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By Peter Zhang

Room and pillar mining under shallow depth is usually conducted with a high extraction ratio, which leaves small pillars with a low safety factor in some old workings in abandoned mines. Pillar sloughage, squeezing or even collapse may have occurred in those old workings with small pillars, either at the time of mining or later. The conditions of the pillars in abandoned mines can affect mining above them. Subsidence fractures and abutment pressure are indications of multi-seam interaction caused by squeezing or collapse of small pillars. To mine over areas with potentially unstable small pillars, the panel layout in the upper seam should be such that multi-seam interaction can be minimized and proper roof and rib support should be installed in the influence zones. This case study presents an example of multi-seam mining above small pillars under a shallow depth of cover. Though the interburden is relatively thick and competent, interaction is still present over the influence zones. Pillar stability and multi-seam interaction analysis, numerical modeling and in-situ monitoring are presented to demonstrate how the upper seam can be mined safely over the small pillars.

Jan 1, 2014

By Jonathan Duncan, Tim Burgess, William Kendall, Jens Lange

"Steel wire mesh is the accepted standard for roof and rib skin control at most coal mines in the United States. Wire mesh is delivered to the mine in bundles that are heavy and awkward to handle. The large size, stiffness, and weight of the wire mesh can present a safety hazard in transporting underground and storing on the roof bolter. Installing wire mesh on the roof and ribs with the roof bolter can be a challenge as well.Synthetic mesh is lighter than wire mesh and can be folded and rolled into a safe, manageable size. A single synthetic mesh roll large enough to cover the roof and ribs in a deep cut can be safely handled by two men. The roof bolter is designed to carry and dispense the roll as it advances and installs primary roof support, resulting in a single pass roof and rib ground control solution. This paper focuses on the design and implementation of the roof bolter synthetic mesh handling system developed by J. H. Fletcher & Co., Huesker, Inc., and Oxbow Mining.INTRODUCTIONRoof and rib skin control in some coal mines has been an issue since mining first began. Roof and rib skin problems vary from mine to mine. The type of roof rock material exposed after mining; the mine atmosphere; and stresses from depth of cover, over mining, and/or undermining are some of the variables that can contribute to roof skin problems from mine to mine.Potential roof and rib skin problems can be time dependent as well. Some mines have roof skin rock, sometimes called draw rock, that falls when drilling the hole for the roof bolt as the initial roof support is installed. Some roof skins are more stable but can fail over time. The failure of roof skin can even be between properly installed roof bolts with roof plates (Figure 1).Mines have most commonly used a wire mesh that comes in individual panels anywhere from 5 ft x 5 ft (1.5 m x 1.5 m) all the way up to 5 ft x 16 ft (1.5 m x 4.9 m) in size. They are typically constructed of 8- or 9-gauge wire welded on a 4 in (102 mm) square pattern. A 5 ft x 16 ft (1.5 m x 4.9 m) panel weighs approximately 35 lbs (16 kg). These steel wire mesh panels can make it a difficult and sometimes dangerous task to deliver them from the surface to the roof bolter and then store on the machine. Manipulating the mesh panels from the storage area on the machine to the final installation position on the roof or rib can also be a daunting task (Figure 2)."

Jan 1, 2010

By A. W. Khair

Laboratory studies indicate that the specimen size influences the compressive strength of coal significantly. In the past, the diameter/height ratio of coal and rock specimens with different geometry and its influence on failure characteristics was discussed (Khair, 1993; Khair, 1994; Khair and Xu, 1994). In the current attempt, tests are designed and carried out under uniaxial condition in the laboratory to investigate the influence of specimen size. Cubical specimens of coal with edge dimension ranging from 5 cm (2 in.) through 20 cm (8 in.) were prepared according to the standards and tested uniaxially. Results show that compressive strength of coal is dependent on specimen size until certain level and later the change in specimen size would not yield significant change in compressive strength. Cubical specimens were chosen for testing because they are not only in close resemblance to underground pillars, but they are also the most stable shape under loading. The failure characteristics of these specimens were analyzed and their applicability to pillar design aspects in coal mines is studied. A detailed analysis of the physical and mechanical properties of the tested coal seam is also presented.

