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By Michael Kelly

Inertial navigation technology has, for the first time, allowed the position of a longwall shearer to be mapped in three dimensions. Following the success of the technology in highwall mining and successful trials on a longwall face, the Australian Coal Association Research Program (ACARP) commissioned a three year "Landmark" project that aimed to advance longwall automation to the level of "on-face observation" by the end of 2004. This project has been completed with the following successful technical outcomes: Automatic face alignment was achieved, using an inertial navigation-based sensor on the shearer, to accurately measure face geometry and feedback signals used to move OEM (Original Equipment Manufacturer) roof supports. Operational on-line measurement of creep with creep information incorporated into face alignment corrections. Inertial Navigation System (INS)-based enhanced horizon control was bench-tested. Operational broadband communications system to shearer using wireless Ethernet on a commercial-product basis. Acquisition of located coal-face features for use in thermal infrared-based horizon control. Automated Longwall Information System (LIS) developed which integrates information from multiple systems and sensors and provides high quality visualisation and control interfaces. Automatic roadway and face convergence monitoring tools successfully tested. Condition monitoring tools developed and demonstrated for improved face reliability. This paper summarises the outcomes of the project and describes the work being undertaken for the 2 year Landmark Extension project approved in April 2005. Consistent with the conference theme, the paper focuses on the ground control aspects of the project.

Jan 1, 2005

By Michael Trevits

The NIOSH Lake Lynn Laboratory (LLL) is a unique research facility, located about 50 miles southeast of Pittsburgh, Pennsylvania, that is designed to provide a full-scale mining environment for testing and evaluation of mine health and safety technologies. The LLL occupies more than 400 acres and is composed of surface test and training areas and an underground mine. The Lake Lynn Experimental Mine (LLEM) was built at an abandoned commercial limestone quarry where surface mining ceased in the late 1960's. Later, new underground development was constructed to simulate modern-day coal mining scenarios; including room-and-pillar and longwall mining layouts. In January 1994, a sinkhole opened southeast of the No. 4 Portal of the LLEM and since then, the area of the underground failure and surface deformation has continued to expand and now includes several interconnected sinkholes. A concern developed that the overburden instability could expand and affect the structural integrity of the nearby highwall and the No. 4 Portal. It was unsafe to conduct a detailed underground survey of the mine in this area because the mine roof conditions near the No. 4 Portal had deteriorated significantly. It was decided to investigate the overburden conditions near the No. 4 Portal using ground penetrating radar (GPR). A GPR survey grid was located along an access road that passes over the top of the portal. To delineate the mine conditions near the portal, antennas whose frequency spectra produced pulses centered near 100- and 200-MHz were used. The results of the GPR survey suggests that the overburden rock units appear to be laterally consistent to a depth of about 15-ft. Below that point, the overburden appears to be significantly disturbed and it was hypothesized that this area contains a large roof fall. A follow-up ground truth survey of the mine roof conditions was conducted from the mouth of the portal. It is concluded that the observations and measurements made from the radar records appear to be correct as a large roof fall was observed and measured from the mine portal area.

Jan 1, 2005

By Shuangsuo Yang

Coal ribs can roughly be divided into three types: (1) roof and floor rocks are similar to ribs, (2) roof and floor rocks are stronger than ribs, and (3) roof and floor rocks are weaker than ribs. Different types of roof/floor and ribs will exhibit different types of ground pressure around an entry. Most coal mines belong to the 2" type with ribs fractured or even broken. In this case the mine ground pressure depends on the occurrence and development of deformation and fracture of the ribs. If it's not properly controlled, the following deteriorating process will follow: the roof bent downward > the ribs squeezed and broken > rib sloughing and collapse > rib support to the roof reduced > the roof bent downward further > the ribs broken further. In this paper rib instability is divided into four types: compression/shear sliding rib fall, gravity sliding rib fall, cross arch rib fall, and cleavage rib fall. Since failure in thin walls is largely of tension type whereas that of thick walls by compression or shear, a concept is proposed here to utilize a thick bolted rib to stabilize entry ribs, i.e. the thickness to height ratio of the thick bolted ribs

