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By Brian E. Travis

Recent Developments in the utilization of polymer grid structures for Longwall Shield Recovery operations are discussed. Specifically: various Longwall screen designs and the numerous methods employed during installation. Also discussed is the role of polymer grid structures in head and tailgate mf and rib control and their role in controlling soft bottom often associated in shield recovery operations.

Jan 1, 1993

By Joseph C. Zelanko

Cable bolt support techniques. including hardware and anchorage systems, continue to evolve to meet U.S. mining requirements. For cable support systems to be successfully implemented into new ground control areas, the mechanics of this support and the potential range of performance need to be better understood. To contribute to this understanding, a series of 36 pull tests were performed on 10 ft long cable bolts using various combinations of hole diameters, resin formulations, anchor types, and with and without resin dams. These tests provided insight as to the influence of these four parameters on cable system performance. Performance was assessed in terms of support capacity (maximum load attained in a pull test), system stiffness (assessed from two intervals of load-deformation), and from the general load-deformation response. Three characteristic load-deformation responses were observed. An Analysis of Variance identified a number of main effects and interactions of significance to support capacity and stiffness. The factorial experiment performed in this study provides insight to the effects of several design parameters associated with resin-anchored cable bolts.

Jan 1, 1995

By D. E. Winston

Roof falls are the major cause of fatalities in the, coal mining industry and the prevention of roof failure is a major concern of mine management. Many ground failures observed underground are associated with geological discontinuities such as fractures, faults, clay veins and sandstone channels inherent in the earth's crust (Rinkenberger, 1977). To properly design a mine requires an advance knowledge of such geologic discontinuities and this is not always available from exploration boreholes. The use of remote sensing for mine planning is a relatively new development, and is at present being used primarily by the Roof Control Support Branches of the Mane Safety and Health Administration (MSHA) in Denver and Pittsburgh. However, technical advances, coupled with public access to previously unavailable photographic products, make remote sensing a useful aid in the difficult process of mine planning (Jansky and McCabe, 1979). Remote sensing techniques are being used to predict the location of geological features in advance of mining which influence roof conditions. The features appear on photographic images as linears, which are plotted on a mine map and serve as a planning tool for mine management. Also, during development of entries toward a linear, mining personnel will be on alert for signs of unstable roof conditions which might normally go undetected. Preventive action can then be taken before a fall occurs. A confusing aspect in remote sensing, analyses is terminology such as linear, lineament, fracture trace and joint. In this report the term "linear" refers to a line-like appearance on an aerial photograph or satellite imagery which signifies a naturally occurring geologic feature no the earth's surface. The objective of this paper is to describe the use of remote sensing techniques as an aid in predicting geological discontinuities which might produce hazardous roof conditions to a mine operating in the Pocahontas No. 4 Seam in southern West Virginia. Mine projections and roof control plans will he developed based on this and other available information such as data from cored drill holes.

Jan 1, 1982

By D. J. Maconochie

This paper describes the investigations and results of monitoring of deformations of houses located within the area of influence of a pillar collapse over the Westfalen No. 3 coal mine near Ipswich, Queensland. The subsidence resulted in minor subsidence of at least 18 modern houses and serious damage to 4 others. The history of the events and the measures taken to deal with the physical problems arising are described. The investigations and results are described and related to the mining methods and geology. The stability of coal pillars up to 9.6 m high was considered and computer modelling undertaken to relate surface subsidence to estimates of the extent of pillar failure. Assessments were made of the likely extent of subsidence during the incident. Measurements of distortion and tilt were obtained as the ground slowly subsided and criteria established to determine when the structures were deemed to be unsafe. Detailed surveys of houses affected or anticipated to become affected were also undertaken. Four houses were condemned and subsequently demolished as a result of excessive tilt. The methods of assessment are described and the implications of the results related to the various house designs.