Jan 1, 1996

By Takashi Sasaoka, Hiroshi Takamoto, Akihiro Hamanaka, Pongpanya Phnthoudeth, Hideki Shimada, Jiro Oya

"Indonesia is the second largest coal exporter to Japan, accounting for about 30 Mt annually. They produced over 400 Mt in 2015, over 99% of which is from open-cut mines. However, the conditions of surface mining are becoming worse year by year: the stripping ratio is increasing, the economy is worsening, and the infrastructure for coal transportation from inland mining areas is not being maintained. To meet the demand for coal in Indonesia and the rest of the world, underground mines have to be developed. In consideration of growing need, our research program is conducting a study on the potential for an underground coal mine in Indonesia. This research is being done through the roadway heading research program, which is looking into developing an underground coal mine from an open pit highwall. The greatest challenge for underground coal mine development in Indonesia is the maintaining the safety of the mine roadway during heading because the roof rock is exceptionally weaker. There is a potential for heading below mobile, unconsolidated soft sediment, and instead mining a deep area. This increases the likelihood for problems in the stability of the support system due to increasing ground pressure. The ground behavior around the roadway was measured using telltales, extensometers, and convergence measurements. Moreover, rock property tests were also conducted on exploration drilling cores. Based on the geological dates and monitoring data, a series of numerical analyses were conducted in order to assess support needs in the main roadway under different depths. Results of numerical analyses indicate that the current arch support design is effective when the mining depth is lower than 100m. However, if the mining depth is larger than 100m, the current arch support design should be changed to include the application of higher yield strength material, shorter spacing, etc. Moreover, bolting may also be useful if ground pressure is high locally. Based on a series of measurement data of ground and support behavior, a control criterion for main roadways under weak geological conditions is proposed in this paper."

Jan 1, 2017

By Dongfeng Yun, Zhu Liu, Wendong Cheng, Zhendong Fan, Dongfang Wang, Yuanhao Zhang

"For the purpose of studying the strata behavior due to multislicing top coal caving longwall mining along-the-strike direction in steeply dipping extra thick coal seams, the shield support pressures of the upper and lower slices of Panel 37220 in Dongxia coal mine were monitored using the KJ513 dynamic monitoring system. The set up rooms adopted the ""horizontal line-arc segmentinclined line"" form and used different types of shield supports. The results showed that the strata pressure of upper slice Panel 37220- 1 changed slightly along the strike direction, while along the dip direction it exhibited strong to weak pressure from bottom to top. The first weighting interval oflower slice Panel 37220-2 was about 60.Sm, and the average periodic weighting interval were about 22.6m. The strata behavior of Panel 37330-2 exhibited a spatiotemporal characteristic in that periodic weighting occurred first in the middle-upper part, followed by the middle and upper parts, arc segment, and finally the lower part. During the periodic weighting, the weighting interval and intensity also exhibited strong space characteristics. The average dynamic load coefficient was 1.48 and the maximum lateral pressure of the side shield was 900Kn1000kN.INTRODUCTIONThe steeply dipping coal seams account for about 20% of proven reserves and 10% of output in China (Wu, et al, 2014). About 50% of coal mines in the western China have steeply dipping seams, and are mainly distributed in Sichuan, Gansu, and Chongqing. When the steeply dipping seam employs longwall mining along the strike direction is employed, the waste rocks fill the gob nonhomogeneously along the dip direction, the deformation and caving of surrounding rocks exhibit obvious asymmetry and spatio-temporal characteristics with particular and complex strata behavior. In recent years, many research on strata behavior due to multi-slicing top coal caving longwall mining along-the-strike direction in steeply dipping extra thick coal seams have been performed with significant results (Shi, 1999; Wu, Xie, and Ren, 2010; Wu, Xie, Wang, and Ren, 2010). However, there has been a complete lack of research on monitoring the strata behavior due to multi-slicing top coal caving longwall mining in steeply dipping extra thick coal seam. Therefore, the strata behavior of multi-slicing panels 37220-1 and 37220-2 was systematically investigated in this research."

Jan 1, 2016

By Timothy J. Matthews, Timothy J. Batchler, Ted M. Klemetti

"From 2011–2016, there were 1,511 documented injuries, including 7 fatalities, from ground falls in underground coal mines in the United States. The majority of these ground-fall injuries were not caused by a major roof collapse, but from falls of smaller rocks from the immediate roof. Roof screen can significantly reduce the number of these injuries and has been widely used in underground coal mines for surface control. Because of the potential of reducing ground-fall injuries, the National Institute for Occupational Safety and Health (NIOSH) is further evaluating the performance characteristics of welded wire screen as used in underground coal mines by conducting a laboratory testing program using the Mine Roof Simulator (MRS) in Pittsburgh, PA.The load-displacement characteristics of an 8-ft x 12-ft panel of 8-gauge welded screen were evaluated using a newly designed, large laboratory screen test frame with multiple load pull locations. This screen was tested in a configuration that simulates current installation practices in U.S. coal mines. In this study, the effects of varying the number and position of the load pull location on the screen performance were evaluated. Ultimately, the type of information obtained in this and similar studies can be used to aid in developing wire roof screen design criteria and to assist mine operators in the selection and use of roof screen in underground mines.INTRODUCTIONThe large majority of ground-fall injuries are caused by falls of smaller rocks from the immediate roof. Various controls are currently being used in mines to control this surface rock, including the use of wire roof screen. In mines where wire roof screen has been installed, injuries from rock falls have been reduced dramatically (Robertson and Hinshaw, 2001). Roof screen has the potential to prevent hundreds of injuries caused by the fall of small rocks between permanent roof supports (Compton et al., 2007). Because of this potential for reducing ground-fall injuries, the National Institute for Occupational Safety and Health (NIOSH) is evaluating the performance characteristics of welded wire screen as used in underground coal mines by conducting a laboratory testing program in the Mine Roof Simulator (MRS) in Pittsburgh, PA."

