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By H. N. Maleki

Tension-torque relationships were investigated *n a coal mine for bath standard 5/8 in. (16 mm) bolts and a vibrating wire instrumented bolt, using conventional and controlled installation techniques. The instrumented bolts differed from the standard bolts by their head size and hole preparation procedures. The controlled installation technique developed by the U. S. Bureau of Nines (USBN) involved using hardened washers and lubrication in the bolt assembly, and maintaining a minimum thrust level during bolt installations. The object of this study was to determine the tension to torque ratio (lb/ft-lbs; for standard bolts and instrumented bolts for both conventional and controlled installation techniques, and to modify the bolt assembly so that the ratios would be equal for the instrumented and standard bolts for both installation techniques. It was shown that the instrumented bolts installed in faced holes had a similar tension torque ratio td that of standard 5/8 in. (16 mm) bolts installed in unfaced holes for each installation technique, and thus they were representative of other uninstrumentea bolts. This was achieved by evaluating the influence of several factors oh the relationship, including: facing the hale surface, introducing washers and lubrication in the bolt assembly, and applying different levels of thrust at installation due to bolter operator practice. The tension to torque ratio fur conventional bolts was only 21 (lb/ft-lb) for the coal mine, resulting in an installation tension of 4000 lbs (17.8 kg) with the typical installation torque of 150 to 400 ft-lb. This tension level was approximately 50 percent of the required bolt tension, and thus, it was concluded that torque standards are not sufficient to assure adequate bolt tension. .he low tension levels were due to the particular wait hardware in use, operator practice, and bolt fencing.

Jan 1, 1984

By M. Guana

Island Creek Corporation is predominately an underground mine operator deploying room-and-pillar and retreat longwall mining methods for extracting coal. Wide variations are encountered in overburden depth, stratigraphy, and insitu stress fields. This requires major adjustments in mine design among mines and occasionally within a mine. Simple rock mechanics principles are utilized in mine design to optimize safety and productivity. Physical observations and micro deformation monitoring of roadways are the primary techniques employed. Pillars and artificial support systems are the primary design elements modified. The specific case histories reviewed in this paper include narrow panels with high extraction for conventionally mined rooms, pillar sizing for longwall gate entries at great depths, and bolt type selection for difficult ground conditions.

Jan 1, 1988

By Christopher Phillips

In light of recent events in the mining industry, there has been an increasing demand for technology to detect underground voids and abandoned mine workings. This paper summarizes the use of geophysical methods for this application. Geophysical methods have been successfully employed in the detection of underground voids in several disciplines, including foundation analysis, road and infrastructure analysis, and darn analysis, but is not yet being widely employed by the mining industry. The principal reasons are that the combination of the complex geological setting of a mine, mine design, surface conditions, and improper choice of geophysical method often makes the task of locating abandoned mine workings with geophysics a frustrating, time consuming, and often unsuccessful venture. While there are several geophysical methods that have been demonstrated for the successful detection of abandoned mine workings, there is still no 'silver bullet' to solve the problem in every case. The choice of geophysical method to detect abandoned mine workings should be made on a site specific, and sometimes target specific, level. This paper reviews current methods, and introduces recently developed methods, for the detection of underground voids and abandoned mine workings.

