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By Joseph A. Cybulski

In response to the mining of reserves with increasingly adverse round conditions and the roof support recommendations of current rock mechanics theories, roof support systems have continued to improve. A few of these newer bolting systems. while giving improved performance, require a new method to check bolt installation. Previous1 , a torque wrench had been the sole means to check the installed torque of a roof bolt. However, due to the characteristics of soma of the newer bolting systems which can prevent a reliable manual torque check and a recent change in the federal roof control regulations, an alternative method to a manual torque check is gaining acceptance. This alternative method improves monitoring the hydraulic pressure of the roof bolting machine torque circuit and provides a safe, reliable and quick wav to check bolt installation in those instance when an accurate manual torque check cannot be made.

Jan 1, 1990

By Mark K. Larson, Douglas R. Tesarik, Heather E. Lawson

"Load transfer distance (LTD) is simple in concept and usually evident in underground coal mines. Many people in the mining industry recognize LTD as the distance from the panel to where the mine ribs and pillars show evidence of renewed spalling, floor heave, or other effects of increased weight due to longwall mining or pillaring. Barrier pillars, in particular, are designed to shield mains and other relatively permanent facilities from this loading. LTD is also important in determining the extent and degree to which mining increases the load on pillars and ribs in the gate roads. Generally, a long LTD reduces loads in gate roads, but may require larger barrier pillar widths to protect mains or adjacent panels from excessive loads. Therefore, a long LTD may make it easy or difficult to meet various objectives of mine layout design . LTD reflects overburden geology in two ways: First, overburden that is weak and readily caves will limit both the amount and distance of load transfer. Second, stronger, stiffer, sandier, and more massive overburden increases both the amount and distance of load transfer. As such, LTD is central to coal mine layout design and calibration of numerical models that seek to anticipate these transfers of load during mining. However, the term does not have a consistent definition in the literature, and various instruments and observational techniques with varying sensitivities and thresholds have been used to indicate the onset of mining-induced stress increase and, subsequently, to determine an LTD. Consistency is important for meaningful comparison of ground response between mining sites and for accurate calibration of models.This paper adds to the body of observed and reported LTDs by presenting cases with relatively sandy and massive overburden at two western coal mines. These two cases include observation and measurement of LTD with multiple methods and provide insight into how distances reported relative to different criteria and instrumentation could be adjusted for comparison against a common base. This base is the criteria used by Peng and Chiang (1984) to determine their empirical equation. In one of these two cases, LTD was recently measured at a western U.S. coal mine (Mine A) to be approximately four times that calculated using the Peng and Chiang empirical equation. LTD measurements were examined using various instruments at Mine A and at adjacent Mine B. The measurements at Mine B showed that LTD was significantly greater than that calculated by the Peng and Chiang equation. Difficulties with BPC installation and fittings at Mine B permitted only ranges of LTD to be determined from some BPCs. Even so, the LTDs and ranges of LTDs determined were consistent with the LTDs determined at Mine A."

Jan 1, 2015

By Thierry Lavoie, Mark K. Larson

"Engineers at the National Institute for Occupational Safety and Health (NIOSH) and Itasca Consulting Group, Inc., conducted a study to determine the procedure for calibrating a caving model implemented in FLAC3D. The model is calibrated to measured surface subsidence. This sedimentary caving model was developed by Itasca for NIOSH for the purpose of more closely simulating mechanical processes during caving. When a model is considered calibrated to surface subsidence, the load between the extracted panel's roof and floor is a reasonable estimate of gob loading. Such information can also provide an estimate of the amount of overpanel weight that is transferred to the abutment. This load distribution is a parameter needed, for example, to estimate loading of pillars in longwall gate roads. For the current case, a calibrated model resulted in a calculated abutment angle of 30.6°considerably higher than the assumed value used in empirical methods, but reasonable considering the presence of massive stratigraphic members in the overburden. Because of additional information available after this study that the extracted seam height was actually greater in the first panel, a corrected range of abutment angle was estimated to be from 27.7° to 30.6°, still significantly higher than the empirical assumption. The expectation is that better estimates of abutment loading profiles will result in improved evaluations of mine layout design and, therefore, reduce the number of fatalities and injuries resulting from falls of ground.INTRODUCTIONThe safety of miners in underground coal mines depends on careful consideration of the mechanisms involved in failure and transfer of load. The successful design of pillars and panels in longwall and room-and-pillar coal mining requires thorough attention to any information and measurements available that help understand these mechanisms. Although empirical methods, such as Analysis of Pillar Stability (ALPS) Mark (1987); (Mark, 1992) or Analysis of Retreat Mining Pillar Stability (ARMPS) (Mark and Chase, 1997), can provide a sense of success or failure, complex geology and failure in the roof or floor material or complex material behavior of the coal can make evaluation by an appropriate numerical modeling tool necessary. The numerical tool must simulate important mechanisms and appropriate detail that underlie the mechanism. For example, Starfield and Cundall (1988) advised using ""the simplest model that will allow the important mechanisms to occur, and could serve as a laboratory for the experiments you have in mind."" To that end, data gathering about the geology, geometry, and material behavior is very valuable. Such data facilitate selection of an appropriate model and model inputs. Moreover, this data facilitate improved assessment of risk to miners and how to minimize that risk."