Jan 1, 1992

By J. Marc Coolen

Marrowbone Development Company operates a large drift mining complex in the central Appalachian coal field. In 1997, five continuous miner supersections produced close to 9 million tons of raw plant feed. All production is from the Coalburg seam, a 5 to 10 ft thick coal seam with multiple coal benches and shale binders. The immediate roof lithologies consist of laminated shales, sandstones, or a mixture of sandstones and shales. The mine area is bisected by the regional Warfield anticline and associated Warfield fault. Mining conditions vary considerably due to frequent changes in seam and roof geology. The following geological categories can be distinguished: 1) presence of coal riders in the immediate shale roof, 2) excessive seam slopes around the Warfield fault, 3) splay faults associated with the Warfield fault, 4) zones of abundant slickensides, 5) abrupt roof lithology changes (sandstone - shale), 6) splitting and merging of different benches of the Coalburg seam, 7) sandstone washouts, 8) excessive roof dilution, 9) pillar sizing problems due to seam anomalies (soft fireclay binders). Several examples of these features are discussed in detail. Also, their relationship to roof fall occurrences is evaluated. Early recognition of potentially adverse geological conditions is of prime importance for the economic viability of the mining plans. Detailed core drilling in advance of the mining faces and coordination of the core data with underground mapping are the main forecasting tools.

Jan 1, 1999

By Dennis R. Dolinar

Roof falls, even of supported roof, still constitute a major hazard in underground mines. However, associated with any fall or instability is a pattern of roof movement. Therefore, the National Institute for Occupational Safety and Health, Pittsburgh Research Center, has been conducting research into the development of practical extensometer systems that can be used to measure this displacement and to determine if a roof fall may occur, thus increasing miner safety. For extensometers to be used in the detection of potential roof falls in coal mines, an understanding of the movement and displacement rates that will lead to roof failure is required. Because roof falls are unpredictable, it is often very difficult to obtain this information. Therefore, in a coal mine in the lower Kittanning seam in Pennsylvania, a room widening experiment was conducted to intentionally cause a roof fall while roof movement data was collected. In this experiment, two adjacent rooms 5.5 m (18 ft) wide supported with 1.5 m (5 ft) resin-grouted bolts and instrumented with extensometers were widened to 9 m (30 ft). In one of the rooms, 3.6 m (12 ft) cable bolts were installed as supplemental support. In the room with no additional support, a roof fall occurred 72 h after the room was widened. Much of the 3 cm (1.2 in) of movement in this room resulted from the instantaneous and transient response to mining with displacement rates up to 7.6 cm/d (3 in/d) being measured. This was followed by a steady state displacement phase with a rate of 0.43 cm/d (0.17 in/d). Just 12 h before the fall, movement deeper in the roof caused the rate to accelerate to 1.1 cm/d (0.44 in/d). The roof in the room with the supplemental cable support did not fall even though the total roof deformation was over 7.6 cm (3 in). Significant roof movements and strains in the cabled room were detected to a depth of 3 m (10 ft) while maximum cable loads were over 180 kN (40,000 lbf). Essentially, the roof was in postfailure with the cables maintaining the material, while roof stability was indicated by a steady state displacement rate of only 0.025 cm/d (0.01 in/d) at the end of the test.

Jan 1, 1997

By M Nombe

Based on the analysis of a case study at POWELTON No.2 MINE, it was determined that mine stability problems had occurred due to floor softening. A fireclay (underclay) layer in the immediate floor was softening after coal extraction and failing under pillars load. The thickness of soft floor was considered as the governing factor in the determination of the magnitude of floor displacement. The effect of floor thickness on floor displacement was evaluated by creating seven models that were input into the LAMODEL program. The properties of the soft floor were determined from a bearing capacity test performed in the Mains close to the area where mine stability problems had occurred. Moisture increase was considered in the reduction of floor bearing strength. Various strain-softening properties were allocated to the materials representing the soft floor. The LOW GAP POWELTON No.2 MINE was modeled and LAMODEL program was used to determine stress and convergence on both the coal seam and the fireclay seam. The results of critical stress and convergence obtained from modeling were compared with the actual floor failure area in the mine.