Jan 1, 2005

By Thomas Barczak

Longwall mines typically use some form of standing support for secondary roof support in longwall tailgate entries. Although there have been several new support products developed for this application, there remains no universal design criteria to optimize the application of these support technologies. The requirement for optimization and proper support selection is to understand the degree of control that the support has on the ground behavior. The ground reaction curve and numerical modeling was used to evaluate the impact of standing support on ground behavior. LaModel was used to evaluate the impact of standing support on main roof and floor behavior and pillar yielding. The conclusion drawn from this study was that standing supports do not have sufficient capacity to control main roof or floor loading or prevent the resulting convergence of the tailgate entry. However, it is imperative that this "uncontrollable convergence" be considered in the support design to prevent premature failure of the support. A FLAC model was used to evaluate the near-seam roof and floor behavior in conjunction with the global vertical and horizontal stresses. The model suggests that standing roof supports can have some impact on the ground behavior as the elastic response of the rock is exceeded and rock structure deteriorates from the stress concentrations that develop around the tailgate opening. During this phase, the capacity and stiffhess of the standing support can be critical to the stability of the opening, as eventually the rock mass will be transformed into a partially detached structure whose weight must be supported by the standing support. This work is part of a ground control program of research at the National Institute for Occupational Safety and Health (NIOSH) aimed at improving mine safety by reducing roof fall injuries and fatalities.

Jan 1, 2005

By John Kucish

Roof bolting in the Pittsburgh Coalbed takes many forms today: coupled partially grouted bolts, fully grouted rebar, passive cable bolts, tensioned cable bolts, and torque tension rebar. The Federal No. 2 Mine of Peabody Energy has recently made a significant advance in longwall headgate primary roof support, with the change fiom an 8 ft long coupled partially grouted bolt to a 6 ft long torque tension system. The coupled partially grouted bolt consists of a 4 ft long 0.804 in diameter rolled deformation bar thread coupled to a smooth 718 in headed bar. The coupled partially grouted bolt is anchored into a 1 318 in borehole with 4 ft of high speed resin. The 718 in diameter smooth bar is tensioned by rotation into the treaded coupler, upon setting of the resin, compressing the immediate roof. The change was initially driven by occasional failure of the coupled partially grouted bolt at the threaded coupler, due to lateral movement caused by horizontal stress. A fully grouted % in diameter torque tension bolt, in a 1 in borehole, was proposed as a cost effective primary bolting for the high horizontal stress conditions. The upper 2 112 ft of the rebar is anchored in fast set, medium viscosity resin and the bottom 3 K ft is anchored in slow set, special low insertion force resin. The lower end of the rebar is threaded with a nut that permits the counter clockwise spinning of the bolt to mix the resin, at maximum rotational torque. Upon setting of the high speed top resin, the nut is spun clockwise to tighten the nut against a metal dome plate. The plate is forced against the roof to compress the immediate roof, A complete headgate entry has been successfully supported with the torque tension system. The mining of the adjacent longwall panel was completed in September 2004. The torque tension system provided a 25% savings over the previously employed coupled partially grouted bolt system.

Jan 1, 2005

By Kresho Galovich

Quinsam Coal Mine located in Vancouver Island, BC, Canada is mining the No. 1 coal seam at the 2 North/3 North mine and the No. 3 coal seam at 4 South Mine. This paper describes its geology and structure, mining and processing, development and depillaring practices as well as methods of roof supports under various geological conditions.

Jan 1, 2005

By Anthony Lannacchione

There has been a persistent need to forecast roof falls so that miner's exposure to hazardous underground environments can be minimized. Several monitoring techniques have been developed and are used today with varying levels of acceptance in the mining industry. This paper examines the potential for monitoring microseismic emissions activity as a means of forecasting roof falls. The use of this activity to forecast roof falls has drawn only limited attention, resulting in a lack of published field performance data. This deficiency is being partially addressed by analyzing data obtained during longwall mining at Moonee Colliery in 1998. The Moonee data base contains a wealth of information concerning roof fall forecast parameters and the seismic alarm criteria used to develop these forecasts. Four seismic alarm criteria were developed and used by Moonee with varying degrees of success. Roof falls were forecasted 73% of the time with average forecast times of 54 minutes. Ninety percent of the predicted roof falls had a warning time, i.e., the time between warning and roof fall event, of greater than 1 minute. The fraction of forecasted roof falls decayed logarithmically as a function of warning time, until only 20% of events were predicted more than 100 minutes prior to roof falls. False alarms occurred in 50% of the warnings. Many of the false alarms were quickly followed by a cessation in mining which could have temporarily halted the on-going failure process. If mining had continued immediately after the false alarms, a roof fall may have occurred soon after. The microseismic activity collected .from Moonee Colliery demonstrates that techniques to forecast roof rock instabilities in underground mines are possible.