Jan 1, 2018

By Bill A. Kyslinger

"In underground mining, machine design is predominantly dictated by mine conditions and individual customer desires. In partnership with Foresight Energy, J. H. Fletcher & Company was tasked to design and manufacture a new roof bolting machine with six independent drilling apparatus on board capable of drilling and bolting the roof and ribs with material handling. This is the first Fletcher® six-head machine to be designed and built for the mines in the United States. The machine is intended to work in the Illinois Coal Basin.The objective was to produce a machine capable of drilling and installing six bolts simultaneously with a limited number of operators. The goal of the mine is to decrease the time to bolt a cut to improve the safety level of the current roof bolting method, improve efficiency and to improve the bottom line cost of entry development. The customer wanted four mast feed drills at the front of the machine dedicated to installing roof bolts and then another two mast feed drills behind them dedicated to rib bolts. This dictated the requirement of latched controls, which would allow the operator to start drilling one hole and then latch the controls to be able to move on to the next. To accomplish this, we developed a unique hydraulic latch circuit to maintain operator safety and compliance. Guarding was added to prevent an operator from coming into accidental contact with a latched drill.The result of the design is a machine with a single platform and six independent masts with drillheads: four masts strictly for drilling and installing roof bolts on the front of the platform and two masts on the back of the platform for rib bolts. The feed and rotation controls at each operator's station include a latch control for drilling. The latch control will allow the operator to lock in the feed and rotation once the hole has been collared, allowing the operator to move on to the next hole. The rear of the machine is equipped with material handling. There are two material pods with winch controls as well as a mesh rack that includes mesh lift, mesh tilt, and mesh sump.The six-head roof bolter allows fewer operators to drill and install roof and rib bolts, which in tum lowers the miners' roof exposure per cut. This design reduces the operator's exposure from the inherent pinch points and rotary hazards once he has engaged the latch drilling. Therefore, the machine will help to decrease the time to bolt a cut, improving productivity while enhancing the ability to operate the machine safely."

Jan 1, 2016

By Pengfei Wang, Guorui Feng

With increase of cover depth, dynamic incidents, such as large gateroad convergences and coal bursts, are frequently encountered when mining deep longwall panels. It would be more adverse due to large inclination of the coal bed. Because of the shearer and armored face conveyor (AFC) sliding downhill, toppling of shields, disconnection of AFC to the stage loader are related to it. Tangshan coal mine is a typical deep, inclined coal mine situated in the east of China. The split-level longwall panel layout is being adopted for mitigating problems above, where tailgate entries of longwall panels are driven below gob edge and along the floor, while headgate entries are driven along the roof. Wire mesh and steel sets have been used empirically for support for tailgates for about a decade, which reduces the tunneling speed. In view of this fact, the paper serves to investigate the proper adjustment of the tailgate locations and to analyze the resulting stress and yield conditions according to support strategy. First, field measurements and observations were carried out. Stress data distributed within surrounding rock mass were obtained, especially within the roof since the roof consists of only a coal sheet with a thickness of 2–4 m. Roof pressure of the tailgate represents the pressure at the gob edge since it is below the gob edge. The convergence data were also collected. Numerical modelling using FLAC3D™ was conducted and validated by side abutment stress data. The double-yield constitutive model was used to simulate the gob. The finalized tailgate layout and design were determined through comparison of three scenarios. The research in this paper can help engineers choose the proper tailgate layout and support strategies for coal mines that are going to adopt a split-level longwall panel layout for mining deep, inclined longwall panels.