Jan 1, 2003

By Chris Mark

Fully-grouted roof bolts comprise more than 80% of the primary roof supports used in U.S. coal mines. However, nearly 1,500 MSHA reportable, non-injury roof falls occur each year, and most of these are attributable to failure of the roof bolt system. Anchorage failure is one failure mechanism for fully-grouted bolts. As roof deformation works its way upward, the bolts can become heavily loaded near their upper ends, If the applied load exceeds the anchorage, the bolts will simply pull out. Research dating back 30 yrs indicates that this type of anchorage failure is most likely when the roof rock is weak, just where roof support is most critical. In soft shale or coal roof, the small amount of data available in the literature indicates that 20-30 in of resin anchorage may be required to achieve the full capacity of the bolt. In other words, the "full resistance zone" of a 60 in bolt may actually be just 30-40 in. Despite its potential importance, there is no widely accepted anchorage test for fully grouted bolts. Standard pull tests have sometimes been employed, but they provide no information on the anchorage near the top of the bolt. An alternative, first described more than 25 yrs ago in the U.S., is the short-encapsulation pull test (SEPT). With this test, the bolt is installed with only a short (1 ft or less) tube of resin. In recent years variations of this test have become international standards. This paper describes recent studies using short encapsulation pull tests in the U.S. Tests were conducted in the National Institute for Occupational Safety and Health (NIOSH) Safety Research Coal Mine at Bruceton and at underground mines in Pennsylvania and West Virginia. The study found that the SEPT can be used to make a simple evaluation of resin bolt anchorage. Suggested procedures for conducting SEPT are included. The study also confirmed that poor anchorage can be an issue, particularly where the roof rock is very weak. Some simple techniques for improving anchorage, and thereby the effectiveness of fully grouted bolts, are discussed.

Jan 1, 2002

By Yingxin Zhou

Data from these field studies and previous case study data have been combined to define ultra-dose seam mining environments and relate them to observed failure conditions. A rating system for ultra-close multi- seam design has been developed and field studies have verified the applicability of the design criteria according to geologic structures, lithology and spatial data. This rating system has been combined with design and depth considerations to create a protocol for quantitatively predicting potential damage in ultra-dose seam mining conditions. A brief discussion of the characteristics of ultra-dose seam mining and its related failure mechanisms is also presented

Jan 1, 1990

By Ben Mirabile, Alan Campoli, Rodney Poland

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

Jan 1, 2010

By Mohummad Akram

Statistical analysis of multi-seam mining case studies demonstrated that geologic structure and lithological type and sequencing were predominant factors in entry failures. Finite element analysis was used to evaluate the effects of stress field changes on entry instability under differing geologic conditions. Analysis showed the roof to be particularly vulnerable to shear with the location of the failure site changing to meet loading and geologic conditions. Effects of external support on roof stability were examined. Results were correlated with field data to determine stress levels at which failure could be expected to occur. Based on this research design, criteria were developed for roof stability evaluation under specified interactive loading conditions.

Jan 1, 1993

By Winton J. Gale

Coal mine pillar design formulae available to mine planners are typically based on relationships determined for specific site conditions. Application of these methods is difficult when other factors, relating to mining or geological conditions, not specifically addressed in these relationships are encountered. A review of pillar design methods, coal strength properties and relevant field monitoring of pillar behaviour has shown pillar strength and deformational characteristics are extremely sensitive to in situ behaviour of the rock and other material components that make up the coal pillar system. A method has been developed that has been found to provide excellent correlation between existing field data using the strength and deformational characteristics of materials determined in selected laboratory tests. This method is based on definition of the leading conditions, accurate modelling of the strength, confining conditions and deformation occuring in the roof, floor and coal seam and definition of the in situ strength of coal based on underground monitoring of appropriately sized coal pillar. The design method is considered to provide an accurate and rigorous pillar design method that will give mine planners a more rational mine design capability which is based on the mine geometry and geological setting of the operation. It is envisaged that availability of such a method will allow significant optimisation of pillar layouts and more closely define the geological and mining issues that relate to pillar design optimisation.

Jan 1, 1992

By Leo Gilbride

Western U.S. longwall operators face increasing challenges with optimizing ground control and productivity as mines reach greater depths and coal bursting hazards increase. Some western U.S. mines, many known to be bump-prone, achieved a successful balance between ground control and productivity by transitioning to side-by-side longwall panel mining combined with a yield pillar gateroad system. With this design, development footages could be minimized and pillar bumping averted by controlled yielding at moderate depths, generally in the range of 450 to 600 m. Over the past four decades, the yield pillar system has won wide acceptance among western mines facing pillar bursting hazards, particularly those in the Wasatch Plateau and Book Cliff coal fields of central Utah. However, recent attempts among the deepest Utah operators to mine side¬by-side panels with yield pillars at depths in excess of 600 m have been met with mixed success and, in some circumstances, with serious difficulty. Challenges include violent face bursting and excessive tailgate convergence outby the face, which can be crippling to ventilation. The use of interpanel barriers, i.e., barriers left between longwall panels, offers one possible solution to mining under deep cover with bump-prone geology. Interpanel barriers have already been adopted by Utah's deepest longwall mine, and others are considering their use. The geomechanical implications of mining with and without interpanel barriers, and the competing tradeoffs between ground control and ventilation are discussed.

