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By David Hill

"End of panel longwall face recovery is almost certainly the most involved recurring geotechnical problem faced by operators, with major loss potential should problems occur. The paper presents Australian experiences and updates the outcomes of an industry sponsored research project on the geotechnical issues associated with conventional longwall recoveries.A number of critical features of the geotechnical environment, support design and mining geometry have a pronounced impact on ground control during face recovery. A model of roof behaviour at the take-off point has been developed and validated. Key geotechnical issues include low roof competency, an adverse weighting environment, geological structure, horizontal stress concentrations at the gate ends and the capacity and. integrity of the shields. All of these are identifiable either at the support design stage or, at worst, prior to the start of powered support removal, which is the critical stage of the recovery process.Key aspects of the geometry and process are the ability to maintain powered support resistance during bolt-up and recovery, the direction of shield removal, the impact of chutes and the speed of the shield removal process.The author presents case studies that illustrate these issues and the associated ground behavior.INTRODUCTIONEnd of panel face recovery is almost certainly the most involved recurring geotechnical problem faced by operators, with major loss potential should problems occur. However, unlike most geotechnical aspects of coal mining, very little research has historically been undertaken on the issue of conventional longwall recoveries. This is in marked contrast to the design of pre-driven recovery rooms, an issue which has attracted considerable research interest (Thomas, 2008). In 2006, Strata Engineering completed an Australian industry (ACARP) sponsored research project aimed at defining and minimising the geotechnical threats during longwall face recovery (Strata Engineering, 2006). The research project had the overall objective of developing guidelines for the specification of ground control strategies, so as to minimise the likely geotechnical threats relating to the safety, operational costs and production delays associated with the recovery of a longwall face."

Jan 1, 2010

By Peter Fischer

Between 45,000 and 50,000 claims for subsidence are submitted each year to the German hard coal industry. In order to improve the service to claimants a quality management was established in 2005. This paper describes the process now used for handling these claims. A quality check has also been carried out by way of a customer survey, which was performed by an independent research agency. The results of the survey are presented in this paper. In Germany, research into mining subsidence mainly involves the prediction of ground movements caused by deep mining operations. Special areas of research are subsidence reducing aspects of the extraction panel planning, especially from the point of view of mining dynamics, as well as securing and restoration measures. This work seeks to prevent or minimize mining-induced damages close to the surface, for instance, buildings or infrastructure installations (such as pipelines), or underground mine openings (e.g. shafts). Roof collapses and surface fractures caused by shallow mine workings of an earlier era currently constitute a special area of investigation.

Jan 1, 2006

By Gary B. Petersen

The author has developed a seven-step process called the Applied Rock Mechanics (ARM) Protocol that the author has used to solve numerous roof stability problems in mines throughout North America since 1975. It is a practical evaluation process using trained observation, innovative data collection instrumentation, video borehole cameras, analytical processes, and controlled testing methods that have become highly effective in solving ground control problems in every type of underground mine. This paper will describe each of the steps of the protocol and how the rock mechanics engineer applies them to resolve a typical ground control problem.

Jan 1, 2012

By Brijes Mishra

This paper presents a correlation of acoustic emission (A.E.) with physical and mechanical properties of different types of rock and coal specimens which were tested under aegis of a consultancy project from a Columbian Mining Company. In this study, three types of rocks which are sandstone (Arneisca), siltstone (Arciolita) and claystone (Limolita) and two different types of coal were tested. The tests were carried out under constant loading rates according to ASTM Standards for determining Young?s Modulus and Poisson?s Ratio. In both cases a MTS electro-hydraulic loading system was used. Mode of failure in each material was characterized by the acoustic emission and the results were substantiated by the deformation characteristics of the materials during failure.