Jan 1, 2018

By Andrew Lewis, Amarit Nitaramorn, Alexander Garcia, Peter Altounyan

"Indonesia is a major coal producer, the vast majority being sourced from opencast operations. Underground production to date has been constrained by unfavorable ground conditions and limited local experience. However, an underground trial in East Kalimantan has now shown that it is possible to successfully extract coal and mine safely, despite the technical challenges.A trial drift mine has been worked to a current maximum depth of 160 m (525 ft) in a dipping coal seam. The 3 m (10 ft) thick coal seam is overlain by very weak mudstone and sandstones. The mudstone forming the immediate seam roof strata proved a particular challenge given its adverse reaction to water and overall friability.Rock bolts were used as roadway support, the system being carefully selected to optimize effectiveness. An innovative method of partial extraction was trialed, which demonstrated the potential for productive mining despite the ground conditions. Roof falls have occurred within the working area, and roadways demonstrate reasonable stability over time.Throughout the course of the trial, strata behavior monitoring has been an important aspect, and a comprehensive ground control monitoring system is in place. This has enhanced the ability to increase the level of support where required and to react to deteriorating conditions. In addition, monitoring information has allowed a quantitative assessment to be made of the technical feasibility of future full-scale mining.INTRODUCTIONWith current production at over 200 million tons, much of this destined for overseas markets, Indonesia is the second largest exporter of coal (Ritschel and Schiffer, 2007). The majority of the coal is sourced from the Kalimantan coalfields. Mining is predominately opencast, yet in recent years there have been attempts made to introduce underground operations. This move would permit continued access to good quality seams that are beyond the reach of viable opencast mining."

Jan 1, 2010

By Rajendra Singh

Considering the importance of a fully mechanized depillaring operation, the Indian coal mining industry has introduced a number of such depillaring operations at depths of cover ranging from 60 m to 377 m. The overlying strata of these depillaring faces vary widely from highly laminated, weak and easily caveable to massive, strong and difficult to cave. Most of these mechanized depillaring operations were carried out in difficult site conditions, however, performance monitoring in the field has showed good production, productivity and safety results. Field studies have shown that the use of roof bolts as breaker line support for this technology worked well for moderate strength overlying roof strata, but experienced difficulties for both extremely weak and strong/massive overlying roof strata. It is observed that the performance of a breaker line support along the goaf edge deteriorated with an increase in depth of cover of the depillaring face. Practice of a straight line of extraction (single row of pillars) during the mechanized depillaring below competent roof strata experienced a considerably large hanging area inside the goaf, which needs to be managed either by induced caving of the roof strata or through an increase in width of the excavation. Observations of good performance of a fully mechanized depillaring face under highly laminated and weak strata at a shallow cover is mainly due to a faster rate of extraction. However, the mechanized depillaring underneath laminated and weak roof strata for a deep-seated coal seam was forced to go for partial extraction mainly due to strata control problems. Discussing the implications of main technical and operational differences between the conventional (semi-mechanized) and fully mechanized depillaring, this paper presents results of different strata control studies conducted at different mechanized depillaring sites with varying geo-mining conditions.

Jan 1, 2014

By Ali Naeimipour

Availability of accurate geological information about the rock mass surrounding a tunnel or mine working is the key to enhance and optimize the required ground support measures. Various approaches have been used to obtain data on ground conditions, including the possibility of characterizing the ground while drilling for roof bolts, by the Measurement While Drilling (MWD) system, via optical, sonic and acoustic televiewers, and using various types of gamma probes. While there are many different systems for characterizing the ground in longer, larger-diameter holes drilled downward, the options for using probes and logging systems in short, small-diameter holes drilled in horizontal or an upward direction are very limited. This paper will present the results of recent field tests using optical televiewer (OPTV) to analyze the joints and voids in boreholes drilled in different directions. The studies show that OPTV is a promising tool; however, getting a good quality image from the upward drill holes still need to be studied. Meanwhile, estimated in-situ strength of the intact rock is needed to complement the jointing pattern for rock mass classification. For this purpose, preliminary steps for the development of a borehole scratcher to estimate rock strength will be discussed in this paper.

