Stankus (Stankus, 1997), has been recognized as an important tool in ground control design. This concept is based on the Optimum Beam Building Effect (OBE), which is defined as the roof beam that has no separation above or within the bolted range and having the shortest bolt possible. This paper will present an application of this concept at the American Coal Company. Galatia mine. This mine previously used a 6' and 7' length bolt. However, since seam thickness has gotten smaller in the Southern area of the nine, a two-piece bolt is required. A two-piece bolt increases ground control costs and delays production. Therefore, a one-piece, shorter bolt, if feasible, can reduce costs and expedite development. In this analysis, Computer modeling is first conducted to determine bolt length and installed load. Second, a special bolt is developed, that can achieve the proper installed load as determined by the computer modeling. Third, underground bolt pull and load cell tests were conducted to evaluate bolt performance. Finally, an underground "bench" test was conducted. The test results have shown that entry convergence in the short bolt (5) test area is less than the 6' bolt area. Overall roof condition in the test area was as good as the 6' bolt area. Based on this analysis, the mine has converted to a shorter bolt in the low seam area and it is working well.

Jan 1, 2000

Effective strata control, utilising fully encapsulated roof bolts, is dependent on the installed quality of the reinforcement elements. One mechanism by which fully encapsulated roof bolts may become less than fully effective is by gloving (glove fingering) and un-mixing of the resin. Following some small roof failures containing gloved bolts, investigations have been undertaken in some New Zealand coal mines to determine the extent of, and mechanisms involved in, the gloving of fully encapsulated roof bolts for a range of roof types and installation methods. Gloving, in this context, refers to the resin cartridge partially or completely enveloping a length of the bolt, typically with unmixed resin filler and catalyst/hardener remaining within the cartridge. Results have shown that gloving and un-mixing is a systematic and widespread phenomena, occurring across a range of resin and/or bolt manufacturers, and across a variety of roof types. Gloving was found in bolts installed using: hand held pneumatic and continuous miner mounted hydraulic methods, under run of mine (ROM) conditions by mine workers, and under controlled "best practice" conditions. The roofs bolts investigated are all 1800mm (6ft) long, and have shown that, on average, 485mm (-19") of the bolt length is gloved and/or unmixed. This equates to a 27 percent reduction in effective bolt length. The effected length of bolt is sufficient to impact on the load transfer/reinforcement capabilities of the bolt system, and hence impacts on the design assumptions and subsequent stability assessments. Furthermore, there is a direct relationship between the mechanism for the gloving of bolts and an increased occurrence of resin loss and reduction in encapsulations length in soft (less than 10 MPa) and/or highly fractured rock. Investigations have concentrated on developing an understanding of the mechanisms involved. This has been undertaken using both field installations and recovered bolts, as well as test bench trials. The mechanisms involved have been confirmed as being: the development of a pressure front as the bolt encounters the resin and is spun up the hole, which, in turn, leads to over-pressurisation and radial expansion of the resin cartridge, resulting in an increase in diameter of the plastic resin cartridge, which allows the bolt to be spun up into the cartridge without making sufficient contact to shred the cartridge or the hardener tube, resulting in an unmixed portion of resin.

Jan 1, 2003

By E. Bane Kroeger

Rib failure is a hazard that has resulted in many injuries and fatalities in underground coal mines, especially in soft coal seams. Conventional rib control methods including rib boarding, shotcreting. steel meshing and geogridding, are fairly expensive and time consuming to install. Some methods, such as rib boarding, have met with marginal success at controlling rib failure. Under this research, the Rib Strap System (RSS) introduced by Dr. Chugh in 1999, was modified and new components were added. Both bench scale and full size prototypes were tested in the labs at SIUC to determine the best materials for fabrication and easier methods for assembly and installation. This laboratory research has developed new methods of securing the strap ends to smaller rib hoards, a new device to post-tension two straps together, and a technique for replacing straps without having to drill new rib bolts or for retrofitting straps to rib hoards that are already in place. The method used to secure the strap end to rib boards developed during bench-scale testing was dubbed the wrapped staple technique. It is very simple, requiring only 10-15 staples, with the end of a strap secured to a rib board in about 45 seconds. Several different prototype designs for a new device to join the strap ends together and tension the strap were fabricated and tested in the labs at SIUC. The device, dubbed the rib strap buckle, was very easy to install and held the straps firmly. One specific buckle design worked extremely well during testing and exceeded all expectations. The laboratory research also developed a method of replacing a damaged rib strap that can also be used to add rib straps to existing rib boards. The technique uses nails, spacer blocks, and band clamps to secure the new board and strap. This technique was developed to allow one person to replace a strap using only a hammer and screwdriver, negating the need to drill and install a new rib bolt using mine equipment such as a roof bolter or scoop. In addition to the technical feasibility, the cost of materials for the rib strap system was compared to the rib boarding method currently being used at a mine in the Illinois Basin. The mine is using 20 rib boards on each pillar at cost of about $223.60. The costs for the rib strap system depend on the materials chosen for fabrication but for the base case, were about $97 per pillar.