Jan 1, 2005

By Xianxin Shi

In surface electrical exploration the high resolution earth resistivity method (HRRM) is a very effective method for detecting abandoned drift mines workings. When the abandoned mines are more than 500 ft (150 m) deep, its detection capability reduces greatly and requires more effort to implement. In Yan Quan coal mine, Shanxi province, we tried to adapt this method for underground application. Two survey lines were designed with the spacing of current and potential poles 20 m and 10 m, respectively and measuring points at 2m. The measurement radius of I line and I1 line were 140 m and 60 m, respectively, and the infinitely far pole was 1200~2000 m from the survey line. (Note the I and II lines are located on the north and south ribs of main tunnel, respectively). The survey results showed that abandoned workings were located at 25-70m, Survey Line I and at 80-1 10m, Survey line 11. Based on this finding, the longwall panel gateroads and set up entry were properly located thereby providing safe mining of the No. 15 Coal seam. Key Words: Abandoned coal mine, High resolution earth resistivity, Underground electrical exploration

Jan 1, 2005

By Marc Arl

Failures of the face and roof above longwall shields have caused days and sometimes weeks of lost production. A common recovery method for these failures has been to pump light weight cementitious grout into the roof and face cavity to stabilize the area This approach while effective is very time consuming and costly. Mines in several coal producing nations have over the past few years been applying phenolic foam grouts in these situations in lieu of cementitious materials. Phenolic foam is a two-component injection product intended for cavity filling, air and gas sealing and the consolidation of highly fractured strata. The properties of phenolic foam; rapid application, quick setting, high expansion rate, high compressive strength and excellent anti-static properties, produce a fast, safe and cost effective cavity filing solution. The product is also classified as fire resistant and so is also suitable for sealing off underground heatings and for aiding fire fighting operations in deep mines. This paper will discuss the application and use of phenolic foam in various underground coal mines in the world over the past few years.

Jan 1, 2005

By Dion Pastars

Resin based grouts are the main form of rock bolt anchorage in the underground coal industry in Australia and New Zealand. To be effective, the system requires the mixing of the catalyst and mastic components of the resin, as well as shredding of the laminate cartridge that contains the resin. An unknown measure is the load transfer characteristics of a bolt where the resin is well mixed but remains encased in the cartridge (gloved). Laboratory and in situ field investigations have been undertaken to quantify the performance loss due to mixed gloved bolts. This work showed repeatable results, indicating serious performance loss of the gloved and mixed system, with load transfer approximately 10- 15% of a non-gloved system (MacGregor, 2004). The in situ testing has demonstrated the relationship between the adhesion qualities of the resin and the mechanical interlock generated by radial confinement with progressively increasing tensile load. Effective load transfer is defined by the ability of the system to sustain shear stress on the bolt hole wall.

Jan 1, 2005

By Shu Yan

The high resolution resistivity method (HRRM) is developed specifically for detecting underground cavities and tunnels. HRRM has a special feature in that it can recognize and cancel static shift, which makes it different &om the high density resistivity method (HDRM). In searching for various means for detecting underground cavities, we found that the detecting depth of the transient electromagnetic field method (EM) depends mainly on the measurement duration, not the loop area. In addition, TEM can also be used to locate the high-resistivity bodies. In order to use them for local working site conditions, we combine HRRM with TEM to become a combined electromagnetic method. Since the late 1980's this method has been used to locate abandoned mines and air passages and burning centers of mine fires with great success. This paper cites case studies for which this technique was successfully used.

Jan 1, 2005

By Craig Compton

The The National Institute for Occupational Safety ane Health (NIOSH) Pittsburgh Research Laboratory (PRL) is continuing to investigate the behavior of fully grouted roof bolts in the weak roof rock of the Safety Research Coal Mine (SRCM). This paper describes the results of three studies: A series of 24 pull tests of bolts installed fully grouted and overcored to leave 12 inches of grouted bolt. The tests compared the pull-out performance of offset-head roof bolts with that of standard 518-inch bolts; A second series of 24 tests that compared the pull-out loads obtained by bolts installed with 1 R of resin (a Short Encapsulation Pull Test or SEPT) to that of fully grouted bolts overcored to leave only 12 inches of grouted bolt, and An investigation into the pressures generated during the installation of fully grouted resin bolts. All of the bolts installed and pulled were overcored and removed from the roof after the pull tests to allow inspection of the resin. The first study found that there was no significant difference in pullout load between the offset-head bolts and the standard bolts. The second study, comparing the SEPT bolts and the partially- overcored fully grouted bolts, indicated that SEPT can significantly underestimate bolt anchorage grip factor, suggesting that the SEPT is a conservative measure of actual bolt performance. Significant loss of resin to cracks in the roof was observed in the bolts overcored in the SRCM. The third study explored one possible explanation for the resin loss, high pressures generated during bolt installation. These tests employed bolts installed in strain gauged steel tubes. The results confirmed that significant pressures (greater than 4,000 psi) can be generated during bolt installation. The results of the pressure tests, combined with the observations of resin loss in bolts installed in the SRCM, suggest that under some circumstances resin loss and under-encapsulation could take place and lead to degraded bolt performance. Glove fingering was observed in all recovered bolts to various degrees. The limited comparative data suggested that the effect of glove fingering ranged from slight to moderate. Complete mixing of the resin was observed on all of the 40 bolts recovered (28 fully grouted and 12 SEPT). Australian and U.S. resins were compared and the Australian resins were observed to have much smaller catalyst compartment areas and lower resin viscosities. These differences are suggested as potential explanations for occasional resin mixing problems noted in Australian resin bolt installations.