Jan 1, 2002

By Clarence O. Babcock

Since Vicat in 1833, the width to height ratio of a mine pillar has been taken as the fundamental variable in pillar design. From work in the laboratory by many investigators testing rock, Coal and concrete samples, it has been concluded by some that pillars with a width to height ratio of 10 to 1 are indestructible. It has also been concluded that a constrained core exists within the pillar which increases the pillar strength. The role of the roof and floor, if mentioned at all, is often noted in an incidental way. In the present work on laboratory testing of model pillars on concrete, coal, and rock instrumented with special strain gages, it was concluded that the end constraint and not the width to height ratio is the significant variable in determining the pillar strength. In tests where the end constraint is steel, a large compressive stress is produced on the horizontal plane of the pillar, and this effect increases as the width to height ratio is increased, resulting in an increase in pillar strength. If the end constraint is not steel but something with a small Young's modulus, the state of stress in the horizontal plane may be tensile, increasing as the width to height ratio increases, resulting in a decrease in pillar strength. Related to mining, the results are that a large width to height ratio pillar is strong for strong roof and floor and weak for weak roof and floor. That is, the roof and floor and not the width to height ratio determine the pillar strength. The confined core condition should be verified by testing if large pillars are to be used. If there is no confined core or the pillar is in tension, smaller pillar sizes should be used. The final conclusion is that the geometry alone is meaningless in pillar design.

Jan 1, 1984

By David A. Newman

Severe roof control problems have plagued a West Virginia underground mine since its initial development in the late 1970's. Adverse roof conditions in the Eastern portion of the reserve result from a combination of mining: - perpendicular to the major principal horizontal stress direction, - near lineament intersections, - in areas where the ratio of horizontal stress to vertical stress exceeds 2.00 to 4.00, and - where laminated strata are present in the immediate roof. The focus of this study is to identify the engineering (mine orientation, roof safety factor) and geological parameters (lineament and horizontal stress orientation, horizontal to vertical stress ratio, and immediate roof lithology) causing poor roof conditions and to quantify their influence on projected mining conditions in the Western portion of the reserve Rose diagrams were used to illustrate the correlation between the orientation of eight hundred thirty-six (836) roof falls with that of forty-four (44) lineaments and the principal horizontal stress Similarly a composite map was used to demonstrate the relationship between roof falls and the ratio of horizontal stress to vertical stress The immediate roof strata across the property were categorized as either laminated or non-laminated based upon a thorough examination of one hundred sixty-two core logs. The presence or absence of fireclay, a rider coal, and carbonaceous shale was also noted because of the historic correlation with poor roof conditions. Rock strength and physical property tests were conducted on selected immediate roof strata recovered from coreholes drilled along the mains projected to the Western portion of the reserve Potential roof control problems in the Western reserve were quantified based upon the correlations developed by analyzing engineering and geological data The main conclusion is that laminated roof strata, the rider seam, and its associated fireclay will have the greatest influence on mining conditions. Roof problems attributable to horizontal stresses will not be as severe in the West due to an increase in overburden depth and corresponding decrease in the stress ratio. Recommendations are provided for mining orientation, the layout of mains and submains, panel location, and roof support based on intended service life.

Jan 1, 1999

By Gregory Hendon

Jim Walter Resources, Inc. (JWR), has successfully longwall mined for many years at depths ranging from 1200'-2500'. However, full pillar extraction has proven difficult and generally economically unfeasible. Overburden and redistributed stresses at these depths require relatively large pillars, which become unmanageable with most pillar extraction practices. The economic benefits of taking gateroad pillars as part of a longwall face have been recognized for some time, including increased life of mine recovery, elimination of belt moves, reduced overcast requirements, and improved longwall to continuous miner ratios. Until recently, the associated risks of pulling pillars prevented any extensive use of this concept at JWR. Due to geological, economic, and longwall repeatability problems, JWR accepted the risks, and undertook pillar extractions with longwall faces in several different applications. The applications included taking a stable pillar (250' wide) as a longwall panel, taking yield pillars on the headgate and tailgate of panels, taking yield pillars and stable pillars in the middle of a panel, mining through chain pillars in the middle of a panel, and taking a support pillar on the tailgate end of a panel. This paper describes the background and experience of pillar extraction with longwalls at JWR.