Jan 1, 2016

By Peter Zhang, Daniel Su, Essie Esterhuizen, Mark Van Dyke, Berk Tulu, Dave Gearhart

"Roof falls in longwall headgate can occur when weak roof and high horizontal stress are present. To prevent roof falls in the headgate under high horizontal stress, it is important to understand the ground response to high horizontal stress in the longwall headgate and the requirements for supplemental roof support. In this study, a longwall headgate under high horizontal stress was instrumented to monitor stress change in the pillars, deformations in the roof, and load in the cable bolts. The conditions in the headgate were monitored for about six months as the longwall face passed by the instrumented site. The roof behavior in the headgate near the face was carefully observed during longwall retreat. Numerical modeling was performed to correlate the modeling results with underground observation and instrumentation data and to quantify the effect of high horizontal stress on roof stability in the longwall headgate. This paper discusses roof support requirements in the longwall headgate under high horizontal stress in regard to the pattern of supplemental cable bolts and the critical locations where additional supplemental support is necessary.INTRODUCTIONLongwall mining is the primary underground coal mining method in the United States and currently accounts for more than 60% of the underground coal production. The longwall headgate, as a passageway for the longwall crew, intake air, material supplies, and coal belt transportation, is critical for both safety and continuous production of the longwall panel. A roof fall in the longwall headgate would not only result in substantial interruption of production but could potentially cause injuries or fatalities. Rehabilitation of failed roof in the headgate would also expose miners to the risk of injuries. Roof falls in the headgate, though infrequent, mostly occur in the belt entry near the face. Considerable research has been conducted to determine the effects of various factors on headgate roof stability, as well as effective measures to support the roof in longwall mines in the Pittsburgh seam (Mark, Mucho, and Dolinar, 1998; Chen et al., 1998; Su and Hasenfus, 1995; Su, Thomas, and Hasenfus, 1999; Su, Morris, and McCaffrey, 2002; Su, Draskovich, and Thomas, 2003; Hasenfus and Su, 2006; Van Dyke et al., 2015). Previous studies have demonstrated that high horizontal stress and transitional roof geology are primary factors that cause headgate roof failure. These studies also showed that panel orientation, retreat direction, pillar sizes, and roof support played an important role in the stability of a headgate.In underground coal mines located in the eastern United States, the magnitude of the maximum horizontal stress is typically three times greater than the vertical stress, and about 40% greater than the minimum horizontal stress. Mark, Mucho, and Dolinar (1998) studied seven cases of headgate failures caused by high horizontal stress in different coal seams in the United States and stated that roof stability is affected, to a large extent, by rock type, entry orientation, and longwall orientation. The effects of horizontal stress can be summarized in these statements: (1) A laminated roof is very vulnerable to high horizontal stress. (2) Entries that are aligned with the maximum horizontal stress will suffer less damage on development than those perpendicular to it. (3) Horizontal stress concentration and relief depends on panel orientation, the direction of retreat, and the sequence of longwall panel extraction."