Jan 1, 2005

By Murali Gadde

Numerical simulation of cutter roof failure is a daunting coal mine excavation design issue. The complex progressive failure mechanisms associated with cutter failures are extremely difficult to replicate in computer models. However, this paper shows that with a proper selection of constitute behavior and implementation of cutting sequence, it is possible to realistically reproduce cutter failure using continuum models. Strain-softening material behavior and a systematic step-by-step model solving for a four-entry-and- three-crosscut model produced results that are similar to cutter patterns noticed in field. These results show that traditional modeling with geometries created in one model-step has limited applicability and may even provide misleading conclusions under some circumstances. Most importantly, the proposed modeling methodology provided some insights into the reasons for the inconsistent spatial distribution of cutters often noticed in coal mines. The modeling also revealed the usefulness of cutter mapping to determine the directions of in situ horizontal stresses.

Jan 1, 2005

By Baisheng Zhang

The definition of Ultra-close multiple seams as defined by the floor disturbance depth, h, due to mining in the upper seam is proposed: it refers to those coal seams that are spaced very closely, i.e. h,, the distance between seams, is small or equal to h, , and mining of any one of the seams will significantly affect the others. Those seams are called the ultra-close multiple seam group. Theoretical formula for defining it and practical examples are given in this paper. Underground measurements and numerical analysis show that in ultra-close multiple seam mining, the characteristics of ground pressure due to lower seam mining is different from that of single seam mining. The major differences is that the roof, as a result of damaged caused by the upper seam mining, is full of factures; the roof broke up in the belt entry and fell down easily; support loading at the face was small without clear periodic weighting phenomenon. Based on these results the roof structure model and roof control theory for ultra-close multiple-seam are established.

Jan 1, 2005

By Anton Sroka

The dimensioning of shaft safety zones is a substantial task of mining subsidence engineering. On the one hand, the coal reserves in shaft proximity are to be mined as complete as possible, because they can be made accessible economically. On the other hand, the maintenance of the shaft operation is to be ensured at each time, since shafts represent the most important link between underground and aboveground. Regarding these two criteria, this publication presents a model for the optimization of shaft safety zones. Beyond that, extraction methods in shaft safety zones are described, in particular with consideration of minimized mining influences on the shaft.

Jan 1, 2005

By Guangyi Sun

Wall rock classification method for coal mine support is the main factor affecting mine support. It is greatly affected by the combined effect of randomness, fuzziness and human being's incomplete knowledge. There are several coal rock classification methods. Using different rock classification methods the same engineering rock mass can be classified into different classification leading to different construction practices.

Jan 1, 2005

By Jian Yong Chen

The results of a laboratory investigation of pullout tests conducted on grouted, plain cable bolts are reported. The main purpose of the study is to determine experimentally the shear bond stiffiess of cement grouted and resin grouted cable bolt systems, which is an important input parameter for numerical modeling of cable bolt support. Three nominal embedment lengths of 152mm (6 inch), 203mm (8 inch) and 254mm (10 inch) were used and two types of grout namely cement and Anchortite resin were used. Two water- to-cement ratios of 0.3 and 0.4 were employed for the cement grout. The concepts of effective shear stress and effective shear stiffiess are explained and adopted to calculate the shear bond strength and the elastic shear bond stiffiess per unit length. A comparison of results with previous research is presented to reveal the effect of water-to-cement ratio and embedment length on the shear bond characteristics of grouted cable bolts.