Jan 1, 2014

By Bo-Hyun Kim, Steve Berry, Mark K. Larson

"When coal pillar bursts occur, they involve the sudden expulsion of coal and rock into the mine opening. These events occur when relatively high stresses in a coal pillar, which serve as support in underground workings, exceed the critical capability of the pillar. This causes the pillar to rupture without warning. A cleating is a type of naturally occurring joint system unique to coal seams. However, cleatings are pervasive throughout the coal seam and are much more tightly spaced than joints occurring in other rock types. In this study, researchers from the National Institute for Occupational Safety and Health (NIOSH) investigated 84 coal samples obtained from a Utah coal mine by conducting both unconfined and triaxial compressive tests in order to examine the response to stress as a function of both confinement and orientation between cleat and loading direction. The results of the study show that the confining pressure dictated not only the peak compressive strength but also the brittleness as a function of the major-to-minor principal stress ratio. The spalling limit of the coal estimated by the s-shaped brittle failure criterion appears to be very dependent on the angle between the cleat and the loading direction, particularly at lower confinement.INTRODUCTIONCoal pillar bursts, or bumps, remain a most critical safety concern in underground coal mining, despite significant advancements in engineering controls. As shown in Figure 1, between 1983 and 2014, there were nearly 400 cases of reportable dynamic failure accidents in coal and nonmetal mines, resulting in 20 fatalities, 155 lost-time accidents, and an estimated 48,000 lost man hours (MSHA, 2015). These types of events have been documented for well over 100 years within the American underground coal mining industry. During this time, mining practices and support technologies have evolved considerably, resulting in an overall decrease in the rate of dynamic failure-related injuries and fatalities. Although techniques and practices of mining are highly advanced, coal pillar bursts, or bumps, continue to occur (Mark and Gauna, 2015). If coal is expected to fail in a brittle manner, behavior changes associated with relatively low tensile strength, such as the transition from tensile to shear failure, have to be considered and reflected in the adopted failure criteria. Rock failure in tension takes place at low confinement around excavations due to tensile failure in heterogeneous rocks (Diederichs, 2007). The prospect of tensile-dominant brittle failure diminishes as the confinement increases away from the excavation boundary. Therefore, it is expected that the transition from tensile to shear mode in the failure mechanism occurs as the confinement level changes and conditions for tensile failure are prevented or strongly diminished. In addition, many uncertainties remain because of the highly anisotropic characteristics of coal seams associated with geologic structure and the mining-induced spatial redistribution of stress in coal pillars. Thus, to prevent fatalities in underground coal mining, continuous effort is required to better understand the catastrophic failure mechanisms in coal mines."

Jan 1, 2018

By Paul C. Hagan, Jianhang Chen, Serkan Saydam

"Modified cable bolts are commonly used in underground mines due to their superior performance in preventing bed separation when compared with plain strands. To better test the axial performance of a wide range of cable bolts, a new Laboratory Short Encapsulation Pull Test (LSEPT) facility was developed. The facility simulates the interaction between cable bolts and surrounding rock mass, using artificial rock cylinders with a diameter of 300 mm in which the cable bolt is grouted. Furthermore, the joint where the load is applied is left unconstrained to allow shear slippage at the cable/grout or grout/ rock interface. Based on this apparatus, a series of pull tests were undertaken using the MW9 modified bulb cable bolt. Various parameters including embedment length, test material strength and borehole size were evaluated. It was found that within a limited range of 360 mm, there is a linear relationship between the maximum bearing capacity of the cable bolt and embedment length. Beyond 360 mm, the peak capacity continues to rise but with a much lower slope. When the MW9 cable bolt was grouted in a weak test material, failure always took place along the grout/ rock interface. Interestingly, increasing the borehole diameter from 42 mm to 52 mm in weak test material altered the failure mode from grout/rock interface to cable/grout interface and improved the performance in terms of both peak and residual capacity.INTRODUCTIONFully grouted cable bolts have been used in underground mining industry for many decades. Initially, plain cable bolts manufactured by winding seven flexible steel wires together were commonly used (Thorne and Muller, 1964). Laboratory and field tests lead to a better understanding of the transfer process between grouted cable bolts and the surrounding rock mass, which is beneficial to improve the reinforcing performance of cable bolts in engineering practice (Fuller and Cox, 1975; Cox and Fuller, 1977; Schmuck, 1979; Stillborg, 1984). Nevertheless, as in many cases the initial cable was sourced from discarded steel with a smooth surface along the strand, plain cable bolts did not always meet performance expectations (Windsor, 1992). Over time, it was realised that cable surface geometry plays an important role in determining anchorage performance. Consequently, modified forms of cable bolts were developed. For instance, twin-strands which were made by using spacers to combine two plain cables together improved anchorage capacity two-fold (Matthews, Tillmann and Worotnicki, 1983). However, this required a large borehole to be drilled. Epoxycoated strands had remarkable performance in practice but were difficult to install without damaging the epoxy layer (Dorsten, Hunt and Kent, 1984). In the 1990s, there was a rapid development in the cable bolt design. A typical example was birdcaged cable bolts. They were initially suggested by Hutchins et al. (1990) via unwrapping traditional seven-wire strands and generating a number of nodes together with antinodes along the strand. But it was difficult to make birdcaged cable bolts that could be coiled for transporting."