Jan 1, 2018

By Tom Blevins, Roland Walker, Jinsheng Chen

"The Dywidag-Systems International DSI Tandem Anchor bolt, with an improved expansion shell-washer design, can substantially reduce potential entry roof falls caused by twisted or deformed expansion shells of the traditional mechanical anchor bolts during installation. In addition, the improved anchorage system can also ensure that a consistent and high installed load is achieved, which is critical for effective beam building under thinly laminated or layered roof conditions. This paper discusses the genesis and anchorage performance of the Tandem Anchor bolt, and analyzes the tension/torque relationship of different mechanical shell anchors using data obtained from both lab and field tests. It also discusses roof bolting mechanisms, roof bolting systems, and factors influencing effective beam building. Finally, numerical modeling was used to analyze the effect of bolt pretension magnitude on entry roof stability.INTRODUCTIONThroughout the history of underground mining, keeping the roof from uncontrollable collapse has been the greatest concern of the miner. Tremendous strides have been made in better understanding, predicting, and supporting the mine roof. This conference has spent the last twenty-eight years sharing information and distributing it to the mining community. A paraphrased statement from former Secretary of Defense Donald Rumsfeld adequately describes the challenges to the mining engineer as it pertains to roof control: it is a study of known knowns, known unknowns, and unknown unknowns. It is the hope of the authors to address some of these unknowns.The paper discusses the development of bolt anchorage systems from dry shells to shells with resin-assisted anchorage. It looks at some of the issues faced with the anchorage shells being used when introducing the insertion pressures caused by resin cartridges. The rationale behind the shell design changes was to compensate for this resin induced stresses.An improved expansion shell assembly (a slotted expansion shell base, a tapered cramming plug, and a novel support nut with tapered top) for mine roof bolts makes up the Tandem Anchor (U.S. Pat. No. 6742966); this minimizes the possibility of twisting seen with traditional mechanical shells and thus prevents springy bolts and shell leaves from breaking. A fully grouted Tandem Anchor bolting system has the advantages of both the pure mechanical point-anchor and the non-pretention fully grouted bolting systems. Once installed, the installed load or pretension will be locked in and never bleed off. Compared with the fully-grouted (2-speed resin) tension rebar bolting system, the fully-grouted Tandem Anchor bolting system can (a) reduce bolting cycle time (about 15 seconds per bolt), boosting coal production and productivity; (b) provide a greater installed load or pretention; and (c) achieve a consistent tension/torque ratio, which gives better bolting quality control. Therefore, a fully grouted Tandem Anchor bolting system is the most effective means to reinforce a weak rock mass intrinsically by the theory of beam building. For thinly laminated or layered roof conditions, a higher installed load or pretention (50% or more of the bolt's yield strength) can make a roof bolting system much stiffer, which results in less roof movement. Numerical modeling results show that the magnitude of the roof's tensile stress and relaxation zone can be substantially reduced under a higher installed load or pretention."

Jan 1, 2010

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 Rob G. Jeffrey, Ken W. Mills, Jesse W. Puller

"A coal mine in New South Wales is longwall mining 300m wide panels at a depth of 160-180m directly below a 16-20 m thick conglomerate strata. As part of a strategy to use hydraulic fracturing to manage potential windblast and periodic caving hazards associated with this conglomerate strata, the in situ stresses in the conglomerate were measured using ANZI strain cells and the overcoring method of stress relief. Changes in stress associated with abutment loading and placement of hydraulic fractures were also measured using ANZI strain cells installed from the surface and from underground. This paper presents the results of in situ stress measurements and stress change monitoring undertaken as part of the hydraulic fracturing program.Overcore stress measurements have indicated the vertical stress is the lowest principal stress so that hydraulic fractures placed ahead of mining form horizontally and so provide effective pre-conditioning to promote caving of the conglomerate strata. Monitoring of the full-scale hydraulic fractures has confirmed the hydraulic fractures grow horizontally.Stress changes monitored during hydraulic fracturing formed part of a broader program to investigate fracture geometry and growth rates to confirm the characteristics of the hydraulic fractures placed. This monitoring showed that vertical stress in the conglomerate strata was being increased by up to 1 MPa in close proximity to the hydraulic fracture and had the effect of tending to promote asymmetrical growth of subsequent fractures about the injection borehole.Monitoring of stress changes in the overburden strata during longwall retreat was undertaken at two different locations at the mine. The monitoring indicated stress changes were evident 150 m ahead of the longwall face and abutment loading reached a maximum increase of about 7.5 MPa. The stresses ahead of mining change gradually with distance to the approaching longwall and in a direction consistent with the horizontal in situ stresses. There was no evidence in the stress change monitoring results to indicate significant cyclical forward abutment loading ahead of the face consistent with the observations of face conditions underground adjacent to both measurement locations. The forward abutment load determined from the stress change monitoring is consistent with the weight of overburden strata overhanging the goaf indicated by subsidence monitoring."

