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By K. Y. Haramy

Deep coal mines with strong roof and floor strata frequently encounter face and rib bursts. The burst problem becomes more severe with increased depth. While the exact causes of bursts are often difficult to determine, localized high stress zones are common to their occurrence. This Bureau of Mines report describes a study at a mine using longwall systems that experienced both face and floor bursts. The study correlates shield loading, entry closure, and forward abutment pressure increases to observed burst occurrences. The results indicate that strong roof strata that overhang behind the longwall supports create additional abutment stress. When caving lags behind the face and the abutment zone does not advance ahead of the face during mining, stresses on the face may increase to a critical level, resulting in a burst. The critical level occurs when the stress in the abutment zone exceeds the ability of the coal and/or adjacent strata to store strain energy. Caving characteristics may be improved by inducing fractures in the roof or by providing sufficient support resistance to shear the roof. Data analysis of a major burst indicated a dramatic increase in floor heave, with a maximum occurring 80 to 100 ft inby the face, and a lag in the cave line behind the face supports. Analysis of the effects of caving characteristics and floor heave on burst occurrences is presented.

Jan 1, 1987

By Thomas Barczak

A new generation of hydraulic mine support prestressing devices has been developed. These thin-walled steel shells are machine-welded and can be inflated with water or any liquid to provide prestressing for a wide variety of roof support products ranging from Can supports to props and cable bolts. With an expansion capability of several inches, depending on the geometry and size of the unit, they can also establish roof contact eliminating the need for wooden wedges or crib blocks that are commonly employed with several standing roof support products. Capable of withstanding pressures from 1,000 to 6,000 psi, these cells are able to transfer roof loading into the support structure without rupturing. A recent development has been the addition of an inexpensive yield valve that provides control of the maximum pressure and load development on the support. This paper examines the performance capabilities of these inflatable prestressing units and the impact they have on the performance of various support systems, including an evaluation of the overall stiffness of the support system and the load control during yielding of the prestressing unit. Recommendations are made regarding the design requirements of the prestressing unit to optimize the support performance. A summary of mine applications using this technology is provided with general comments regarding their impact on ground control.

Jan 1, 2004

By Christopher Mark

The past decade has provided a wealth of practical experience with longwall pillar design. Design formulas developed specifically for longwalls have proven their value in numerous applications. Analytic methods, including numerical models, have a1 so made important contributions. These advances have been based on basic research into abutment loads, coal pillar mechanics, and the interaction between pillar performance and entry stability. The goal of this paper is to review the state of the art in longwall pillar design from the standpoint of the practitioner. Actual case histories are presented to illustrate the current capabilities and limitations of pillar design methods. The paper also discusses the advances that can be expected in the future.

Jan 1, 1990

By Z. T. Bieniawski

A major study was performed on determination of long term strength of coal strata directed to the design of coal pillars to ensure their stability beyond the life-time of a mine. Based on field investigations, numerical modeling and reliable data from 12 case histories, three aspects of time effect in the strength of coal strata were studied; (1) strength reduction based on the concept of volumetric strain estimate from in-situ tests, (2) strength reduction in terms of three failure criteria applicable to coal strata: original Hoek-Brown criterion, modified Hoek-Brown criterion, and Generalized criterion, and (3) long-term strength estimation as a function of coal strata quality RMR based on case studies. From these investigations, an integrated approach to long-term pillar stability is proposed, based on numerical modeling and empirical pillar strength formulation. The values of factors of safety for coal pillars are analyzed in terms of probability of failure and practical meaning for mine design purposes.

Jan 1, 1994

By J. S. Oram

Maltby Colliery, operated by RJB Mining (UK) Ltd is successfully mining the Parkgate seam in Yorkshire at a depth of 1000m using longwall retreat. Extraction in the Parkgate seam is influenced by interaction from previous workings in the Swallow Wood Seam 160m above. The paper describes in-situ stress measurements and simple gate road convergence measurements carried out to assess the extent of the interactive influence. The stress measurements, obtained using the stress relief overcore technique, were carried out from a maingate development roadway in an area where the stress redistribution under an overlying pillar and adjacent panel goat could be measured. The measured vertical stress distribution confirmed a significant interactive influence with high imposed vertical stresses under the overlying panel edges. Simple roadway convergence monitoring stations established in the gateroads of a retreating panel and in the development gateroads of the adjacent panel, confirmed higher rates of roadway deformation relating to overlying panel edges and pillars, particularly in the areas where a vertical stress window developed during panel retreat. In addition to highlighting a close relationship between closure rate and the measured vertical stresses, the convergence monitoring proved valuable in establishing characteristic deformation behaviour under specific interactive influences and also in defining the optimum location, extent and time of installation u£ additional roadway support and reinforcement. The information from the measurement programme has enabled the Mine Management to gain a better understanding of the interactive influences on roadway behaviour and was instrumental in designing the layout of panels in an area of the North East district of the mine where previous experience had indicated the combined influence of high interactive stresses and weak roof lithology resulted in difficult strata conditions both at development and on panel retreat. The planned location of panels and gateroads took into account both mining operational considerations and the need to avoid potentially high risk interaction zones as highlighted from analysis of the monitoring results. To obtain additional data on parameters influencing roadway deformation, extended roadway convergence monitoring has been established.