Jan 1, 2004

By Nikolaos Polysos

Besides considering the given geomechanical conditions, the geological/geotechnical logging of drill cores and heading faces during the driving of parallel entries and the resulting rock classification form the basis of the assessment of the proneness to caving of the roof strata in the actual mining phase. Both types of separation planes, parallel to the stratification as well as intersecting the bedding, will be defined and assessed within the immediate roof strata depending on the lithological structure. These data may hold the potential to plan the winning and design its operational organization in a way that - to a major extent - future damage of the workings by increased caving or cavities can be predicted in advance. Following the general description of the separation plane structure, the combined influence of the petrographic and structural geological roof properties on the operating cycle of the planned working face will be presented and illustrated.

Jan 1, 2003

By Venkata S. Vutukuri

Compressive strength of cylindrical specimens of a model material and sandstone with various diameter/height (d/h) ratios was determined in unconfined compression tests. It was observed that the compressive strength increases with increase in d/h ratio. Triaxial compression tests were also conducted on the specimens of the same materials with a d/h ratio of about 0.47. It was observed that the axial stress at failure increases with increase in confining pressure. A very interesting correlation was found between the effect of d/h ratio on compressive strength in unconfined compression tests and the effect of confining pressure on axial stress at failure in triaxial tests. The relationships between d/h ratio and confining pressure, s3 in MPa are:- For model material - s3 = -0.95 + 1.7957*(d/h) 0.7883. For sandstone - s- (-0.4554 + 0.9888* (d/h) 1.0355. The correlation coefficients for these equations are 0.9997 and 1. These equations are valid for d/h ratios of up to 10.

Jan 1, 1993

By D. A. Payne

Large excavations, such as Iongwall panels, result in extensive vertical stress redistribution in the surrounding strata. The large abutment stresses developed may produce damage to pre-existing or planned excavations in the same seam or in seams above and below the workings. Knowledge of the magnitude and location of these stresses is therefore important in the design of mine openings; pillar sizes for panel and pillar layouts, roof supports in longwall gateroads and workings over or above pre-existing or planned extraction in adjacent seams. In an attempt to reduce costs, the Cape Breton Development Corporation (CBDC), a Federal Crown Corporation responsible for operating two retreat longwall coal mines, examined the potential for either interpanel barrier pillar width reduction or entire pillar elimination by the adoption of dual life gateroads for the longwall panels. In order to assess the potential for reduced interpanel barrier widths or total elimination, an investigation of the redistribution of vertical stresses around longwall panels in the Sydney Coalfield was established. The study was conducted jointly by the Cape Breton Coal Research Laboratory (CBCRL), of CANMET (a division of Natural Resources Canada) and the Denver Research Center (DRC) of the United States Bureau of Mines. The program included monitoring of vertical stress changes around longwall panels and gateroad behaviour in two seams. USBM-style hydraulic borehole pressure cells connected to chart recorders for continuous monitoring were deployed at four sites, two at Lingan Colliery and two at Phalen Colliery. This report describes the investigations conducted at Phalen Colliery. Contoured plots of stress redistribution around two sites are presented.