Jan 1, 2015

By Khamis Y. Haramy

The U.S. Bureau of Mines installed surface and subsurface instruments at a mine site in Colorado to monitor and characterize the overburden response to longwall mining. Instrumentation included a time-domain reflectometry (TDR) cable, a multiple-point borehole extensometer (MPBX), vertical-deformation surface monuments, and in-mine pressure cells for monitoring abutment, pillar, and gob loads with respect to the longwall face position. The purpose of the study was to collect data that could be analyzed to correlate the design of the mine layout to the resulting overburden failure response. Determining the extent of caving and fracturing is important in the arid and semiarid Western United States because of the possible consequences to the fragile underground hydrologic systems upon which the land owners and users depend. This study is unique from past investigations because the overburden contains massive sandstone members that impose special conditions on the caving process and pressure redistribution above the longwall panels. This paper presents the results of this correlation study.

Jan 1, 1992

By Brent A. Slaker, Khaled M. Mohamed

"Understanding coal mine rib behavior is important for inferring pillar loading conditions as well as ensuring the safety of miners who are regularly exposed to ribs. Due to the variability in the geometry of underground openings and ground behavior, point measurements often fail to capture the true movement of mine workings. Photogrammetry is a potentially fast, cheap, and precise supplemental measurement tool in comparison to extensometers, tape measures, or laser range meters, but its application in underground coal has been limited. The practical use of photogrammetry was tested at the Safety Research Coal Mine, National Institute for Occupational Safety and Health (NIOSH). A commercially available, Digital Single-Lens Reflex (DSLR) camera was used to perform the photogrammetric surveys for the experiment. Several experiments were performed using different lighting conditions, distances to subject, camera settings, and photograph overlaps, with results summarized as follows: The lighting method was found to be insignificant if the scene was appropriately illuminated. It was found that the distance to the subject has a minimal impact on result accuracy, and that camera settings have a significant impact on the photogrammetric quality of images. An increasing photograph resolution was preferable when measuring plane orientations; otherwise a high point cloud density would likely be excessive. Focal Ratio (F-stop) changes affect the depth of field and image quality in situations where multiple angles are necessary to survey cleat orientations. Photograph overlap is very important to proper three-dimensional reconstruction, and at least 60% overlap between photograph pairs is ideal to avoid unnecessary post-processing. The suggestions and guidelines proposed are designed to increase the quality of photogrammetry inputs and outputs as well as minimize processing time, and serve as a starting point for an underground coal photogrammetry study.INTRODUCTIONThe stability of underground mine ribs has been a safety concern for underground coal mines for decades. Unfortunately, the average rib fatality rate has been about 1.3 per year between 1996 and 2013 (Jones et al., 2014). In an effort to better understand coal rib behavior, photogrammetry is being investigated in this study as a measurement tool for surveying ribs in an underground coal mine environment."

Jan 1, 2016

By Ismet Canbulat, John Naylor, Jason Emery, Peter Craig, Andy Sykes

"Longwall mining is by far the most common method of underground coal extraction in Australia. The industry trends and expectations are placing increasing emphasis on the reliability and productivity of these operations. The longwalls are becoming wider and longer while retreat rates are continuously increasing due to significant improvements achieved in longwall equipment reliability and automation. This increased longwall productivity is placing significant emphasis on the reliability of longwall panel development.Although there have been significant improvements in the reliability of continuous miners and hydraulic drill rigs, the traditional resin encapsulated bolt installation is still the principal method used in all major coal-producing countries around the world. Anglo American realised an opportunity existed to introduce an alternative roof bolt installation technique called “spin to stall” in Australia. Spin to stall was first introduced in Anglo American Coal in South Africa where it has been successfully used for over a decade, though implementation of South African spin to stall resin in Australia has proven to be near impossible due to a significant difference in geotechnical conditions, mining method, and, subsequently, roof bolting equipment. Therefore, a new spin to stall development project was initiated between Anglo American Coal and Jennmar Australia (SPIN2STALL®). This paper summarises the journey of this project, the results, and the successful implementation of spin to stall achieved at Grasstree Mine.INTRODUCTIONThe Anglo American Coal business unit operates Grasstree and Moranbah North underground longwall mines in the Bowen Basin of Central Queensland, with a third longwall mine, Grosvenor, currently being developed, and two more (Aquila and Moranbah South) in the project pipeline. The vision for Anglo American is to achieve “Zero Harm” through the effective management of safety at all operations, while for the coal business unit, at the same time to achieve industry-leading operational performance. Currently, both Grasstree and Moranbah North longwalls are operating at industry best practice rates. This is placing increased pressure on the development process to allow such high productivity levels to be sustainable."