Jan 1, 2006

By Anastasia M. Suchowerska

The design of effective ground support requires a sound understanding of the pre-mining state of stress in the stratum to be mined. Irregularities in the stress field encountered during multiseam mining are governed primarily by the previous mining in the surrounding strata. The aim of this study is to quantify the effects of rock mass transverse isotropy on the vertical stress redistribution in the rock strata beneath supercritical longwall panels. Wilson?s equations for determining the stress distribution induced in and beyond a single longwall panel after it has been mined have been adopted, and a plane strain finite element analysis of an elastic medium, together with the stress changes predicted by Wilson, was used to calculate the final pre-mining stresses in the underlying strata. Values of the independent shear modulus (G¢) of the rock strata, ranging from 0.1 to 1 times the isotropic shear modulus (Giso) in the plane of the strata, and a Poisson?s ratio (?) of 0.25 have been investigated. The key finding of this study is that the predicted magnitude of vertical stress in the transversely isotropic strata beneath a mined supercritical longwall panel is larger and changes more quickly with horizontal distance than is the case for an isotropic rock mass. This finding is of significance for the design of ground support measures in multi-seam mining operations.

Jan 1, 2012

By Mark K. Larson

Researchers at the National Institute for Occupational Safety and Health?s (NIOSH) Spokane Research Laboratory are developing a borehole profilometer to dynamically measure the roughness pro-file of boreholes used to install roof bolts fully encapsulated with resin. Numerical measures of roughness were calculated from profiles of borehole surface roughness to determine potential roof bolt anchorage capacity. The concept of dynamically profiling was proven through the following series of laboratory tests: a sensitiv-ity test using various grits of sandpaper, a known-profile test along a section of a concrete hole, and a simulated borehole test in a pipe with machined grooves. Two profilometer prototypes were devel-oped that measure slight changes in the radius of a borehole using either strain-gauged, spring-steel arms or rigid, steel arms attached to a spring-loaded cone and a linear potentiometer. Both instruments performed reasonably well in the laboratory and were subsequently tested in boreholes drilled in two concrete blocks using different drilling techniques to obtain three different borehole surface roughnesses. A Z2 roughness parameter was calculated with data from the first profilometer, and an average radial increment was calculated from the test results of the second profilometer. Although both instruments were able to readily distinguish the difference between smooth and rough boreholes, the correlation coefficient (r2) for a linear relationship between Z2 and average radial increment was 0.577. Pull tests were conducted with resin bolts installed in the concrete blocks, but maximum pull-out strength could not be correlated to borehole roughness because in each of these tests, failure occurred at the resin-bolt interface. A more sophisticated prototype has been designed to measure surface roughness and also accurately determine the location and tilt of the instrument in the borehole. However, this instrument has not yet been fabricated or tested.

Jan 1, 2007

By Andre Zingano

The objective of this paper is to study the effect of annulus thickness on the quality of resin mixture for fully grouted resin bolt. Pullout and mixture tests were made in underground coal mines for the following arrangements: (a) borehole diameter 1.14 in. (29 mm), and roof bolt diameter 0.75 in. (19 mm) with steel wire around the roof bolt; (b) borehole diameter 1.14 in. (29 mm), and roof bolt diameter 0.75 in. (19 mm) with no wire around the roof bolt; and (c) borehole diameter 0.95 in. (24 mm) and a roof bolt diameter 0.75 in. (19 mm) with no wire around the roof bolt. The mixture test in steel pipe showed that the best resin mixture is for borehole with 0.95 in. (24 mm). The arrangement (b) produced big voids around the bolt. But for the 0.95 in. (24 mm) hole, arrangement c, the mixture was the best. It was corroborated with the pullout tests results where there is a difference in grout stiffness: the 0.95 in. (24 mm) borehole is about 10 times higher than a borehole with diameter 1.14 in. (29 mm). On the other hand, for the cohesive strength the difference is not significant. Numerical models were built to simulate the pullout tests, and also to simulate the roof support at an intersection. Convergence at two underground intersections, consisting of an immediate roof with laminated sandstone, was monitored to evaluate the performance of the roof supports, using the 1.14 and 0.95 in. (29 and 24 mm) diameter boreholes (i.e. arrangements ?a? and ?b?). The convergence readings showed that the 0.95 in. (24 mm) borehole diameter resulted in a smaller, although it was not significantly different.