Jan 1, 1998

By James H. Fletcher

Much data and experience has been accumulated, especially in the last 5 or 6 years, to show that modern roof trusses, both of the Birmingham type and the bolt-and-channel type, perform well to support certain kinds of coal mine roof. For some time now, roof trusses of the Birmingham type have been effective in controlling thick shale roof, which tends to sag and fall over a period of about eight weeks. These falls leave dame-shaped cavities which are reminiscent of the pressure arch theory of roof failure. Lately there has also been significant interest in supporting some longwall panel entries with channel and-bolt systems. These systems utilize two vertical center bolts and two 45 degree end bolts through a heavy gage channel. Both types of truss systems have long bolts, which require 8 to 9 Foot holes on a 45 degree angle, and point anchor resin bolts, which utilize a 2 or 3 foot rebar grouted in a thin annulus of polyester resin. Consequently, many coal mining people have been impressed with the very good anchorage characteristics and tensionability features of these systems. However, the same people have been proportionately dismayed to find that very often the most difficult part of introducing a trussing program to a mine is deciding on the machine specifications which determine the truss installation rate. The purpose of this paper is to indicate aspects of truss bolter design and use which are not shared by roofbolter design and its vertical pattern of bolts. Of the two types of drill units conventionally accepted, arm feed units and mast units, only one 15 judged suitable. While the arm feed unit offers low collapsed height with a long drill feed length, a great attribute for low seam use, it has not lent itself to being rolled over to a 45 degree angle. One reason for this inability is that many items which are conventionally mounted on the arm feed unit cannot be allowed to rotate with the unit. These items include drilling controls, tool Cray, lights, canopy or safety post, panic bar, and stab jack(s). If these items were independent of the arm feed drilling unit, they would have to be out of the way of the boom arms, links, and feed cylinder as the unit moves. To ease this problem, the arm feed unit can be made very short and even mounted across the machine. However, the resulting short feed length is undesirable. Several short drill steel extensions are required to drill a relatively long hole, making this procedure time-consuming as well as increasing the likelihood of drilling a crooked hole. Another reason for abandonment of the arm feed unit is that a very stiff drill guide (or "centralizer") is required to start the hole. Using the mast tilt control, the roof bolter operator will force the bit against the roof and will rotate the bit without feeding to cut sideways into the roof to form a hole face. Omission of this step often results in the skidding of the bit toward the rib. To date, no such sturdy drill guide has been designed for an arm feed drill unit. The mast style unit has been the most successful design for angle drilling. It is easily rolled over to a 45 degree angle or to 90 degrees and, on single head models, often has been made to roll through 180 degrees. The mast style is compact, in plain view and is easily fitted with heavy duty manual or hydraulically operated drill guides. It can be mounted directly on a machine chassis, or onto a swinging boom, or onto a slider arrangement in a broad variety of configurations which will accommodate controls, tool trays, stab and roof support jacks, lights, canopies, and panic bars. The only significant difficulty with mast drilling units occurs in lower mining heights when desirable low mast height is accompanied by undesirable short feed length. While the lead extension in the drill string can be as large as the mining height will allow, a short feed length will permit only the use of shorter middle extensions and drivers, and perhaps will. require the use of two different length wrenches. The associated problem is the relatively short distance from the drillhead to the drillguide. This distance is further shortened when raising the drillhead to get the bit to the roof. One might keep longer lead extensions on the machine; drill a vertical pocket for the bit, starting the angle hole at this pocket; or modify the mast. If the mast is made so that the distance from the drillhead to the drillguide remains constant while the mast extends, after which the drillhead travels up the mast, the shorter mast can be made to start the hole more easily. However, short teed length will still result in longer drilling time. It is obvious from these points that a proper choice of mast is simply the highest one which will be moved easily in the given mining height. This, of course, goes against the grain of most experienced coal mining people who realize that a relatively small decrease in mining height can create a problem correctable only with the purchase and installation of shorter masts. If the mining