Jan 1, 1995

By Y. P. Chugh

The use of wooden supports, supplementary to the primary method of roof control using roof bolts in mines, consumes over 3 million cubic meters of hardwood in the U.S. annually. These supports arc primarily used in the form of cribs and posts. Along with a rapid depletion of high quality timber resources, supplies fluctuate seasonally, costs are escalating rapidly, and product quality is highly variable. Environmental considerations of global climate change put additional pressure on deforestation for utilization of timber for artificial supports. On the other hand, management of coal combustion byproducts (GCBs) from power plants has become a major issue to maintaining a healthy coal industry. The USA currently produces over 100 million tons of CCBs annually and the average cost for their management in the US is about $20/ton. This cost is expected to escalate rapidly with tougher environmental regulations. The principal author has been directing research, development, and demonstration studies for CCBs-based artificial supports and lightweight structural materials in mines for the past seven years and has made significant progress toward commercially viable products. More specifically, first and second generation crib elements and post elements have been developed, characterized analytically, and demonstrated in the field. It is estimated that about 2.5 x 10" tons of fly ash could be utilized for artificial supports in U.S coal mines and this would double if these materials were utilized in non-coal mines as well. The author believes that CCBs-based artificial supports have the potential to replace wooden supports and blocks with better performance and cost competitiveness while managing CCBs in an environmentally sound manner. This paper focuses on the development and field demonstration of CCBs-based artificial supports for use in underground mines, and its pilot scale fabrication facility. Recent analysis results on engineering performance evaluation of the developed crib under various loading conditions using finite element method are presented. The following comments highlight the developments: I ). Engineered artificial supports, crib and post elements, using CCBs as a major constituent, have significant potential for application in mines because their structural performance is significantly better than wooden cribs counterparts. 21. Engineered crib elements provide about 50% larger area for air-flow than a conventional wooden crib. 3). Engineered crib elements are not flammable. 4). Each engineered crib element utilizes about 10 kg of fly ash, about 40 % of the weight of crib element- Therefore, a typical crib 2.0 m high utilizes about 200 kg of fly ash. 5). Each 16.5 cm diameter engineered post utilizes 50 kg of fly ash. 6). Assuming 3.0 million cu. meter of wood consumed for post and crib support systems, it is estimated that about 4 - 5 million tons of fly ash may be utilized for supports fabrication in the USA. 7). An engineered post has excellent post-failure characteristics similar to wood. In addition, the engineered post also has excellent loading and unloading characteristics close to the yield point of about 75% of the ultimate load carrying capacity.

Jan 1, 2004

By H. N. Maleki

The results of five years of geotechnical investigations are presented to develop productive and stable longwall layouts for the Foidel Creek Mine. The program was initiated during the pre-mining stage, and has continuously provided the data required for mine design. From several stress determinations at the mine, the relationship between geologic structure and the stress field/depth was established. The results were used for orienting the entries for improved stability. Cave conditions and load transfer to panel boundaries were evaluated from closely monitored full extraction mining and computer analysis. Back-analyses of ground movements, as compared with the actual measurements, indicated that cave conditions were favorable in spite of the presence of competent, thick-bedded sandstones in the mine roof. Gate pillar design using a yield-rigid concept was developed through computer analyses and underground instrumentation, resulting in 35 and 75 ft wide pillars. The influence of a slickensided bedding plane at the roof contact on pillar yield zones, core confinement, and pillar behavior was evaluated.

Jan 1, 1988

By Z. T. Bieniawski

This paper presents the results of a survey of room and pillar dimensions and design practice in U.S. coal mines aimed at improving the design procedures in room and pillar mining. A review is given of the current pillar strength formulas and suggestions are made for better utilization of research results in engineering practice.

Jan 1, 1981

By J. Nielen van der Merwe

The main objective of the research described in the paper was to determine the causes of falls of roof in South African coal mines. The south African Colliery Manager's Association and the members of the South African National Institute of Rock Engineering (SANIRE) who are employed by coal mines lent full support to the work. Fifteen major roof falls were investigated in detail and their causes established. This data was supplemented by mapping a large number of roof falls on four coal mines in less detail. The total number of recorded roof falls was 182. The data bank simulated the data bank of roof falls that resulted in fatalities in terms of the total number of falls recorded and the thickness distribution of the collapses. It was found that the causes of the falls differed for different thickness ranges of roof falls, The thin falls, classified as "Skin falls", which accounted for approximately 70% of all fatalities, were predominantly caused by ineffective joint support and excessive bolt spacing. Ineffective joint support was found to be a dominant cause of roof falls for all thickness ranges, while the influence of excessive bolt spacing diminished with increasing fall thickness. However, it remained a significant cause of roof falls even for the major falls. Burnt coal, dykes, bad mining practice, weathering and inferior materials were found to be minor causes, but nonetheless contributed to the falls. Horizontal stress was a minor cause, with increasing contribution for thicker falls. It was also found that the indicators of horizontal stress coincided with areas of reduced roof rock strength. In general, roof falls occurred in areas where the roof rock was found to be less competent in terms of rock mass rating systems. It was concluded that the Coal Mine Roof Rating (CMRR) system developed by NIOSH in the USA held promise for application in South Africa and should be investigated further.