Jan 1, 2015

By Kevin J. Ma, John Stankus, Dakota Faulkner

"Expandable rock bolts are widely used in hard rock mines as an efficient ground control product. However, capacity and service life can be significantly reduced if the metallic body is subjected to corrosion. In some hard rock mines in the U.S., highly corrosive ground conditions exist, and it has been reported that inflatable rock bolts have corroded within a few months after installation. To provide mining industry a cost-effective inflatable bolt and combat the corrosion issues, Jennmar Corporation, Inc., and its subsidiary Keystone Mining Services, LLC (KMS), analyzed corroded bolt samples, identified root causes, evaluated properties of various coating materials, and developed a new inflatable rock bolt, Python M3TM, that is protected with an innovative PyFlexU2TM coating. The new generation Python M3 features improved steel chemistry for reliable performance, modified profile for better inflation, and surface preparation and coating application. The PyFlexU2 is impervious to liquid and air, durable, and UV resistant. With a flexible adhesive, and highly corrosion-resistant undercoating, and a very hard sacrificial surface coating, the PyFlexU2 coating system provides the Python M3 superior protection against chemical corrosion and physical scratch damage. The under-coating has exceptional flexibility and adhesion to prevent coating micro-cracks or fractures after bolt inflation and possesses excellent corrosion resistance to acids (pH <3), alkalis (pH >11), fuels, and salt solvents. The corrosion and scratch resistant PyFlexU2 coating offers very effective bolt protection for extra longevity in highly corrosive environments. The Python M3 coated with PyFlexU2 has been tested in the most challenging conditions, including laboratory corrosion tests in extreme acidic and basic solvents, rock slurry, and borehole scratch insertion tests. With demonstrated corrosion and scratch resistance, the product has been greatly welcomed by hard rock mines in the West and is currently installed in large scale. This paper identifies the root causes of the bolt corrosion, discusses the analysis process, and details laboratory and underground tests carried out on the Python M3 coated with PyFlexU2. The Python M3TM and PyFlexU2TM are subjects covered by pending U.S. Patent Applications assigned to FCI Holdings Delaware, LLC."

Jan 1, 2017

By Adam Mackenzie, Dan Payne, Yass-Marie Rutty

"Historically, the Crinum mine has experienced significant falls of ground when longwall production slowed to prepare for recovery in weak roof areas. These conditions continue through the recovery process and result in both safety concerns and delays. When mine plans and exploration revealed that most of the mine's future longwall recoveries were located in weak roof areas, a decision was made to try pre-driven recovery roads as a solution to the problem. After completing eight pre-driven recovery roads with varying degrees of success and numerous lessons, the Crinum North mine now utilizes a modified Pre-driven Recovery Roadway (PDRR) to improve the longwall take-off process in weak roof areas. During mine development, a standard roadway is driven where the final recovery location of each longwall is planned. After the installation of secondary support, the PDRR is backfilled with a cement-flyash mix to provide support to the roof, and confinement to the ribs and floor of the roadway. The method has been refined over the last four years to provide greater strata stability and improved operational and safety performance compared with conventional take-offs at Crinum, and has resulted in a site record of longwall relocation in 11.5 days (pull mesh to picks in coal). This paper describes the evolution of the PDRRs from Crinum East to Crinum North, including lessons from initial attempts and changes to the secondary support regime, the operational approach during the final stages of retreat, the backfill strategy and plans for the future.INTRODUCTIONThe Crinum mine is the underground component of BHP Billiton Mitsubishi Alliance's (BMA) Gregory Crinum mine, located northeast of Emerald, Queensland (Figure 1).The Crinum mine has a history of roof control problems coming into and during longwall recoveries. Weak roof, combined with the slow mining, which is a consequence of preparing for equipment recovery, pulling mesh (which also creates tip-to-face issues), and the lengthy bolt-up process, often results in loss of immediate roof and subsequent roof falls. In fact, approximately 50% of the first 13 longwall recoveries (which were at depths of 180 to 200m) experienced roof fall delays, the longest of which took four months to mine the last pillar and recover the longwall. This recurring problem prompted the mine to investigate options to reduce or eliminate the problem."

Jan 1, 2016

By Ross W. Seedsman

The logical framework recognises that a coal mine roof can be intrinsically stable or may collapse in one of four ways. Suspension of the immediate roof is one of fundamental ground control strategies available to a coal mine engineer and is recommended for three of the four collapse modes. Correctly implemented suspension offers the greatest improvement in roof stability and greatest reduction in longwall risk. For the control of maingates ahead of retreating longwall faces the ideal suspension support (if required) consists of angled, partially debonded, medium-length tendons installed as far behind the development face as practical. For situations where the roof may be subjected to tensile horizontal stress, immediate support by equally spaced short vertical tendons is required. The step away from fully-grouted tendons improves their survivability during the onset of compressive failure in the roof, minimises the risk of isolated loading, and allows a more robust TARP for roof movement. All suspension systems require a strap, sling or truss between the suspension elements.