Jan 1, 1982

By Craig Byington

The stress-field orientation mapping and analysis (SOMA) technique for determining the operative stress field near mine workings and its relationship to various fracture sets is described using Dickenson-Russell Coal Company's Laurel Mountain mine as an example. Carried to its practical application, this technique ultimately defines the optimal orientation for the mine workings wherein pillars, rather than rock bolts or other roof support methods, dominantly shoulder support of the highest-probability, potential, roof-fall blocks. It also provides a predictive tool describing local variability in rock deformation and in secondary roof support methods. Fracture discontinuities within a rock mass, either as pre¬existing natural fractures or as mining-induced fractures, are uniquely necessary for every brittle-deformation ground failure including roof falls. Prediction and mitigation of roof falls requires quantifying the interaction between the fracture sets and the operative principal-compressive¬ stress-axis orientation (olo). The SOMA technique utilizes the interaction between fractures and 61o, specifically their dilation or closure, to calculate the orientation of 610, and to estimate the orientations of 62o and o3o. A stereonet program is used to organize and statistically analyze the fracture data, and then to determine the optimal orientation for the mine workings. The final step in the SOMA technique involves modeling the Laurel Mountain mine using a 2-D, finite-element, modeling program. This assures that the interpretations regarding the optimal working orientation closely match the deformation features observed in the mine. It also provides a predictive tool describing highly variable stress and strain partitioning, seemingly erratic rock-bolt failures and the interactions between different sets of mine workings within different coal seams. The critical importance of including the fracture sets is well illustrated in the Laurel Mountain mine where the effects of earlier mining of an underlying seam is contrasted in both a fractured and otherwise identical non-fractured model to illustrate the consequences of ignoring fractures in a predictive roof-fall model.

Jan 1, 2004

In recent years, improvements made to the longwall system have accelerated at a faster pace than those made to the gate entry development system. As a consequence, unless planned years ahead of time, extending the panel length is nearly impossible without some innovative approach. At Cyprus Amax Coal's Emerald mine the G panel length was extended by 3,500 ft- by developing three entries across it to facilitate development of its headgate and tailgate entries simultaneously when the adjoining F panel was in operation. After evaluating alternative supporting methods and associated risks, determination was made to backfill these entries and crosscuts using a low strength flyash cement mixture prior to mining thru. Instrumentation was also used to monitor the stress change or front abutment stress in both the coal and the backfilled material ahead of the face. Longwall mining thru these three entries took about four eight-hour shifts and proved to be very successful. The designed flyash cement mixture provided adequate roof stability and caused no difficulty in the shearer's cutting while eliminating an in-panel longwall face move and minimizing the risk of roof or floor failure in the in-panel openings, or in the worst scenario loss of the face during the longwall cutting thru. This approach provided the intended result of extending G panel and recovered about one million tons of coal. This paper summarizes the engineering design of the cutting-thru project and flyash cement mixture, front abutment stress changes within the longwall coal block, backfilled material, and coal pillars ahead of the longwall face, and our underground observations

Jan 1, 1997

By Mark F. Sindelar, Yi Luo, Hua Jiang, Michael T. Shook

"Convergence of roof and floor in underground mine openings is a common occurrence. This convergence not only adversely affects the ability of workers, equipment and supplies to travel through the mine, it also reduces the effectiveness of the mine ventilation system, which is essential for the dilution of methane gas and airborne respirable dust. While installing secondary standing supports to control floor and roof convergence, such supports, by nature, partially obstruct a portion of the airway. These added obstructions inhibit the ability of the ventilation system to operate as efficiently as it could by increasing the resistance in and reducing the cross-sectional area of the airway.This study introduces and demonstrates the benefits of The Eye CAN™ standing roof support, which controls floor and roof convergence and is less obstructive to air flow than conventional wooden cribs. Laboratory findings show that the normal resistance of a supported lined airway is reduced by using this new product from Burrell Mining Products, Inc., while providing the same roof support characteristics of an established product-The CAN®. Load vs. displacement curves generated from laboratory tests demonstrated that this new product behaves with the same roof support characteristics as others in The CAN product family. Ventilation data gathered from a simulated mine entry was then used for computational fluid dynamics (CFD) modeling. The CFD analysis showed an improvement with The Eye CAN versus other accepted forms of standing roof support.This proof-of-concept study suggests that, when using this new product made by Burrell Mining Products, Inc., not only will the convergence from the roof and floor be controlled, but airway resistance will also be reduced.INTRODUCTIONOne of the basic elements of underground mining is the necessity to support the mine roof. It is well-known that easier reserves have been mined so that today's underground mines present challenging conditions. Factors influencing roof support decisions include mine depth, mining method, overburden composition, and agency regulations. Mining engineers, therefore, have to balance three objectives: safety, engineering, and cost. While safety is obviously paramount, and engineering often complements safety, the cost effectiveness of any product, method, or device warrants additional consideration in today's harsh business climate. Avenues for adaptation and improvement are found at the intersection of the three objectives."