Jan 1, 2008

By Yi Luo

Subsidence events occurred over inactive room and pillar (R&P) mines, including abandoned mines or sealed portions of active mines, are classified as unplanned subsidence because of their timing and distribution are unpredictable. When investigating such subsidence cases, many uncertainties exist and disputes often focused on whether the observed structural damages are caused by mine subsidence or other natural or artificial causes. However, solid evidences to identify the causes are often lacking. In order to conduct a thorough and impartial investigation, good knowledge in subsidence theories and other ground control subjects and broad experience are required.

Jan 1, 2009

By Stephen Iverson

The National Institute for Occupational Safety and Health (NIOSH) is currently performing research to help mine operators minimize the amount of loose or damaged rock surrounding a blasted opening. Improperly designed blast rounds can result in excessive wall rock damage that may reduce the rock mass competency and increase ground support requirements. Unnecessary blast damage can cause many safety and operational concerns including an increased potential for injury from rock falls and other hazards resulting from sub-optimal blast designs. This paper focuses on the ground control and safety implications of blast damage in underground mines. A reduction in rock quality due to blasting can increase the amount of ground support required. Case study data collected by NIOSH in underground metal mines during standard drill and blast production rounds included blast vibration monitoring, detailed three-dimensional laser scanning of the as-built excavation, and geotechnical mapping of development headings.

Jan 1, 2007

By Steve Tadolini

Underground roof falls can have devastating effects on the safety of operations personnel, and equipment, and seriously impact production. Immediate steps are usually taken to danger off and secure the area while clean-up efforts are designed and implemented. A critical step, often overlooked due to production demand, is the determination of - why the roof fall occurred so that additional occurrences can be avoided in future developments or what measures can be taken to identify areas that have similar ?symptoms?? Forensic engineering includes the investigation of materials, products, structures or components that fail or do not operate/function as intended. The authors define forensics in ground control engineering as the study of evidence discovered while examining underground roof falls by applying expert observational techniques and established mining engineering principles to determine the probable cause, hypothesize solutions, and design engineering safeguards to prevent reoccurrences. Simply stated, the primary steps in the forensics of underground roof fall techniques are: ? Assess regional and local conditions prior to the event. ? Assess post-event conditions. ? Hypothesize plausible ways in which the pre-event conditions ? became the post-event conditions.Search for evidence that either denies or supports the various ? hypotheses.Apply engineering skill to relate the various facts and evidence into a cohesive scenario of how the event may have occurred. This paper details the proposed technique by utilizing a roof fall case study that required the examination of five primary factors: mine design parameters, excavation geology, method of excavation, method of support, and mining cycle times.

Jan 1, 2009

By Greg Smith

This paper documents the use of bench testing equipment developed to enhance the understanding of, and improve upon, common roof bolt support systems. Most roof bolt systems consist of components that are covered within the scope of ASTM (American Society for Testing and Materials) standards. However, ASTM does not specify testing methods or performance standards for complete roof bolt ?systems?. It only designates testing methods and minimum performance standards for roof bolt ?components?. Improved understanding and continuous improvement of these systems is essential given the enormous impact that they have on the safety and profitability of underground mining operations. Bench testing equipment has been developed that effectively measures and records multiple points of deformation in a rock bolt support system while load is being applied. With this testing capability, an improved understanding of component and system stress distribution can be obtained and devices and methods for visual load indication can be developed. This paper is formatted as case studies where testing was performed to demonstrate load versus deformation profiles and to develop system improvement products.

Jan 1, 2012

By Thomas M. Brady

The Spokane Research Laboratory/NIOSH and the University of British Columbia (UBC) geomechanics group are focusing on the development of safe and cost-effective underground design guidelines for weak rock masses having an RMR in the range of 15 to 45. Weak ground conditions, ground support, and mining methods used in several North American underground mines were observed. The RMR values were calculated to update both manned entry span design and non-entry stability graphs, plus a database on underhand mining methods was created to reflect existing North American mining conditions. The immediate rock mass was characterized and analyzed in terms of prevailing type of ground support, potential failure mechanisms, and rock behavior to define how existing design curves must be modified for the existing weak rock mass. The current NIOSH research attempts to provide rock mechanics tools to assist a mine operator in making sound economic decisions that will also ensure a safe working environment.

