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By David W. Evans

"Induced hydraulic fracture of strata during roof bolt installation is a potentially prevalent, but masked phenomenon within the underground coal industry. Previously reported resin testing programs (McTyer et al., 2014) examined the relationship between resin mixing effectiveness and varying bore hole diameter. The methodology employed within this earlier test program facilitated a further critical area of research – the measurement of back pressures generated within the bore hole during standard rock bolt installation practices. Experimental data has indicated that fluid resin can be pressurised to levels where it exceeds the compressive strength of the strata, inducing hydraulic fracture within the immediate area of the bolting horizon. The routine cycle of roof bolting serves to propagate this effect, progressively fracturing and delaminating the roof during mine advancement. This masked phenomenon can lead to a perception of difficult ground conditions - mining efficiencies and costs are therefore affected, with increased needs for additional support subsequently required to restabilise the inadvertently damaged roof.Further analysis of the parameters associated with resin bolt installation has now been conducted, assisting in the development of an empirical relationship between bore hole pressure, bore hole diameter and bolt insertion times. This relationship has been analysed for 15:1 ratio resins and 2:1 ratioresins, within 28mm and 30mm boreholes. Further to this, load transfer performance has been comparatively assessed for both 28mm and 30mm boreholes, suggesting that for 2:1 resins, acceptable resin mixing and load transfer can be obtained within a 30mm bore hole. The combination of 2:1 resins, utilised within a 30mm bore hole, may well provide the optimal solution to reduce the risk of hydraulic fracture in weaker strata during resin bolt installation.INTRODUCTIONA growing number of industry papers have previously investigated areas of concern associated with the performance of cartridge style resins in roof bolting, predominantly focussing on the effects of plastic film gloving, inadequate resin mixing and the pressurisation of resin within the bore hole. These three effects have a critical influence on the load transfer of the steel bolt element, through the cured resin and into the surrounding strata.Gloving occurs due to the plastic film of the resin cartridge partially encasing or wrapping around the steel roof bolt element – a known phenomenon over many years (Pettibone, 1987). The plastic film creates regions of discontinuity between the bolt, cured resin and borehole, reducing effective load transfer into the strata. Experimentation conducted into the effects of bolt ends fully encased by plastic film (Pastars and MacGregor, 2005) revealed that load transfer can be reduced by 85 to 90% in worstcase occurrences. It is also known that the aggregate filler size used within the resin can assist in shredding and breaking up the plastic film – this effect was observed in a previous study on resin mixing effectiveness (McTyer et al., 2014)."

Jan 1, 2015

By Ihsan Berk Tulu, Michael Sloan, Ted Klemetti, Michael M. Murphy, Gabriel S. Esterhuizen, Jame Sumner

"In this paper, the advantage of using numerical models with the strength reduction method (SRM) to evaluate entry stability in complex multiple-seam conditions is demonstrated. A coal mine under variable topography from the central Appalachian region is used as a case study. At this mine, unexpected roof conditions were encountered during development below previously mined panels. Stress mapping and observation of ground conditions were used to quantify the success of entry support systems in three room-andpillar panels. Numerical model analyses were initially conducted to estimate the stresses induced by the multiple-seam mining at the locations of the affected entries. The SRM was used to quantify the stability factor of the supported roof of the entries at selected locations. The SRM-calculated stability factors were compared with observations made during the site visits, and the results demonstrate that the SRM adequately identifies the unexpected roof conditions in this complex case. It is concluded that the SRM can be used to effectively evaluate the likely success of roof supports and the stability condition of entries in coal mines.INTRODUCTIONSince the introduction of roof bolts in the coal mines during the late 1940s and 1950s, roof bolts promised to dramatically reduce roof fall accidents (Mark, 2002). However, ground falls still remain a significant factor in underground coal mine injuries and fatalities. In 2013, ground falls accounted for 4 of the 14 fatalities and 166 of the 1577 reported lost-time injuries in underground coal mines (MSHA, 2015).The design of appropriate support systems requires the understanding of: 1) the variable nature of the rock mass, 2) the performance and characteristics of the roof support, 3) the interaction between the rock mass and the installed support system, and 4) the in-situ and mine-induced stress distribution around the excavation. Over the past 25 years, multiple design approaches have been used in coal mine ground control. The approaches include empirical mechanistic methods, empirical statistical analysis, rules of thumb, and numerical methods (Hebblewhite 2006). In the U.S., Analysis of Roof Bolt Systems (ARBS) can be given as an example of an empirical method. ARBS uses relatively simple equations to calculate the intensity of support provided by a roof bolt system and compares it with a suggested ARBS value (Mark et al., 2001). The suggested ARBS design equation is derived from an analysis of 100 case histories. The ARBS design equation is dependent on two parameters: depth of cover and Coal Mine Roof Rating (CMRR). More recently, a probabilistic design approach was developed by Canbulat and van der Merwe (2009) in South Africa. In this method, the variability of the rock mass, the mining geometry, and support characteristics are included in the analytical models. The major advantages of these two methods are: 1) they can be applied rapidly and easily, 2) complex rock mass/ roof support interaction mechanisms are represented with simple equations, and 3) they are supported by large databases. However, both methods generally ignore mining-induced stress distribution, details of the roof support system, details of the geological setting, and the interaction between the support system and the rock mass."