Jan 1, 2014

By Yvette Heritage

"The risk of fatalities from rib failure is still prevalent in the coal mining industry. This risk has prompted further research to be conducted on rib deformation in order to understand the mechanisms of rib failure, with the long-term objective being to improve rib support design. This paper presents the results of ACARP research project C25057, which investigated the mechanics and drivers of rib failure. The results of rib deformation monitoring at three different mines in Australia provides rib deformation characteristics for overburden depths ranging from 160 m to 530 m. Monitoring includes deformation during development drivage conditions and during the longwall retreat abutment stress environment. The rib deformation monitoring covered three different seams: the Goonyella Middle Seam, Ulan Seam, and Bulli Seam in the Bowen Basin, Western Coalfield, and Southern Coalfield, respectively. The observed mechanisms driving the rib deformation ranged from bedding shear failure along weak claystone bands to vertical shear fractures to kinematic failures driven by shear failure dilation. The variation in mechanisms of rib failure, together with the seemingly consistent method of rib support design, prompts the question: What exactly is the role of rib support?INTRODUCTIONThe current risk of rib fatalities in the coal mining industry has prompted further research into understanding the mechanisms of rib failure. Three Australian mines assisted further research by providing sites for rib deformation studies as part of the Australian Coal Association Research Program (ACARP) project C25057. The mines included in this study were Moranbah North Mine, Ulan West Mine, and Appin Mine. This paper provides key results of the rib deformation monitoring relevant to assessing the mechanisms of rib deformation.The approach of monitoring rib deformation and rib support loads was used to measure and characterise the dynamic rib deformation present in both development and longwall retreat stress environments. The characterisation of rib deformation, together with rock failure modelling, was used to determine the mechanisms for failure within the rib and to assess the interaction of rib support with the failure process. The mechanisms of rock failure are considered an important factor in understanding the drivers for the failure. Consideration of the site-specific failure mechanisms can provide for a more tailored support design."

Jan 1, 2018

By Winton Gale

"The aim of this paper is to summarise the results and conclusions of Australian Coal Association Research Project (ACARP) Report Cl3013 which relate to water inflows into a mine which occur through the overburden above and adjacent to longwall panels. The study assessed available data of inflows into underground coal mines and utilised computer simulation of water flow through fracture networks. The study concluded that flow into mines is typically via an interconnected network of pre-existing and mining induced fractures. The height above the coal seam that mining induced fractures extend is typically related to the width of the panel. However the potential for those fractures to form a connected network which can facilitate flow, is related to the amount of subsidence and the depth of mining. The study compares model simulations with measured data and provides guidelines to estimate the average hydraulic conductivity of the overburden above extracted longwall panels in Australia.INTRODUCTIONWater inflow into coal mines has been a design issue for many years. Guidelines as to the potential for water inflow have been developed in many countries based on local experience and the form of mining being undertaken. In most instances, the guidelines relate to inflows which would endanger underground personnel and operations.In more recent times, water inflow criteria for mines has been widened to include lesser inflows which may not impact on mine safety or operations, but have the potential to reduce water flow within streams and surface aquifers. For the purpose of this paper the larger inflows which are readily measured in a mine or may impact on mining safety are defined as mine inflow and the lesser inflow relating to aquifer water loss as environmental inflow.The water losses referred to are those which enter the mine from the surface or from near surface aquifers.The empirical relationships developed as mine design guidelines or regulations typically relate to high flow (mine inflow) situations and in this paper, these have been reviewed as to their application to environmental inflow. In many cases environmental inflows were unlikely to have been noted or recorded in many mining operations in the past."