Jan 1, 2016

By Bob J. MacDonald

The Cape Breton Development Corporation is a federally owned Crown corporation in Canada that operates two coal mines the Prince and Phalen Colliery in the Province of Nova Scotia. Retreat longwall mining was first introduced to the shallower workings (I 80m) of Prince Colliery in the early 1980's. Phalen Colliery started longwall retreating in 1987 and since that time has extracted twelve panels. In 1993 there had been a total of eight longwalls varying in widths from 140-230m mined in Phalen Colliery that is on the Phalen Seam. Up to this point there were only minor ground control problems on the faces except for one of the earlier longwalls that was mining a split seam. There is some interaction on Phalen workings from remnant structures in the overlying Lingan and No. 26 Collieries which worked the Harbour Seam. Induced abutments loads along pillar edges have been observed and resulted in poor face conditions when mining the Phalen Seam. The ninth panel, 6 East was the first panel to suffer a major roof fall from the First Major Weighting. This was also the first panel to undermine a paleo sandstone river channel named the Lower Sandstone Unit (LSU). For the first time in Phalen's history subsequent longwalls began to experience periodic weighting events. The 6 East panel suffered a number of periodic weightings and on two occasions had to use foam cement to fill the cavities that resulted. On the next east side panel, 7 East, there were numerous periodic weighting events, but interestingly there was no significant First Major Weighting. 7 East was the first 260m wide panel and all others were 230m or less. This longwall was 3,400m long and began producing in December of 1994 and was still cutting coal in May of 1997. There were five significant roof fall events on this panel, three of which required foam cement to fill the cavities. Of these three the interruption to production varied from four days to seven months. There were definite precursors to each of the weightings including: 1) an increase in audible noise (termed bumping) on the face, 2) supports went rapidly into yield, 3) roof convergence increased, 4) water percolated from the face roof strata, and 5) severe spalling of the coal occurred resulting in increased tip to face distance. Longwall face weightings are a result of geomechanical factors and cannot be avoided However, the loss of roof control is a different matter and highly subjective to operational procedures. The causes of weightings, their magnitude and impact on the mining at Phalen have been investigated. The following factors have been identified as relevant to these occurrences. 1. The influence of pillars in the overlying Harbour Seam workings. 2. Location of the LSU relative to the Phalen Seam. 3. Thickness of the LSU. 4. Pressure arch effect from the adjacent gobs. 5. Poor operational practices on the longwall including: a) slow rate of retreat; b) inadequate supply of pump pressure to the hydraulic supports; c) premature yielding of the yield valves; and d) poor face alignment practices. This paper will review the events that took place on the 7 East longwall and show that the Lower Sandstone Unit is the primary cause of the weightings. However, other factors contributed to the loss of roof control and the formation of the roof cavities.

Jan 1, 1997

By John A. Rusnak

Point load testing is used to determine rock strength indexes in geotechnical practice. The point load test apparatus and procedure enables economical testing of core or lump rock samples in either a field or laboratory setting. In order to estimate uniaxial compressive strength, index-to-strength conversion factors are used. These factors have been proposed by various researchers and are dependent upon rock type. This study involved the extensive load France and point load testing of coal measure rocks in six states. More than 10.000 individual test results. From 908 distinct rock units, sere used in the study. Rock lithologies were classified into general categories and conversion factors were determined For each category. This allows for intact rock strength data to he made available through point load testing for numerical geotechnical analysis and empirical rock mass classification systems such as the Coal Mine Roof Rating (CMRR).