Jan 1, 2015

By Ximeng Li

The entries that are subjected to dynamic pressure are much more difficult to maintain due to repeated disturbance. A case study of an entry stress distribution was performed using the FLAC3D program. By analyzing the distribution of stress field around the entries, this paper provides guidelines for entry support design in the lower (#16) seam subjected to the repeated disturbance from longwall mining in the immediate overlying (#17) seam, 72ft (22 m) above. The results showed that there was stress superposition inside the barrier pillar in the lower seam, 15ft (5m) to 45ft (15m) deep, during development. The influence zone of the front abutment pressure in the upper (#16) seam was about 100ft (30m) outby the faceline. The stress-relieved zone was from 0 to 100ft (30m) inby the face. The area further inby the face (i.e., 230 ft (70 m) inby the face) was within the gob compaction zone. Along the face advancing direction, the affected zones of the entries in the lower (#17) seam that were subjected to the dynamic pressure from longwall mining of the immediate overlying seam could be divided into four stages: pillar development stress stage, front abutment pressure stage, unstable gob stage, and stable gob stage. Those entries within an area from 100ft (30m) outby to 100ft (30m) to 230ft (70m) inby the faceline should be reinforced with special supports. The numerical modelling matched the monitoring results well.

Jan 1, 2013

By Phil R. Ames, Anil K. Ray, Murali M. Gadde, John A. Rusnak

"Many factors can be responsible for coal mine roof falls including, mining geometry, stress conditions and local geology. In the Illinois Basin coal mines, roof instability is commonly attributed to the low strength of the immediate roof, which is also moisture sensitive. Recently, in order to understand the mechanisms of roof instability, numerical modeling has often been the preferred ground control analysis tool. Since roof materials can exhibit significant spatial variability, such modeling results may not represent every section of the mine. At the same time, it is not feasible to carry out numerical modeling for the full range of geological and mining conditions possible at a mine. Operationally, it is more convenient and highly practical to have a simple map that depicts the expected roof conditions, determined through either complex numerical models or simple empirical analysis throughout the reserve area. In this paper, a case history is presented that shows how a combination of simple empirical analyses of geologic data and past ground control experiences at a mine can be synthesized into a roof stability map, which can then be used to forecast future ground conditions. The usefulness of such a roof stability map will be examined in terms of the predicted and actual ground conditions encountered over a period of more than a year after the map was created.INTRODUCTIONA roof fall, which can result in fatalities and lost work time, is considered to be one of the most severe ground control hazards in underground coal mines. In general, there are many factors responsible for roof falls, including mining geometry, stress conditions and local geology. In the Illinois Basin, roof falls are commonly attributed to the weak nature of immediate roof rocks, and some superficial falls may be initiated due to moisture sensitivity. Some unstable areas also occur when the immediate roof is highly laminated.Numerical modeling is a useful tool used to understand the mechanism of a roof fall by incorporating site-specific parameters. In the past, numerical modeling has been used to explain the mechanism of roof falls as well as simulate· roof falls and cutter behavior, but such work had been strictly site-specific (Gadde and Peng, 2005; Ray, 2009). Because of the restrictions imposed by the input parameters, numerical modeling results cannot represent the entire mine. In the real world, mining conditions vary from place to place, and even in a single panel, modeling results valid at one site may not apply at another nearby site. At the same time, due to the lack of input data pertaining to rock characteristics and in-situ stress variations, it is not practical to carry out numerical modeling for each local area of the entire mine site. In addition to these difficulties, mine operators prefer simple tools to understand the ground conditions at their mine sites. One simple and commonsense based tool is the roof stability map. A stability map not only synthesizes the geologic and stress analysis data empirically, but it can also be used to predict future ground control issues at that mine. Because of this practical appeal, stability maps are more likely to gain mine operators' acceptance and be used in their planning operations. In this paper, a case study is presented on the development of a 'Roof Stability Map' that was principally used for roof fall prediction for a mine in the Illinois Basin."