Jan 1, 2015

By Phillip E. Gramlich

Through extensive practical experience and multiple studies, tensioned roof control systems have proven beneficial in difficult mining conditions. Due to increased mining of less desirable seams, tensioned roof control systems have claimed a progressively larger share of the total number of roof bolts installed in the US coal industry. Each tensioned roof control system has its benefits, but also has problems concerning cost, cycle time, stress concentration, load retention, and protrusion into the mine opening. For example, resin-assisted mechanically anchored bolts (also known as resin point anchor bolts) have a fast cycle time and the potential for high tension loading, but the stress from the mechanical shell is concentrated in a small area and can create concerns with certain roof structures (Zhang and Peng, 2001). Resin point anchor bolts can be difficult to fully grout. The cost of resin point anchor bolts can be an issue; a two-piece resin point anchor bolt has a large number of parts (10) and manufacturing steps (9), adding to its higher cost. Tension rebar bolts can achieve high loads and are easier to fully grout but have longer cycle times. In addition, a high percentage of the installed load can ?bleed off? if the resin mixing time or the ?hold time? before tensioning is short-circuited. Tension rebar bolts can be notorious for protruding into the mine opening, creating an obstruction for man and machine (Figure 1), in particular, with reduced mining heights. A new tensioned roof control system has been developed that doesn?t have moving parts, is cost effective, provides fast cycle times, has a low profile, and is simple t install.

Jan 1, 2014

By Houquan Zhang, Ming Li, Guimin Zhang, Bei Zhang

"The support quality of bolts in deep roadways is one of the important factors for efficient and safe coal production. A new kind of non-destructive testing technique and equipment was used to monitor the axial bolt load in real time in deep roadways. Based on the test results, the working status of bolt support in deep roadways was evaluated. The research results show that the variation characteristics of axial bolt load is consistent with the distribution characteristics of rock pressure no matter whether it is in the initial support stage or mining disturbance stage. The axial load of bolts located 20m outby the development face has an overall rising trend within 3-5 days after installation. Within a certain distance in the front abutment pressure zone in front of the face, the axial bolt load increases with the advance of coal extraction. When coal and rock in the abutment pressure zone yield, the axial bolt load is dropped correspondingly. This kind of non-destructive testing technique provides an advanced means of detection and evaluation on bolt support quality.INTRODUCTIONMany coal seams more than 800m deep are being mined in eastern China. Roadways of large cross-section are being developed in coal seams more than 600m deep in western China (Kang et al. 2014). Moreover, these roadways are commonly supported by roof bolts and have encountered many support problems, including soft rock strata, intense mining disturbance, and abnormal tectonic stress. The stability of its surrounding rocks is difficult to maintain, the roof bolt even fails before mining (Shen 2014; Jiang et al. 2015). Therefore, it is very important to develop an effective method to detect the bolt quality in real time and evaluate the bolt's safety status.During installation of roof bolt, the installation quality is heavily affected by installation equipment and tools, field conditions, and operators' skills (Li et al. 2005; Shan 2009). The anchorage length will be shorter than the designed one if the resin cartridges are pushed to the bottom of excessively long drill hole and stay there without being shredded and mixed. The support function of the bolt would be weakened by the shorter anchorage length."

Jan 1, 2016

By Michael Murphy

A multi-stage triaxial procedure has been developed for the enhanced servo controls and feedback systems at the National Institute for Occupational Safety and Health (NIOSH) rock mechanics laboratory. Due to the difficulty of preparing multiple rock specimens for single-stage triaxial tests at different confinements, multi-stage testing provides a huge advantage if only a few samples of coal measure rocks can be prepared from the drill core. A multi-stage test can provide mechanical properties, post-failure properties, and a complete failure envelope for a single specimen. For the multi-stage test procedure, a parameter used to define the slope of the stress-radial strain curve was developed and monitored in real time in order to successfully predict peak strengths at different confining stages. For this paper, multi-stage tests have been conducted on sandstones of varying strengths, including Berea sandstone which has well-documented properties, and fine-grained and coarse sandstone from a western US coal mine. For the tests conducted on the fine-grained sandstone, it was found that the ramp rate was an important factor in the success of obtaining peak strengths during the multi-stage tests. For each rock type, a table including Young?s modulus, Poisson?s ratio, unconfined compressive strength, friction angle, cohesion, residual friction angle, and residual cohesion are reported. The values from these tables have been used as input parameters for projects at NIOSH requiring numerical model input parameters.