Jan 1, 2000

By John M. Karhnak

The Bureau of Mines has a long history of research in Ground Control. For many years, this work was done at Bureau facilities by Bureau researchers. As the tiles changed, however, the area of research interest broadened, and additional methods of implementation, such as con- tracts, were added. 'Ibis paper outlines the organization, goals, and methods of implementation of the Bureau Ground Control Program, along with procedures for project selection. This program organization is followed by several specific examples of Bureau research that will be soon ready for use in the mines.

Jan 1, 1981

By Chris Mark

Perhaps the most significant development in coal mine ground control during the last century was the introduction of roof bolting during the late 1940's and 1950's. From an engineering standpoint, roof bolts are inherently more effective than the wood timbers they replaced. Roof bolts promised to dramatically reduce the number of roof fall accidents, which then claimed hundreds of lives each year, and they were initially hailed as "one of the great social advances of our time." Roof bolting also emerged at a time of rapid technologic transformation of the coal industry, and greatly accelerated the transition to trackless, rubber-tired face haulage. The U.S. Bureau of Mines quickly became the new roof support's strongest advocate. Some state agencies and miners were skeptical at first, but nearly everyone was soon won over. Case histories were reported showing that roof falls could be largely eliminated while productivity increased dramatically. Little wonder that, in the words of one contemporary observer, "roof bolting has been adopted more rapidly than any other new technology in the history of coal mine mechanization." Yet by the end of the 1950's, it was clear that roof fall fatality incidence rates had actually increased. It would be another decade before the superior ground support provided by roof bolts would clearly save lives, The story of how roof bolting was implemented by the mining industry, but took so long to live up to its promise, is a fascinating example of the interaction between economics, technology, regulation, and science. It still has important lessons for today.

Jan 1, 2002

By J. R. Koehler

The failure of yield pillar-based gate mad designs to provide adequate ground control performance is primarily related to the use of "critically" sized chain pillars. A "critical" pillar is one that falls into a range of pillar sizes that are too large to either yield nonviolently or yield before the roof and floor sustain permanent damage, but are too small to support full longwall abutment loads. To directly compare the in-mine performance of critical and yielding pillar designs, the U.S. Bureau of Mines recently completed a field study in a tapering gate road at the Sunnyside No. 1 Mine, Sunnyside, UT. Extreme pillar stresses and associated coal bumps characterize the response to first panel mining of a 16.8-m-wide critical design. Significantly lower pillar stresses, early yielding of the pillar and adjacent panel rib, and an absence of coal bumps suggest that a narrower 12.2-m-wide design more closely approaches proper yield pillar dimensions. Probehole drilling of several 10.6-m-wide pillars revealed low stress levels and substantial pillar and panel rib yielding prior to abutment onset. suggesting a properly functioning yield pillar design.

Jan 1, 1995

By Thomas M. Barczak

A survey of the longwall industry was conducted to examine the performance of modern shield technology. The results of this survey indicate that state-of-the-art shields perform better and last longer than ever before, but premature failures do still occur. In addition, longwalI operators are now using shields longer than ever before and a greater number of fatigue related failures on aging shields are now occurring. A generic assessment of these shield failures is provided, describing the nature of the failures and how widespread they are throughout the industry. An engineering assessment of shield design and factors that cause shield failures is made using both strength of materials and fracture mechanics principles. From this analysis, design practices to improve structural margins of safety and extend the life of the shield are proposed. The existence of unexpected shield failures indicate that current shield performance testing is at times inadequate. Recommendations are made relative to improved shield performance testing protocols including the benefits of testing in an active load frame such as the National Institute for Occupational Safety and Health's (NIOSH) Mine Roof Simulator. Even the most rigorous shield testing procedures, which strive to simulate in-service loading conditions, fail to consider key environmental issues, such as corrosion which is often the cause of structural fatigue failures in modern shields. The survey also indicated that hydraulic failures occur much sooner in the life cycle of a shield than structural failures, and although they can significantly degrade support capability, often go undetected for long periods of time. Methods to detect the hydraulic failures are also provided. The paper concludes with key points to maximizing shield design and life expectancy and ideas for future generation shield designs.

Jan 1, 1999