Jan 1, 2010

By Thomas M. Barczak

The engineering of a support system is driven largely by economics. The goal is to provide effective support at minimal cost. For this reason, wood has been extensively used as a support material for centuries. The cost of timber for mining applications has risen by more than 50% in the past 5 years and is likely to continue to increase as the supply diminishes and further environmental restrictions are placed on timber harvesting. The increased cost and lack of high strength wood in the Western United States has provided incentives to improve the utilization of wood and to develop alternative support materials. This U.S. Bureau of Mines' (USBM) report discusses the basic engineering requirements for the application of various materials for supplemental roof support construction and provides an overview of support systems that use materials other than wood. A comparison of support performance and cost for various material constructions is made to assist the mine operator in support selection. The scope of materials discussed in the report include: (1) conventional mine timber loaded perpendicular to the grain, (2) parallel to the grain timber loading, (3) steel fiber reinforced and air entrained concrete, (4) steel, (5) granular fill materials, and (6) combinations of these as composite support structures. The range of support systems analyzed include wood and concrete cribs, concrete columns and props, steel beams, friction props, and several novel support concepts.

Jan 1, 1994

By Murali Gadde

U.S. coal mines? primary roof supports typically consist of passive resin bolts; however, the use of active bolt systems is increasing. Despite this widespread use, a comparative performance evaluation of these bolt systems has not been done under similar geologic conditions. The performances of three commonly used primary bolt systems were investigated: fully grouted passive rebar, fully grouted tension rebar (using two speed setting resin), and resin-assisted rebar with mechanical anchors. In order to investigate the performance of these bolts, strain gauged bolts of all three types were installed at three different coal mines as part of a larger research project funded by the National Institute for Occupational Safety and Health (NIOSH). This paper addresses the initial installation bolt loads measured at these mines. Analysis of the data showed much lower installed loads on active bolts than is traditionally assumed. It appears that the active load on bolts bleeds off relatively quickly under geologic and operational conditions similar to those at the studied mines. The data also showed that within a short time span after installation, the measured loads on active and passive bolts did not differ significantly. This paper compares the results from over 20 bolts of each bolt type that were all 1.8-m (6-ft) -long, 20-mm (0.804-in) nominal diameter Grade 75 rebar and discusses the relevance and shortcomings of the data and bolt performance.

Jan 1, 2011

By Chris Strawson

Moranbah North is a modern longwall operation mining premium coking coal in the Northern Bowen Basin, Central Queensland. Australia Moranbah North Coal (MNC) is owned and operated by Anglo Coal Australia. Extracting approximately 4.5m of the Goonyella Middle seam using a single longwall, the mine produces 5 to 6 Mt per annum. The weak coal (4.5 MPa), low strength laminated immediate roof, and strong upper roof sandstones, make operation of the longwall at depths in excess of 250m geotechnically challenging. In the past, there have been a number of production delays due to geotechnical issues. Roof instability resulted in a long stoppage on Longwall 105, and the eventual relocation of the face further outbye in the block. (Figure 1). When mining commenced in LW106, there was a requirement for uninterrupted production, particularly in the more demanding inbye area of the panel. Following discussions with a number of Geotechnical experts, it was decided to narrow the face, and test the theories of reduced face weighting due to spanning of the goaf across the panel. A new on line chock monitoring system, and microseismic monitoring was installed in order to characterise the difference in the rockmass response, as the panel width changed from 175m, to 265m, and then 300m. The nature of the goaf formation and impacts on face loading and production are discussed, having the unique opportunity of three different face widths within the same area.

Jan 1, 2007

By Jun Lu

The Pittsburgh seam is the most extensively mined coal bed in the Appalachian Basin. Unlike most other prominent coal seams, the Pittsburgh seam typically includes a sequence of immediate roof coals and intervening rock binders (or ?draw slate?), most of which are within mineable horizons. Furthermore, unlike the main bench, the thickness of the overlying roof coals and their intervening rock binders can vary significantly. For instance, in southwestern Pennsylvania, the Pittsburgh seam main bench typically ranges from about 5.0 to 6.0 feet thick with minimal variation over short distances. On the other hand, the Pittsburgh seam roof coals and immediate roof binder typically range from a few inches to several feet, and in certain geologic settings can vary significantly over short distances. Additionally, in some locations, very thick draw slate can totally replace the roof coals. Since the draw slate, which typically consists of claystone or clayladen shale, is relatively weak, the presence of thick and variable draw slate in the roof and rib can significantly affect mine safety and productivity. This paper presents the adverse effect of thick draw slate on a 1500-foot-wide longwall face in a southwestern Pennsylvania coal mine. Mapping of the thick draw slate, numerical models which illustrate stress distribution and failure associated with thick draw slate, and operational adjustments instituted to mitigate the negative impact of thick draw slate will be discussed in detail.