Jan 1, 2004

By Ross W. Seedsman

The feasibility of 6 m high single pass longwalling has been studied using Newlands Mine as a case study An intensive geological investigation identified a range of hazards but a mine layout was possible that minimised the risks with respect to joints, cleats, angular bedding, coal shears and horizontal stress. Geotechnical design input was required for support capacity, subsidence, gate to face transition, face span, and roof support. It is concluded that longwall face equipment can be made available by modifying existing designs, gate to face transitions will require a number of steps, and a mid-face sprag should not be required for routine operations.

Jan 1, 1992

By Axel Preusse

Due to a political decision, German hard coal mining will come to an end in the year 2018. By then, there will have been more than 150 years of industrial grade mining activities. Located in the western part of Germany is one of the most densely populated areas of Europe. Multiple coal seams have embossed the earth?s surface up to 20 meters (21.87 yards), as mining has subsided. The aftercare of hard coal mining will consist of three tasks: groundwater management, polder management, and groundwater treatment. The Ewigkeitslasten (cost in perpetuity) at the current groundwater level has been determined in the past. The actual cash value is calculated to be about 12.4 billion euros (approximately 16.5 billion dollars). The cost of groundwater management is directly related to the groundwater level. Rising groundwater levels will reduce the cost of pumping water. Known effects of rising groundwater are uplift of the surface, emission of methane gas at the surface, higher risk of cave-ins, and contamination of drinking water horizons. Each of those processes produces cost in order to prevent negative consequences (e.g., uncontrolled methane emissions) or to handle reparations (e.g., damages caused by surface uplifts). In the long run, it is the goal to minimize the Ewigkeitslast. As a first step, all cost-generating processes are specified, and a cost type based characterization is performed. The objective of this case study is to identify key parameters to determine the quality of a cost-generating process (proportional cost, fixed amount cost). Afterwards, it is intended to specify the quantitative impacts of each parameter and to set up an optimization model to minimize the overall cost. The quantitatively specified parameters will form the base out of which the optimization model is created.

Jan 1, 2013

By M. Afsari Nejad

A Transversely Elasto-Plastic Model was configured in FLAC (Fact Lagrangian Analysis of Continua) as a more realistic simulation of stratified and inclined strata behaviour examining surface subsidence above the inclined longwall panels (I ). The failure criterion employed was a modified Mohr-Coulomb failure criterion that assumed a variable cohesion, which changed with respect to the orientation of the plane of anisotropy . Using the proposed numerical modelling technique several longwall panels with different configurations were simulated. The results of both surface subsidence and horizontal displacements were validated against UK data using the Subsidence Engineer's Handbook (S.E.H) subsidence prediction method and the Influence Function Method (2). It was found from the research that the incite properties as well as laboratory to field reduction factors arc depth dependent. A set of relationships for calculation of anicotropic stiffness and strength parameters have been derived. The proposed modelling approach has been successfully applied to surface subsidence prediction for 3 collieries in the UK allowing the results of the simulation to he validated directly against measured data.

Jan 1, 1998

By Thomas M. Barczak

The initial Support Technology Optimization Program (STOP), Version 1.0, was released at the 19th Gmund Control Conference. This original program has since been updated to Version 2.3 which was released in May, 2001. This paper describes the additional features of Version 2.3, focusing primarily on the following three aspects: (I) including uncontrolled convergence into the design requirements for standing roof supports, (21 the addition of design procedures for cable bolts as an alternative secondary roof support, and (3) the addition of new standing roof support technologies. Another new feature which should facilitate the development of design criteria for standing roof support is the capabilily to define ground reaction curves through convergence measurements alone wthout having to make support loading measurements. There are several other new features provided in Version 2.3 which are only briefly addressed in the paper. These include: (I) additional graphics capabilities to facilitate rapid assessment of support comparisons. (2) an East-West designation for support selection to more accurately provide cost and support availability data, (3) additional safety measures including a safety factor to identify support design near the peak support capacity, checks to see if the support dimensions comply with aspect ratio requirements, and measure of roof coverage for the design layout of the support system These new features of STOP provide more capabilities to design and analyze secondary roof support systems for conditions whlch could not be fully analyzed in the original version of the program.

Jan 1, 2001