Jan 1, 2001

By Kot F. v. Unrug

The depletion of thicker coal reserves has resulted in the thinner seams being economically attractive. Surface protection against subsidence limits the extraction ratio to 50% for the room and pillar method as a "no subsidence condition". That rule was developed for pillars with smaller width/height ratio because seams mined at the time were commonly 6 feet thick. Over time pillar ribs deteriorate around the pillar perimeter and thus decrease the area of the pillar. Using 50% extraction as the no subsidence condition in the squat pillar category (below 42 in with w/h > 7) causes unnecessary losses of reserves because squat pillars are stronger. In this paper a method is presented for design of long-term pillars. Based on the analysis of pillar deterioration and field observations, an increase of the "no subsidence" extraction rate to 60% for squat pillars is proposed.

Jan 1, 2001

By Sun Henghu

This paper analyses problems associated with cement based technique in metal mines, and provides a new mining technique of packing the tailing sand and water into solidified material. In the new technique, the cementing agent is a solidifying material containing a high percentage of water and tailing sand. The sand and water solidify into the packed body at the same time. The slurry of the packed body varies widely in concentration and suitability for different mining conditions. It consists of two liquid materials, each composed of a cementing agent, tailing sand and water. The thick liquids are transported to the packing place at the same time. Their pumping property is good; they do not solidify or block up the pipe during transportation. At the packing place, the two liquids are evenly mixed. The mixed liquid flattens out well and its solidifying speed is so fast that it solidifies into a packed body within a very short period of time. The compressed strength of the packed body can reach 1.2-5MPa in one day, which satisfies the requirements of different mining conditions. By using the new mining technique, all the tailing sand can be used again in the packed body and it is low in cost and investment. The mechanisation is easy and thus the working efficiency is increased and the use of labour decreased. Contamination problems caused by excess water drainage under the ground are resolved.

Jan 1, 1992

By H. N. Maleki

This paper presents a field evaluation of six tailgate secondary support systems, with the objective of optimizing support efficiency for maintaining open gate roads. Support systems consisted of a combination of three wooden crib configurations, with either tension rebars or truss bolts. The effectiveness of the support systems was evaluated through measurements of ground movements, support load, and observations along 2000 linear ft of a tailgate. It was concluded that floor heave, crib width to height ratio, cribbing pattern, and support spacing have significant impact on tailgate stability and access after the passage of the first longwall face. Guidelines were suggested for selection of secondary support for other applications.

Jan 1, 1986

By Marc T. Filigenzi

Two of the major ground control safety issues confronting underground mine operations today are shaft pillar stability and the failure of rock around active mine openings. Failure of a mine shaft can lead to the entrapment of workers. Failure of rock around active underground mine openings can lead to roof falls, which in turn can result in worker injuries and fatalities. Finite-element analysis has proven to he a reliable method for predicting stresses and displacements around underground mine openings. However, this is a complex and time consuming technique and is not used as often as it could be in mine planning. The purpose of this paper is to demonstrate one technique developed at the Spokane Research Center that allows the user to create a finite-element model of a two-dimensional section of an underground mine in a relatively straightforward manner. This model is then used to calculate stresses, displacements, and safety factors around mine openings. With this information, mine planners can evaluate the stability of mine openings as well as the stability of pillars and mine shafts. This analysis will help develop mining sequences and layouts that minimize stresses in that section of the mine. This, in turn, should minimize the occurrence of shaft failure, roof falls, and other hazards associated with underground mining.

Jan 1, 1997