Jan 1, 2013

By Tim Miller, Michael M. Murphy, John L. Ellenberger, Gabriel S. Esterhuizen

"A limestone mine in Ohio has had instability problems that have led to massive roof falls extending to the surface. This study focuses on the role that weak, moisture-sensitive floor has in the instability issues. Previous NIOSH research related to this subject did not include analysis for weak floor or weak bands and recommended that when such issues arise they should be investigated further using a more advanced analysis. Therefore, to further investigate the observed instability occurring on a large scale at the Ohio mine, FLAC3D numerical models were employed to demonstrate the effect that a weak floor has on roof and pillar stability. This case study will provide important information to limestone mine operators regarding the impact of weak floor causing the potential for roof collapse, pillar failure, and subsequent subsidence of the ground surface.IntroductionMassive roof falls extending to the surface at a limestone mine in Ohio have been studied collaboratively by the National Institute for Occupational Safety and Health (NIOSH) and the mine owners. This paper provides a summary of the sequence of events leading to observed instability and presents a numerical modeling analysis that investigates the role a weak floor can have on roof and pillar stability.This study builds upon previous NIOSH research in underground limestone mines undertaken by way of a survey that analyzed performance of pillars in 34 different stone mines in the Eastern and Midwestern United States between 2005 and 2009 (Esterhuizen et al., 2011). This survey led to the development of underground stone mine pillar design guidelines based upon a “stability factor” for the pillar system. The factor is compared to operational experience to determine ranges of values that are typical of stable pillar systems. A software package titled Stone Mine Pillar Design (S-Pillar) was developed for easy application of these guidelines (Esterhuizen and Murphy, 2011).Weak floor in the present case study departs significantly from cases included in the previous NIOSH research, in that none of the 34 study mines had weak floor issues. Moreover, this case study is the first in which a weak floor has been monitored routinely as roof falls are occurring. A detailed report on the observations and measurements taken at the mine has been published (Murphy et al., 2015). The previous observations led to the conclusion that although there were weak bands in the pillar, the weak floor was the significant defect that led to the instability issues. The pillars were initially mined in 2004, approximately 10 years before the instability issues began to occur. The objective of this study is to use numerical models to analyze a variety of floor strengths and the impact of moisture content to find the critical point at which the floor becomes unstable, leading to long-term instability issues."

Jan 1, 2015

By William J. Schloemer

INTRODUCTION The history of coal mining the Ostrava Region of the Czech Republic goes back nearly 250 years. Both coking coal for steelmaking and thermal coal for the production of energy are mined here; however, it was the coking capabilities that subsequently turned the region into a major steel-producing area in the early 1800?s, something that continues to this day. Ostrava lies in the northeast corner of the Czech Republic, near the southern border of Poland, and falls within the Upper Silesian Coal Basin. The region contains over 400 seams of coal of which about 150 have been mined over its history and continue to be mined. Eighty percent of the Upper Silesian coalfieldlies in Poland and is presently mined by about 35 coal mines; the remaining 20% falls in the Czech Republic, which presently has four mines operated by OKD, a.s., a subsidiary of Amsterdam-based New World Resources. Traditionally, all the mines in this region have employed the longwall method of mining, of which subsidence is an unavoidable consequence. In fact, due to the long history of longwall mining here, there are areas where the overall subsidence has exceeded 37 meters (121 feet). The region is fairly densely populated with residences and industry, and a considerable amount of coal lies under some of these areas where subsidence is not allowed or has to be minimized. It is this reason that has driven OKD to consider alternate methods of mining that will not create subsidence. The decision was made to consider the room and pillar method of mining in order to leave stable pillars of coal to support the surface. After considering several locations, OKD chose the shaft safety pillar at the CSM mine as a test mining location. To say the least, this is a very challenging location in which to conduct a test. As with the entire region, there are many faults from tectonic activity, the seams are pitching at 12 to 20 degrees, the area is affected by high horizontal stress, and the depth of 750 to 900 meters is perhaps the deepest room and pillar coal mining ever attempted.