Jan 1, 2010

By Stephen C. Tadolini, Minova USA Inc., Peter S. Mills, David R. Burkhard

"Fiber-reinforced spayed concrete has been used for several years in civil and tunneling operations. Research conducted to reduce cure times and increase compressive and flexural strengths resulted in the development of Tekcrete Fast®, a cementitious product capable of obtaining 41 MPa (6,000 psi) compressive strength and 8 MPa (1,200 psi) flexural strength in only 3 hours and reaching 7 day strengths of 62 MPa and 11.7 MPa (9,000 and 1,700 psi), respectively. A single bag product that uses conventional shotcrete and gunite application systems make it a natural crossover product for mining applications. The discovery of incredible adhesion properties and high resistance to chloride permeability helps ensure long-term stability and increases the ease of application. Project results from Disaster City® in Texas and the application for rehabilitating a coal mine belt entry are presented. The case study illustrates the effectiveness of the product in stabilizing a coal mine beltway and adjacent cross-cuts that were subjected to progressive sloughage due to humidity and cyclical loading. INTRODUCTION Original research produced a shotcrete formulation that extends beyond stabilization and can be used to restore the structural integrity of damaged infrastructure. The primary challenge was to develop a shotcrete or gunite that had structural strength within a few minutes to prevent parasitic loading, allowing ingress into damaged structures minutes after applying the mix formulation. This also applies to mining conditions where rapid support of progressive failures can minimize failure. An additional benefit was discovering that the product had extremely high adhesion properties in addition to high flexural strengths. The approach to product design was the development of “single bag” dry mixes that are entirely self-contained, can be rapidly transported anywhere in the field or underground, and can be deployed using simple equipment. Dry mix eliminates issues relevant to high shear water mixing because water is added in the form of a mist at the point of delivery; thus a low water-to-cement ratio can be achieved. However, since there is no onsite powder mixing, the product must have a high degree of inherent homogeneity. Minova offers a commercial version of this material, Tekcrete Fast®, a product that has been successfully deployed in the mining industry and is currently being used in civil, construction, and tunneling operations. The material can rapidly stabilize lose ground in metal, nonmetal, and coal mines. This paper described the technology development, product testing results, and applications and describes a case study to stabilize a coal mine beltway."

Jan 1, 2017

By Hongwei Wang, Hao Zhang, Panshi Xie, Xicai Gao, Youfu Zeng, Yongping Wu, Juan Dou

"The reserves and production of steep coal seams account for approximately 15–20% of the total coal reserves in China and 5–10% of the total annual coal production. More than 50% of the coal is high-quality coking coal and anthracite, based on reviews of steeply dipping seam mining at home and abroad. Fully mechanized mining is considered to be the only safe and efficient way to mine steeply dipping seams. To achieve fully mechanized longwall mining, four issues must be addressed: ground control, equipment stability control, development of complete sets of equipment, and safety. Engineers must focus on many factors of steeply dipping seams, such as the following: stope, roof asymmetrical structure, stability control, “roof-support-floor” system dynamics control, multi-region big-range ground control technology, adjustment false-inclined method, nonlinear layout method, control technology, safety, and development of complete sets of equipment. Engineering practices in China introduce these concepts systematically: fully mechanized mining of medium-thickness seams, fully mechanized high mining of thick seams, fully mechanized caving of extremely thick coal seams, fully mechanized mining of coal seams, roadway support, and so on. A steeply dipping seam is one with a dipping angle in the range of 35°–55°. This accounts for about 15%–20% of the total coal reserves in China. Because of the environment, more than 50% of the coal is high-quality coking coal and anthracite. Mining steeply dipping coal seams is known to be difficult in the mining industry. After the study conducted by Germany, Poland, and the former Soviet Union in the1970s–1980s, the fully mechanized mining basic theory, core technology, and key equipment research have not been a breakthrough. Being fully mechanized is a technological “restricted area” at home and abroad. A lot of steeply dipping seams are excavated by non-mechanized mining, leading to harsh job environments, labor-intensive work, low productivity, frequent accidents, and significant security hazards. The death rate per million tons of coal reaches above 4.0 and is far higher than slow inclined coal seam mining. Making steeply dipping seam mining safe and efficient is a global problem that urgently needs to be solved. Fully mechanized mining is the only way to overcome these problems (Wu, 2003; Wu, Yun, and Zhou, 2000). The realization of fully mechanized coal seam mining must solve four problems. (1) Examine the disaster mechanisms induced by overburden “key strata” mutation under steeply dipping seams as a basis for ground control methods and technical problems. (2) Work to solve the dynamic stability control technical problems of thousands of tons of complete sets of equipment under the steeply dipping seams. (3) Complete sets of equipment must be developed to adapt to the conditions of steeply dipping seams. (4) Overcome the steeply dipping face safety protection technical problems. In the last two decades, a number of universities, research institutes, and enterprises have realized the importance of safety and efficiency of steeply dipping seams in China. This is especially true of Professor Wu Yongping’s “hard coal layer safe and efficient mining” team at Xi’an University of Science and Technology. After several generations’ research and technical work, the team puts forward China’s longwall mechanized coal mining of steeply dipping seams strata control basic theory. This paper puts forth a series of key technologies of fully mechanized mining, develops and manufactures complete sets of equipment by independent innovation, and establishes a perfect face security system, forming a theory and technology system for fully mechanized longwall mining of steeply dipping seams."

Jan 1, 2017