Jan 1, 2006

By Rudiger Baltz

The sudden failure of bodies of rock is a serious problem commonly experienced in the international mining industry. These explosive releases of energy are referred-to as ?bumps?, ?outbursts? and ?rockbursts?. Rockbursts can occur at such a rapid speed that they present a direct threat to safety in large parts of the mine workings. The build-up of excess stress within the body of rock can be attributed to different causes. In shallow workings, for example, sudden and violent failure of the roof strata can be caused by leaving insufficient pillar width when practising room-and-pillar mining. At much greater working depths, as it is the case in the German coal industry, rockbursts are generally attributable to high levels of rock pressure. This can even result in coal outbursts when driving individual roadways. More than thirty years ago the German coal industry suffered from numerous rockburst incidents which caused many deaths and serious injuries. This led directly to the establishment of the Rockburst Prevention Centre, which was created at the instigation of the mining companies and the chief mines inspectorate. The consistent logging and analysis of all rockburst incidents has led to the development of a system that is still used as a basis for preventing underground rockbursts and minimising the risk of such phenomena occurring. Working closely with the mining authorities and mining companies the accredited experts of the Rockburst Prevention Centre have played a key role in helping to develop and implement a range of methods for the early detection and prevention of rockbursts.

Jan 1, 2008

By Rajagopala Reddy Kallu

After the Sago and Darby No. 1 mine incidents, the new regulatory standards for the design of mine seals in underground coal mines of the United States require the mine seals to withstand higher explosion standards. This necessitated for the development of new design approaches and standards. For development of any new design standards or approaches a detailed understanding of effect of key influencing parameters on the stability of mine seal is a must. This paper attempts to address one of the factors, i.e. roof convergence, that play an important role in the stability of mine seal under explosion loading. Initially a couple of three dimensional numerical models were built and tested for different levels of roof convergence. These models confirmed that roof convergence has great influence on seal stability. A detailed study is undertaken, with some simple assumptions, to establish typical influence of roof convergence on the stability of mine seal under different levels of static explosion pressures. Three dimensional distinct element code 3DEC is used for this purpose.

Jan 1, 2007

By Takashi Sasaoka

Chain Conveyor Cutter (CCC) is a chainsaw-type machine and originally developed for the construction of underground walls and/or ground improvements. CCC was developed from the accumulated technology of coal mining, combining the cutting technology of a shearer and the fuctions of chain conveyor. The CCC can cut harder soils and soft rocks, and vertically mixes the cut soils/rocks with cementing material selected through the discharging port installed at the bottom of the machine. In Indonesia, highwall mining trials have already been conducted in several coal mines. However, full-scale and regular operations have not been done yet due to the ground and machine control issues from their geological conditions. In order to overcome these problems, the application of CCC to highwall mining systems was proposed, and its applicability and technical issues to be solved were investigated in this research. This paper discribes the characteristics of CCC system and discusses the application of CCC to highwall mining systems.

Jan 1, 2012

By Vedala Sastry

Longwall mining for coal extraction in deeper deposits is gaining momentum in India, due to the increasing stripping ratios and depletion of shallow deposits amenable for surface mining. In longwall mining, presence of multiple seams with varying interburden thickness is a major problem especially while planning for over-mining. An investigation program was taken up to analyze the effect of the presence of goaf and virgin coal blocks in already developed and extracted lower seam by bord and pillar mining, on the stress distribution in the longwall panel in upper seam. Studies revealed marginal increase in horizontal and shear stress as longwall face passes above goaf to the virgin area present in lower seam. Stress distribution over chock shields was considerably affected when the face in upper seam reached 15-25m zone above the galleries in the lower seam. A clear influence of the presence of solid coal, galleries and goaf in lower seam was found in the loading of longwall panel in upper seam.