Jan 1, 2014

By Lightfoot. Nicholas, Na Liu

"Mining in multi-seam workings has been undertaken for many years in the VK Remnant pillars above and/or below current working areas have an important influence on retreat gateroad conditions at five of the remaining six deep coal mines. These interaction effects need lo be predicted ahead of mining so that longwall panels can be positioned to minimize roadway damage and to identify areas where additional support should be installed early into competent strata when and where it is most effective.Currently, three-dimensional elastic stress analysis using MAP3D is undertaken to predict local vertical and horizontal stress magnitudes during gateroad development and in front of the face on retreat. The predicted stress fields are often used as input to FLAC for roadway modelling.Using Maltby Colliery in South Yorkshire as a case study, this paper illustrates the MAP3D approach, together with its current limitations and uncertainties. Possible future improvements in the analysis method are proposed and the authors would welcome comments on these, or suggestions for alternative approaches.MODELLING OF MULTl-SEAM LAYOUT & MULTI-SEAM INTERACTIONThe remaining large coal mines in the UK arc operating at depths of 800-1, 150 m (2,625-3,773 ft). Production panels are now mined on retreat after the accompanying single entry access roadways have been completed. These gateroads are typically supported with a system of steel rock bolts and cable in the roof and steel bolts and glass re in forced polymer (G RP) dowels in the sidewalls.In addition to new panels being mined in the vicinity of old goafed districts, a significant amount of extraction has usually already taken place in coal seams above and/or below the current working areas. This means that there is also interaction between the current workings and the remnants of the old workings in other seams. As a consequence of the mining methods employed, old workings can have a complex geometry compri ing collapsed and partially collapsed excavations intersper ed with small and large pillars of unmined coal. The unmined coal pillar act as stress concentrators that carry the overburden load while the mined out excavations create stress shadows of varying degrees depending on how much collap e and reconsolidat ion has occurred. This is illustrated by a simple elastic model as shown in Figure I."

Jan 1, 2010

By Pierre-Yves Declercq, Andre Vervoort

"After the mass closures of entire coal mine districts in Europe at the end of the last century, a new phenomenon of surface movement was observed—an upward movement. Although most surface movement (i.e., subsidence) occurs in the months and years after mining by the longwall method, surface movement still occurs many decades after mining is terminated. After the closure and flooding of underground excavations and surrounding rock, this movement is reversed. This paper focuses on quantifying the upward movement in two neighboring coal mines (Winterslag and Zwartberg, Belgium). The study is based on data from a remote sensing technique: interferometry with synthetic aperture radar (INSAR). The results of the study show that the rate of upward movement in the decade after closure is about 10 mm/year on average. The upward movements are not linked directly to the past exploitation directly underneath a location. The amounts of subsidence at specific locations are linked mainly to their positions relative to an inverse trough shape situated over the entire mined-out areas and their immediate surroundings. Local features, such as geological faults, can have a secondary effect on the local variation of the uplift. The processes of subsidence and uplift are based on completely different mechanisms. Subsidence is initiated by a caving process, while the process of uplift is clearly linked to flooding. INTRODUCTION After the mass closures of entire coal mine districts in Europe at the end of the last century, a new phenomenon of surface movement was observed—upward movement in the area above the past exploitation and in the immediate surroundings. Of course, most surface movement (i.e., subsidence) occurs in the months and years after mining by the longwall method (Peng, 1986). This downward movement continues to occur at a smaller rate many decades after mining has been terminated when the water in the underground excavations is pumped to the surface. This is the case as long as a mine is in operation. However, after the closure and flooding of the underground excavations and the surrounding rock, this movement is reversed, and the surface is uplifted. A total uplift of about half a meter has been recorded to date. This phenomenon has been described in several different coal basins in Europe, for example, in Belgium (Devleeschouwer et al., 2008), France (Samsonov, d’Oreye, and Smets, 2013), Germany (Baglikow, 2011), the Netherlands (Caro Cuenca, Hooper, and Hanssen, 2013), and Poland (Preusse, Kateloe, and Sroka, 2013). To date, research has focused mainly on understanding the phenomenon (e.g., Herrero et al., 2012) and identifying general trends, whereby the link with the rise in water levels is an important issue (Caro Cuenca, Hooper, and Hanssen, 2013). The most accepted explanation is linked to the swelling of clay minerals in the argillaceous rocks in the coal strata (Herrero et al., 2012). Without doubt, the full explanation is complex, and swelling is probably not the only cause of the residual movement. Most coal strata rock is weakened upon contact with water. The increase in water pressure also results in a decrease in the effective stress. Both aspects facilitate the fracturing of rock, which normally would result in further subsidence. However, decreases in the effective stresses also result in the relaxation or expansion of the rock, which induces an upward movement (Fjar et al., 2008). All of these aspects, including the long-term residual subsidence due to compaction under dry conditions, result in a net upward movement. The phenomenon discussed here is clearly different from the upsidence, sometimes observed on other continents (e.g., in Australia, Galvin, 2016). When upsidence occurs, the rock near the surface bends and buckles upwards due to the overstressing of the floors of the valleys."