Jan 1, 2014

By Essie Esterhuizen, Michael M. Murphy, Chris Mark

"The design of underground coal mines requires a clear understanding of the overburden response, the loading of pillars, the loading of the gob, the pillar failure process, and the ultimate load carried by partly or fully yielding pillars. Very few highquality stress measurements of yielding pillars and gob loading have been made in full extraction mining. Well-calibrated numerical models can assist in providing a better understanding of the load and failure processes, provided the coal, the overburden, and the gob are all modeled with sufficient realism. A program of numerical model calibration and validation was carried out using FLAC3D.1 The models were calibrated against observed and measured performance of coal pillars and the overburden in operating mines to provide a basic set of input parameters that can be used to provide a realistic first estimate of expected ground response and pillar loading. Input parameters for modeling coal pillar response were based on data from triaxial testing on coal samples, combined with both matching the depth of failure in the coal ribs to observations as well as matching the peak pillar resistance to an empirical equation. The models were calibrated against strong roof and floor case histories in which the pillar strength is governed by failure and yielding of the coal within the pillar and the surrounding strata only had a limited impact on pillar strength. Input parameters for the overburden were determined from a large database of laboratory tests and model calibration against maximum subsidence and subsidence curvature. Further overburden calibration was carried out by matching stresses in the mining horizon to field measurements. Three examples of the application of the calibrated dataset and modeling methodology to field measurements are presented. The results show that a reasopable estimate of the in-seam stress distribution and overburden response can be obtained for both strong and weak overburden scenarios at various depths of cover.INTRODUCTIONThe planning and design of coal mine excavations requires reliable estimates of the expected strength and loading of the mine structures to achieve global stability. Empirical methods are widely used to estimate the strength and loading of coal pillars and have been incorporated into pillar design procedures, such as Analysis of Longwall Pillar Stability (ALPS) (Mark, 1987) and Analysis of Retreat Mining Pillar Stability (ARMPS) (Mark and Chase, 1997), that are widely used in the United States. ~umerical models are finding increasing application as a tool for underground mine design because of their. versatility and the ever increasing computational power available to mine designers. A prerequisite for the application of numerical models is the calibration of the models against observed rock mass response (Hoek et al., 1990; Skiles and Stricklin, 2009). The calibration process may include comparison of model results to measured stress and deformation and modifying the input parameters in a systematic manner to achieve a satisfactory agreement between the model results and measurements. Once models have been calibrated, they can be applied to evaluating similar mining layouts in similar geological conditions."

Jan 1, 2010

By Frank Schmidt

Due to changing geology, rib bolting is an ever-changing problem in ground control. With the economic status of the coal market, the need for safely increasing productivity in rib bolting is at an all-time high. The current solutions used in the market often require a long installation time (e.g. if collapsed holes have to be redrilled) or result in poor quality installations that can lead to insufficient ground control. A new bolting product based on the simple screw principle has been developed to bolt ribs faster and with a more repeatable, higher level of installation quality. The paper covers the product invention and development, the fastening principle and its advantages over current systems and first experiences in the market. The first underground trials have shown that the screw anchors can be installed safely and efficiently, often faster than traditional methods. The screw anchor does not suffer from conventional bolting issues such as collapsed holes due to bad ribs. The screw anchors are designed to obtain steel failure and load testing underground shows consistent fastening in all types of conditions.

Jan 1, 2013

By Ashok Kumar, Rajendra Singh, Petr Waclawik

High-grade coal is locked in the shaft protective pillars at 900 m below surface in the Czech part of Upper Silesian Coal Basin. To optimise recovery of coal from the larger size shaft protective pillar, room and pillar (called bord and pillar in India) is trialled to further develop these on smaller pillars. This development followed a constant gallery width of 5.2 m and 3.5 m height. The monitored pillar size in the first developed panel varied from 860 m2 to 1225 m2 of area. The stability of these pillars (i.e., natural supports) at this depth of cover is observed to be a vital issue to control ground movement and safety of the surface structures. A simple calculation of safety factor revealed that application of an empirical method for estimating size and shape of the pillar is inappropriate due to complex geo-mining conditions of the site. Accordingly, geo-technical instruments are installed in the panel for monitoring the stability of the diamond shaped pillar at different stages of the development. Extensive monitoring of the pillar behaviour by these instruments provided an important set of data for such optimum recovery. An established process of simulation-based pillar strength estimation is often used by the mining industry, but calibration is generally done with the help of empirical formulation. However, for the deep-seated pillar, the strength suggested by the existing empirical formulations (except the CMRI formula) is found to be much different from the instrument observations. Using a study conducted at Czech hard coal mines, an attempt is made to develop a strain-softening-based numerical modelling approach to assess pillar performance at deeper cover. The recorded value and nature of the pillar spalling in the field along with the CMRI formula are used to calibrate the developed simulation approach. An assessment of the stability of the developed pillars using simulated models did not indicate any collapse of the natural supports. This paper briefly presents difficulties in pillar design at great depth of cover and field and simulation results of pillar strength estimation in Czech hard coal mines.