Jan 1, 2007

By Bill Kyslinger

In underground mining, machine design is predominantly dictated by mine conditions and individual customer desires. In partnership with Boart Longyear Poland and KGHM, J. H. Fletcher & Company was tasked to design and manufacture a single-boom, single operator drill module for installation of 1.2 meter expansion bolt in a 1.6 meter height mine. The objective was to produce a machine to provide ergonomic improvements for the operator while working in the mine environment. This dictated the requirement for a small easily controlled, maintenance friendly design with a remote operator?s control station. The selected design method was to use starter and finisher drill steels. This combination, requiring a number of mechanized machine motions, provides the ability to drill the required depth in the specified mine height. To accomplish the task from a remote location, a conscious decision was made to employ current technology in the form of small pressure compensated hydraulics and electronic controls. The result of the design method is a modular assembly with each sub-component designed to be replaceable and adjustable independently from other machine components. The low profile remote roof bolting module is made up of six major sub-components. Each major component is painted a different color to help the operator make the visual connection from the drill module to the operator?s control/display monitor. The Stabilizer (White) secures the module between the mine top and floor. The Drillhead (Orange) produces the drilling rotation and torque but also must slide out of position to allow the machine to manipulate the drill consumables. The Drill Steel Carousel (Blue) holds and indexes the starter and finisher steel from position to position. The Manipulator Arm (Green) moves and guides the drill steels and drill consumables from position to position during installation. The Roof Reference Guide (Yellow) locates the mine roof and guides the drill steels and drill consumables into position. The Linear Bolt Carousel (Purple) holds the drill consumables. The low profile remote roof bolting module allows the operator to drill and install a roof bolt manually or automatically with the push of a button. This design substantially reduces the operator?s exposure in the mine environment, as well as inherent pinch points and rotary hazards. Positioning the operator safely in the confines of the air conditioned cab.

Jan 1, 2006

By Alan A. Campoli

The mining industry has long been searching for an effective structural application that prevents weathering and falls of loose rock, debris, and sediment. J-Crete is a fiber-reinforced, engineered, cementitious composite rock application that is designed, tested, and successfully utilized as such a material. Laboratory evaluation of J-Crete material properties has shown the final compressive strength to be in excess of 7,300 psi (50.34 MPa), with 24 hour strength in excess of 1,500 psi (10.34 MPa). The flexural tensile strength is in excess of 600 psi (4.1 MPa) and is provided through a unique combination of polyvinyl alcohol (PVA) fibers activated by a proprietary liquid additive that prevents them from clumping and enables even distribution throughout the grout. Tensile bond strength in excess of 350 psi (2.4 MPa) at 28 day cure tightens the strata and holds loose material in place. Practically impervious to gas and liquids, J-Crete protects strata against long-term weathering, does not require screening to be effective, and has proven to be a successful waterproofing material. J-Crete has demonstrated the potential to alleviate coal mine roof cutters in soft, wet clay formations. J-Crete reinforces coal mine ribs by bonding directly to the rib, conforms to the strata, strengthens the rib, and eliminates sloughing due to long-term weathering; stabilizes coal mine entries by bonding directly to the brow and roof, and creates a monolithic shell with double reinforced corners.

Jan 1, 2012

By Bill Stormes

This paper will discuss implementation of the Hilti OneStep rock anchor technology to improve face bolting operations during the May 2008 longwall move; increase rock anchor installation capacity; and improve safety by reducing employee exposure periods by utilizing the Hilti OneStep rock anchors.

Jan 1, 2008

By Navid Hosseini

Several empirical equations to estimate coal pillar strength have been presented in academic studies. The development processes of these equations are similar and are usually obtained by fitting the mathematical function (curve) to field data. One of the best criteria to evaluate the quality of fitting for such equations is the correlation coefficient R2, which has limited applicability. It is necessary to calculate the correlation coefficient access to the initial data for which the equation is presented; this is impossible for many coal pillar strength formulas. This paper presents a new approach based on the analysis of uncertainty amplitude to compare the coal pillar strength. This approach utilizes a combination of parameters such as Mean Squared Error (MSE), Root Mean Squared Error (RMSE), function type and degrees of freedom. The confidence level of constants is subsequently formed and the correlation coefficient becomes more comprehensive. Therefore, for an effective comparison, the efficiency and accuracy of coal pillar strength formula can be used. Keywords: Coal Pillar Strength, Correlation Coefficient, MATLAB, Uncertainty Criterion

Jan 1, 2012