Jan 1, 2017

By Khaled M. Mohamed, Michael M. Murphy, Ted M. Klemetti, Heather E. Lawson

"The design of rib support systems in U.S. coal mines is based primarily on local practices and experience. A better understanding of current rib support practices in U.S. coal mines is crucial for developing a sound engineering rib support design tool.The objective of this paper is to analyze the current practices of rib control in US coal mines. Twenty (20) underground coal mines were studied representing various coal basins, coal seams, geology, loading conditions, and rib control strategies.The key findings are: (1) any rib design guideline or tool should take into account external rib support as well as internal bolting; (2) rib bolts on their own cannot contain rib spall, especially in soft ribs subjected to significant load—external rib control devices such as mesh are required in such cases to contain rib sloughing; (3) the majority of the studied mines follow the overburden depth and entry height thresholds recommended by the Program Information Bulletin (PIB) 11-29; (4) potential rib instability occurred when certain geological features prevailed—these include draw slate and/or bone coal near the rib/roof line, claystone partings, and soft coal bench overlain by rock strata; (5) 47% of the studied rib spall was classified as blocky—this could indicate a high potential of rib hazards; and (6) rib injury rates of the studied mines for the last three years emphasize the need for more rib control management for mines operating at overburden depths between 500 ft and 1,000 ft.IntroductionEfforts to improve the stability of underground mine ribs have continued for decades. These efforts by mining professionals around the world persisted throughout the 1990s and 2000s as well, though much of this work focused on rib support methodology and selection of proper support for a specific location. Despite these efforts, it is unfortunate that there has been a continual occurrence of rib-related fatalities in underground coal mines. While overall improvements in rib safety have been achieved, the average fatality rate is still about 1.3 fatalities per year over the last 18 years (Jones, 2014).To manage and control the rib hazard, rib support is used in U.S. coal mines. The current rib support methods for U.S. mines fall into two main categories: rib control based on intrinsic support systems and those based on external support systems. Intrinsic or rib-bolt support requires a roof bolting machine that can install a bolt fixture into the rib. Furthermore, the appropriate level of support needed to control the ribs with an intrinsic-based support system as well as the design parameters for those support systems for various mine conditions have not been established in U.S. coal mines. Furthermore, surface control systems are often an integral part of these support systems and must be considered in the system design."

Jan 1, 2015

By Stephen C. Tadolini, Anand Bhagwat

"Intrinsic supports installed in mines with limited seam or mining heights have always proven to be difficult when the required support length is longer. To date, three solutions have been used to ensure that the correct length bolt is installed to achieve the required anchorage or to maintain immediate roof material: combination bolts, milled-notch bolts, and hot-notch bolts. The combination bolts use threaded sections and couples, which can be screwed together to form the required length. The primary bolt of choice, to minimize costs and achieve the desired support, has been milled- or hot-notch rebar bolts. These notches can be placed at strategic (required) locations along the bolt axis, so the bolt can be successfully bent and straightened during the installation process. However, these notches can reduce the strength of the bolting system; special reductions are detailed in ASTM F432-13 (2013). Technical advances in steel rolling and forged heading processes have led to the development of a deformed rebar bolt termed, the BORE bolt, which stands for Bendable Oval REbar. The BORE bolt can be bent at any location and straightened during the bolt installation cycle. This support exceeds the minimum designed capacities described in ASTM F432-13 and meets the yield and tensile strength requirements of a full diameter no. 6 rebar bolt. The profile and shape also reduces the resin annulus during the installation process to enhance mixing and shreds the cartridge film to help eliminate glove fingering.INTRODUCTIONThe height or depth of competent strata material, in the immediate mine roof, can be greater than the developed mine openings heights. This is especially true in coal mine openings where 50% of the minable seams in the US are less than 50 inches (132 cm). When this scenario occurs, it can be difficult to insert steel bolts in a solid single length. Figure 1 illustrates what difficulties can be experienced when a roof bolter operator is working and supporting a thin seam coal mine. There are three viable options currently available. Lengths of the bolt can be threaded and a steel coupler can be used between the sections to reach the required depth of anchorage. These systems, called “coupled bolts,” usually require a larger diameter hole to facilitate the larger coupler diameter and can be anchored with an expansion shell, resin, or a combination of both. To ensure that the coupler will develop the tensile capacity of the bolting system, required by ASTM 432-13 Standard Specifications for Roof and Rock Bolts and Accessories (2013), the threaded bars should be completely rotated and engaged into the coupler. Premature failures can occur when the threads “strip out” if not inserted completely."