Jan 1, 2018

By Darin Cotton, Tim Burgess, Tim Martin

"As the leading US supplier of roof control drills, J. H. Fletcher and Company® has encountered an extensive set of roof strata challenges and has overcome various drilling issues by varying machine parameters and working with customers and tool manufacturers to develop solutions. Every mine wants to drill and install roof bolts as fast as possible with maximum safety at the lowest possible installation cost for their conditions. In most circumstances, the intuitive method of higher speeds and pressures can actually have a detrimental effect on the roof drill safety and performance.This paper will outline recent tests carried out at several different coal mines in the Eastern United States. The tests focused on optimizing the drilling parameters of feed pressure, feed rate, rotation speed, and drill torque.The drill feed, rotation speed, and rotation torque, as well as the type of bit selected, have a definite impact on the performance of the roof drill including drilling speed, safety, and tool life. The drilling process can be improved while also improving operator safety and reducing bolt installation costs by maintaining the appropriate roof drill settings for the specific strata conditions.The advantages of improving the drilling process includes increased bit life, increased drill steel life, reduced hanging drill steels, reduced clogging of the vacuum system, decreased whipping drill steel potential, reduced noise generation, and increased cutting size which reduces fine dust generation and dust collection system servicing.INTRODUCTIONIn recent times, the economic pressures that coal producers are facing have created an increased emphasis on controlling operating costs. Several coal operators have pointed out their dissatisfaction with low bit life, and there is a renewed interest in improving tool life and machine performance as part of an overall cost control strategy. Operators are looking for ways to reduce tooling cost, maintenance costs, and drill downtime without decreasing drill performance. This renewed interest in reducing operating costs, along with the ongoing desire to improve safety, created a perfect environment to take a fresh look at the existing fleet of machines to see what could be accomplished. The goal was to take a practical approach to reviewing machine parameters to determine what changes could be made. The emphasis was on changes that would be feasible to roll out to an entire fleet of machines in a short period of time with minimal capital expenditure. The thought process was that significant improvements could be made by simply tuning up the machine parameters to provide a more efficient and safer bolting process."

Jan 1, 2015

By Houquan Zhang, Yu Wu, Yanlong Chen, Zhenfu Luo, Aihong Lu

"A non-destructive detection scheme for bolt installation quality was designed by adopting the method of non-destructive detection on bolt installation quality. Based on the field measurements, a random non-destructive detection method for determining the characteristic length including anchoring length, free segment length and initial axial load of bolt was discussed, and the characteristics of increasing bolt axial load in the initial stable stage was obtained. The results show that the bolt axial load and deformation of surrounding rocks correlate each other. Compared with the traditional detection technique for bolt installation quality, the non-destructive detection method has obvious advantages such as random, accuracy, and economic. The method provides a reliable basis for bolt support optimization and stability control of surrounding rocks.INTRODUCTIONBolt support in roadway can make the surrounding rocks and bolt form a structure in the early stage of roadway development through the bolt pre-tension, which can maximize the self-bearing capacity of surrounding rocks. Thus it is a form of active support (Kang, 2007). In order to make the bolt play an active supporting role, it needs to ensure the installation quality of bolting. Thus the bolts can supply a high initial anchoring force and control the deformation of surrounding rocks (Shan, 2009; Wei, 2012). Moreover, bolt supporting is a concealed work. Once installation quality problems appear; it will be difficult for effective detection and screening (Xie, 2008).THE PROBLEMS OF BOLT INSTALLATION QUALITY IN COAL MINE AND ITS DETECTIONThe Problems of the In Situ Bolt InstallationDue to the problems in installation environment, machine, and technique, and workers proficiency (Li, 2003), there are many problems exist in bolt installation. If the borehole depth is too long, the anchoring agent will accumulate at the bottom of the bore, which reduces the anchoring length. Furthermore, if the borehole depth is short due to the poor geological condition, the exposed part of the bolt will be too Jong and the pallet cannot cling to the rock face, which prevent the pre-tension from being applied. The pre-tension is very important for bolt installation. If pre-tension is insufficient the rock bolt cannot control the deformation of surrounding rock efficiently and the bolt anchoring force will decrease considerably. The bolt length is another important parameter for anchoring quality, which will affect the control area of bolt supporting. In addition, the cleanness of drill hole has a great influence on the effective anchorage length of bolt. If the drill hole cleaning is not enough, it will directly affect the anchoring agent and the contact area of surrounding rocks, which will decrease the effective anchorage length and initial anchor-force."