Jan 1, 2005

By E. Bane Kroeger

In underground coal mining, there is often a need for supplemental support for mine openings. In the past, one of the most common types of supplemental support was wooden posts that were installed against the roof using opposing wooden wedges. Underground, wood has the tendency to shrink from moisture loss and dislodge if not under load. Another drawback to using wood is the variability in strength between posts. Defects in the wood such as knots can cause weaknesses that often lead to premature failure of supplemental support. Many mines that install large amounts of supplemental support in certain areas of the mine such as bleeder entries in longwall mining have switched to using steel props rather than wood posts or cribbing. The reactions of steel props under loading are well- defined and there is little variability in strength between props. Steel props and can be fabricated so they can be used in a variety of roof heights without modification. Wooden posts often have to be cut to a usable length underground before installation. This adds to the installation time of the wooden posts. Steel props are more compact and can be lighter than their wooden counterparts, depending on the length and carrying capacity. Often times it is desirable to prestress the supplemental support to improve roof stability. This is often problematic and time consuming with some types if supplemental support. With these factors in mind, research was undertaken at Southern Illinois University Carbondale (SIUC) to design a new steel roof prop. Several new clamping designs were developed and prototypes were fabricated and tested in the labs at SIUC in the spring of 2003. The designs were modified and refined and the first full-size prototype roof prop was tested in January 2004. With the success of the full-size prototypes, a cooperative research program was established between SIUC and Excel Mining Systems, Inc. to further develop the new prop. Development went smoothly and the prop has performed as expected. In February 2005, SIUC and Excel entered into an exclusive licensing agreement. The prop design under license, the K-Prop, will be installed using a lightweight portable hydraulic jacking system under design that can be used to prestress the props, applying load to the roof and floor during installation. By varying the installation load, the prestress load can be varied from about 1,000 to 10,000 pounds (4.448 to 44.48 kN) and at the same time, the carrying capacity of the K-Prop can be varied from 10,000 to 100,000 pounds (44.48 to 444.8 kN). The K- Prop is composed of only 3 pieces and laboratory testing has suggested that it can be installed by a pair of workers in less than two minutes. The speed of installation of the K-Prop should significantly reduce the total installed cost for supplemental support and should provide a safer working environment by prestressing the prop, which will add support load to the roof and floor during installation.

Jan 1, 2005

The effects of corrosion upon the load bearing capacity and ultimate tensile strength of galvanised friction bolts were determined. Corrosion rates were measured by overcoring of the reinforcement elements in situ. Overcoring was achieved at several sites using a specifically designed overcoring drill rig. This rig has the capacity to drill up to 3.0m long 140- diameter core in any orientation and up to a collar height of 7.0m. The recovered core and friction bolt elements were pull tested in the rock mechanics laboratory at the WA School of Mines (WASM) in order to determine their load-displacement characteristics for various embedment lengths. The friction bolt elements were then analysed for rates of corrosion and tested for their ultimate tensile strength. Relationships were formed between these data and the environmental conditions to which the friction bolts were exposed, in order to determine the major factors affecting the corrosion process and how they affect bolt performance.

Jan 1, 2005

By R. Karl Zipf

Multiple seam mining interactions caused by full extraction mining, whether due to undermining or overmining, frequently involve tensile failure of the affected mine roof. The adverse ground control conditions may prevent mining for both safety and economic reasons. Prior researchers have identified the geometric, geologic and mining factors controlling multiple seam mining interactions. This numerical study examines the mechanics of these interactions using a modeling procedure that 1) incorporates the essential constitutive behavior of the rock such as strain- softening of the intact rock and shear and tensile failure along bedding planes and 2) captures the geologic variability of the rock especially the layering of weak and strong rocks and weak bedding planes. Specifically, the numerical study considered the effect of vertical stress, interburden thickness, and the immediate roof quality of the affected seam in both undermining and overmining situations. The models show that for overburden-to-interburden thickness (OBAB) ratios of less than 5, interactions do not occur, and that for OBAB more than 50, extreme interaction is a certainty. In between, the possibility of an interaction was found to depend on gob width-to-interburden thickness ratio, site specific geology and horizontal stress to rock strength ratio in addition to the OBIIB ratio. The models also showed that horizontal stress was profoundly altered well above or below a full extraction area and that these changes are likely to influence the success or failure of multiple seam mining. The role of horizontal stress in multiple seam mining interactions has received little attention in prior investigations. Four factors control the mechanics of multiple seam mining interactions: 1. vertical stress concentration 2. horizontal stress concentration 3. stress re-direction 4. bedding plane slip bands A combination of vertical and horizontal stress increase and high stress gradients in the vicinity of full extraction areas re-orients principal stresses into a very unfavorable direction. This seemingly small stress re-orientation has a profound adverse effect on bedded rock.

Jan 1, 2005