Jan 1, 2018

By Thomas A. Cook

The effectiveness of tensioned roof bolt systems has been well researched and documented over the years (Stankus, 1990, 1991, 1997; Guo, 1997; Denton, 2000; Su, 2007). Higher and more consistent installed tension has been shown to improve the beaming effect and associated roof stability especially in highly-stressed, weak, laminated roof strata. To accomplish higher and more consistent bolt-installed tensions, various types of anti-friction washers have been developed and applied to many types of tensioned roof bolt systems. In addition to increasing bolt-installed tension, these washers also provide a lubricating effect that minimizes sparking during the bolt torqueing cycle. The most popular and widely used anti-friction washer configuration consists of a plastic washer that is used in conjunction with a standard hardened steel washer. This washer configuration has performed well in the field in terms of increasing the bolt-installed tension (or plate load) and the related tension/torque ratio (the amount of tension achieved per one ft-lb of applied torque). However, the installed tension does not always maintain consistency. One reason for this inconsistency is that the plastic anti-friction washer sometimes dislodges and shreds or tears before the bolt torqueing cycle is complete. This condition prevents the plastic washer from acting as an anti-friction medium for the entire torqueing cycle. Jennmar Corporation and Keystone Mining Services, LLC, developed the ?TT? washer in early 2012. The ?TT? anti-friction washer is comprised of two zinc-coated (galvanized) hardened steel washers that are joined together with an exclusive polymer. The ?TT? washer has been extensively tested and applied in the Sewickley, Pittsburgh, and Indiana #5 coal seams. The test results indicate an average increase in installed load and tension/torque ratio of 20%. More importantly, the installed load consistency improved, with a significant reduction in the standard deviation of values. This paper will detail the development and testing of the ?TT? anti-friction washer with case studies of actual mine applications.

Jan 1, 2014

By Ben Mirabile

Over the past three decades, the U.S. coal mining industry has widely used cable supports to supplement traditional primary bolting systems, especially in difficult ground conditions. However, increased mining activity in adverse conditions has underscored the limited effectiveness of the non-tensioned, partially grouted cable supports used to supplement primary bolts. Roof failures in conditions such as corrosive environments, highly laminated strata, low overburden depth and water intrusion have demonstrated that the need for cable technology has reached beyond the traditional non-tensioned, partially-grouted cable tendon. Furthermore, declining market conditions and increased competition for coal customers has demanded that new cable bolt technology be costeffective and readily adaptable to the mining cycle. Jennmar Corporation has developed several cable bolt technologies that can be used as stand-alone solutions or in concert with one another to mitigate adverse conditions. These technologies include rapid tensioning of cable supports, structural surface control and polyurethane injection. The case studies presented in this paper use one or more of these technologies to address adverse mining conditions or special ground control problems.

Jan 1, 2013

By Naj Aziz, Peter Craig

"Double shearing tests were carried out on the 28 mm (1 in) hollow strand Jennmar TG cable bolt to gain a better understanding of the shearing behavior of the cable. The first test was limited to a 50 mm (2 in) travel on the testing machine and produced a shear load of 900 kN (92 t) at the maximum 50 mm (2 in) displacement. The axial load generated on the cable bolt was 238 kN (24.3 t). In the second test, the machine travel was increased to 75 mm (3 in), and first strand failure of the cable, due to shear loading, occurred at 1,354 kN (138 t) vertical load at a vertical displacement of 59 mm (2.3 in). The cable axial load was in the order of 385 kN (39.3 t). Analysis of the failure mode and loads achieved showed that the cable strands bent and the concrete crushed along the shear plane; the shear loading across the concrete and grouted cable then reached the tensile strength of the steel wires.INTRODUCTIONCable bolts were introduced to the mining industry around 1970, initially to surface mining and underground metalliferous mining and then to coal mining in the early 1980s, mainly for roadway reinforcement as a secondary means of support. Cable bolts have since been used as both primary and secondary supports. As primary support, Fuller et al. (1994) described the application of cable bolts, known as FLEXIBOLT, for strata reinforcement in both Angus Place and Ellalong Collieries, in New South Wales (NSW), Australia. As secondary support, cable bolts have also been used as cable trusses, which act to support the immediate roof in a sling-like manner (Fabjanczyk and Tarrant, 1988; Fuller, et al., 1991; O'Grady and Fuller, 1992), and for reinforcement at higher stratification and beyond the rebar bolt length, mainly for anchoring lower strata layers immediately above the coal seam to the higher, competent bedding formation above. Initially cable bolt anchorage was by cementatious grouting and, since the 1990s, by chemical resin. The dominant type of cable bolts used for secondary support in Australian underground coal mines are 588 kN (60 t) capacity cables which are point anchored, pre-tensioned and post-grouted. Point anchored refers to a cable resin anchor. The cables are tensioned on the resin anchor; then the same cable is grouted by cementatious grout pumped to ·fin the annular gap around the cable from the collar of the hole to the resin anchor. Bulbs are located within the resin anchor section for mixing of the resin chemical components and efficient anchorage. The installation of these typically 8 m long cable bolts involves a lot of manual handling of the cables, lifting of heavy hydraulic tensioners, and exposure to resin grouts. Table 1 shows the specification of various cable bolts currently marketed and installed in Australian underground coal mines."