Jan 1, 2016

By Stephen C. Tadolini, Robert Hawker, Peter Mills, Colin Grubb, Tom Meikle

"In unfavorable strata conditions, it is often necessary to install additional long tendon support as part of a primary support cycle. Although these support systems provide the required additional stability to the roadway installation does have a significant effect on the rate of development. To overcome the slow cure time of Portland cement-type grouts, the use of two component resin systems, such as polyurethanes and urea silicates, have become favorable. However, concerns over low modulus and creep properties has led to the development of a two-component grouting medium that displays the properties of traditional cable grouting materials with the rapid reaction times of pumpable resin systems. This paper describes product testing, application, surface trials, underground trials, and full-scale applications of the Tekthix System in a dynamic underground environment. INTRODUCTION Single-component cement grouts have been used to anchor long tendon supports for many years. They range from high- to low-slump Portland cement and can be slow-setting to fast-setting grouts. However, current cement grouting systems, which includes the grout and equipment, have some disadvantages: 1. Low-slump grouts require pumps that can handle a thick, high-viscosity grout, so choice of pumps is limited. 2. Pumping distance is limited with current cable bolt grout pumps; operators often tend to add water to allow pumping long distance, which adversely impacts the quality and strength of the material. 3. Fast-setting grouts tend to cause issues with pump and line blockages due to the reduced working life of these single-component materials."

Jan 1, 2017

By Andre Cezar Zingano

"The objective of this paper is to estimate the coal seam strength and the pillar safety factor for low coal seams using back analysis and rock mass characterization. The coal seam strength is very important to estimate both pillar capacity and mine section design. There are two approaches to estimating coal seam strength: (i) by geomechanics characterization of the boreholes cores; and (ii) by back analysis from pillars successes and failures, or some in-situ tests. For low coal seams (1.2 m, or 47 in.), the confinement of the center of the pillar is very important to defining global pillar strength because the low seam height increases the confinement of the pillar core, even in small pillars. We used in this case study one underground coal mine in the Parana State where the coal seam thickness is 0.8m the pillar height is 1.3m, the entry width is 5m and seam depth is 130m. A panel test was prepared to study the pillar behavior for use of the retreat mining method. The designed pillar size was 6x5m and 1.3m high with a predicted safety factor of 1.0 based on the Hoek and Brown failure criterion is 5.3 MPa. Once no pillar failure was observed, the pillar safety factor was assumed at 1.0 and the coal seam strength was backcalculated. The back analysis estimated the coal seam strength to be 6.2MPa. The confinement of the pillar center directly affects the coal pillar strength, and also the coal seam strength estimated by back calculation.IntroductionThe coal seam strength is very important to estimating pillar strength and mine section design. There are two approaches to estimating coal seam strength: (i) by geomechanics characterization of the coal seam using borehole cores; and (ii) by back analysis from pillar successes and failures, or some in-situ tests like panel test or ultimate pillar capacity (Salamon and Munro, 1967; Maleki, 1981; Peng and Dutta, 1992). For the first approach, lab tests (mainly triaxial tests) and borehole geomechanics descriptions (quality and quantity of the discontinuities) determine the coal seam strength by the Hoek and Brown failure criterion (Hoek and Brown, 1997). For the second approach, a panel test to study the pillar behavior can be built to define coal seam strength by back calculation. The safety factor for the pillars in the test is 1.0, based on the estimated coal strength from the geomechanics characterization. In this case, the probability of failure is 50%. If some pillar failure occurred, and the real pillar size was measured, the back analysis could be applied to define pillar strength and the coal seam strength."

Jan 1, 2015