Jan 1, 2010

By Kevin Jinrong Ma

Underground mines often experience roof falls in entries, crosscuts, and intersections of active mining sections, main travel ways, and belt entries. Roof fall heights greater than 20 ft (6 m) make re-bolting of the newly exposed roof dangerous and impractical. To protect mine personnel, belts, moving vehicles, and other facilities, mine operators typically install steel structures such as square or arch sets in the roof fall areas. Wood lagging is usually installed between the steel-sets to enclose the area and protect the entry from recurring falls. Usually the void space above the steel-sets and laggings is backfilled. However, backfilling high roof fall voids is costly, which causes some operators to leave the voids open. In this case, durability of wood over time and the capability of the steel-set and wood lagging to resist falling rocks are unknown. During the last few years, Keystone Mining Services, LLC (Jennmar Corporation affiliate engineering company) designed, tested, and developed an impact-resistant lagging system to protect steel-sets1. Various steel-sets protected with the impact-resistant lagging were approved by MSHA and installed in different underground roof fall rehabilitation projects. This paper presents (1) design, development, and laboratory testing of the patent-pending impact-resistant lagging panel, (2) steel-set design methodology according to the American Institute of Steel Construction (AISC) national standard, and (3) impact-resistant steel-set design method based on Law of Conservation of Energy. Two underground cases are reviewed to demonstrate the successful application of the impact-resistant lagging system.

Jan 1, 2011

Virtually all mineable Appalachian coal seams exist in a multi-seam environment. This makes it inevitable that most seams will eventually experience interaction induced ground control and mining problems. Indeed, it has been estimated that every working face will experience interaction effects from previous or current workings at least once during its lifetime (1), and that these problems are considerably exaggerated when seams are in close proximity -- a distance of less than 110 feet. The continued increase in multi-seam problems has resulted in considerable research activities over many years (2,3,4,1). Theoretical analysis, numerical and physical model studies, statistical and empirical analysis of numerous interaction related field data have been applied to multi-seam mining situations and have identified many useful trends and design criteria (4,5,6,7). To fully utilize research results and transfer multi-seam mining technology to field engineers, a design model -- USEAM was constructed (8). This model, designed for close seam under-mining situations, was computerized to facilitate utilization. In the current research, a new computer program "MSEAM" was developed to produce a model for both under- and overmining close seam situations. It is hoped that both of these software packages will aid field engineers in using important interactive design criteria to gain a better understanding of interaction mechanisms. Through advance planning with these programs, detrimental interaction may be avoided and minimized, and occasionally a design can be selected which will allow interaction effects to be utilized to the benefit of mining operations.

Jan 1, 1987

By William Kendall

"A tremendous amount of research, analysis, and engineering time is used to design a proper roof support system including the type, length, and location of the roof bolts. Unfortunately, since the roof bolts are being installed under unsupported roof, the exact location for the bolt holes cannot easily be determined and then marked onto the roof. The actual location where the roof bolts are installed is typically left to visual estimates by the operator. This frequently results in either (1) the operator overestimating the space between roof bolts and installing more bolts than required, thereby increasing cost and reducing efficiency; or (2) the operator underestimating the space between roof bolts and installing fewer bolts than required, thereby reducing safety, leading to potential roof failure or possible violations.A patented laser light grid system has been developed by J .H. Fletcher and Monitech, a South African Company, to aid in proper machine positioning in the heading and proper bolt spacing. The system can also show when an entry is over width, requiring additional roof support. The system is relatively simple and inexpensive. The concept is applicable across the full range of roof bolters from low to high seams and from single boom to multiple boom bolters. The system can be configured to meet most bolting patterns.The system consists of several very small 1 milliwatt, class 2, line type lasers that project a line onto the roof. The actual laser is 27mm in diameter x 47mm long (1"" x 1.8""). In South Africa it is approved as intrinsically safe and is mounted inside a 50mm diameter x 64mm long (2""x 2.5"") protective housing. In the USA, we are seeking an X/P approval and the laser will be mounted in a headlight enclosure 110mm diameter x 125mm long (4.3"" x 5""). Fifteen of the systems have been installed in South African coal mines with good results.The system has aided the mines in meeting the bolt spacing tolerance used in the Republic of South Africa, which is typically 15% of the nominal bolt spacing or 7 in for 4-ft bolt spacing. Fletcher has submitted the system to MSHA for approval in the US."

Jan 1, 2016