Jan 1, 1997

By J. K. Whyatt

A comprehensive survey of mine seismicity and rock bursting during development of two sublevels at the Lucky Friday Mine, Mullan, ID, USA, was conducted to better define rock failure mechanisms and sources of ground control hazards. Survey data included rock burst damage reports, seismic event locations and magnitudes and, for the most energetic events, first-motion information. Several subsets of this database, including large seismic events, rock bursts, and microseismic activity near the face, were analyzed. Elements of the large-event and rock burst data sets were nearly independent. That is, there was no relationship between the risk posed by a seismic event and its energy, although such a relationship is well established for the mine as a whole. All data sets showed that certain geologic features appear to control the spatial distribution of events and the spatial distribution of rock burst risk. The data also suggest that. within the scope of this study, the greatest risk of injury occurs when a pocket of heightened rock burst risk is first encountered and that this risk is controlled when miners adapt their practices to these conditions. Recognition of the role of particular geologic features in the spatial distribution of rock burst hazards provides an opportunity for anticipating, rather than only reacting to, a changing level of rock burst hazard. However, much work will be required to make good on this promise.

Jan 1, 1998

By David Bigby

The paper describes research undertaken on an ECSC/K HSE project which investigated several potential physical principles which might be harnessed to provide a non-intrusive means of determining the extent of failure in the near roof of mine roadways and tested the most promising in the laboratory and in the field. It was concluded that the principles which warranted further development were thermal response and laser vibration measurement. In the latter case there is a need to develop an efficient means of imparting energy to the seam to induce sufficient vibration. A new, SIMRAC funded Project will progress work in the field of thermal response.

Jan 1, 2004

By John Cassie

The condition of roadways in the Deep Main seam at Asfordby mine, operated by RJB Mining (UK) Ltd, is strongly dependant on drivage direction relative to the maximum horizontal stress. The mine is laid out with gate roads driven approximately parallel to the maximum horizontal stress giving favourable drivage conditions. This has led to particulary difficult conditions for face installation headings which have to be driven to an increased width and at a high angle to the horizontal stress. A solution to the formation of face headings is described making use of stress relief with the face heading being driven in the zone of reduced stress surrounding a previous heading. In implementing this solution use was made of results from computer modelling and detailed monitoring of roadway behaviour. High reinforcement densities including cable bolts were used in supporting the headings. The experience provides an example of a traditional technique being applied more scientifically. The results obtained demonstrate the effect of stress relief and reinforcement methods in altering drivage conditions and suggest possible alternative strategies for the formation of future face headings in these conditions.

Jan 1, 1997

By Thomas M. Barczak

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

Jan 1, 1994

By David Oyler

Unusual circumstances may require that a longwall retreat into or through a previously driven room. The operation can be completed successfully, but there have been a number of spectacular failures which exposed miners to serious roof fall hazards. To help determine what factors contribute to such failures, the National Institute for Occupational Safety and Health (NIOSH) compiled a comprehensive international database of 130 case histories. The cases include five failures where major rock falls occurred in front of the shields, and six even more serious failures involving major overburden weighting. This suggests two room failure mechanisms. The first is a roof fall type failure caused by loading of the immediate roof at the face as the fender narrows. The second is a weighting type failure caused by the inability of the roof to bridge the recovery room and face area, and affecting rock well above the immediate roof. The data indicate that the roof fall type of failure is less likely when intensive roof reinforcement (bolts, cables, and trusses) is employed together with higher-capacity shields. The overburden weighting failures, in contrast, occurred when the roof was weak and little standing support was used.

Jan 1, 1998

By T. P. Mucho

Mine roof failure due to excessive horizontal stress has been recognized as a major cause of hazardous roof conditions in some mines. Stress measurements gathered by the U.S. Bureau of Mines (USBM) at 24 different eastern mines show horizontal stress to be typically 2 to 3 times as great as vertical stress. The focus of current Bureau work is to develop detailed design parameters to assess and control the effects of horizontal stress. To facilitate the recognition of horizontal stress effects and to easily determine principal stress direction without resorting to cumbersome, expensive, and time consuming field measurements, the Bureau has developed a stress mapping methodology. Stress recognition and direction determination are required to successfully employ a number of control strategies such as mine layout, mining sequences, and support optimization to control the effects of horizontal stress, thereby increasing the safety of U.S. coal mines. This approach has been used in other major coal producing countries, most notably Australia and the UK, and has greatly enhanced the safety of their mines (1). This paper discusses horizontal stress, directional based control techniques, and provides guidelines for the use of the stress mapping technique. A case study of a mine where the technique has been used is also presented.

Jan 1, 1994

Since the initial development and trials of FLEXIBOLT flexible roof bolts, further comparative testing and product development has been completed as part of the changeover to this roof support system at two Australian longwall operations, Ellalong and Angus Place Collieries. Details of the practical implementation of FLEXIBOLTS at both collieries are outlined together with their impact on roadway development rate productivity. At Ellalong where fully encapsulated 2.1 m long bolts are used, the reduction in bolt density is discussed with respect to both support system design and work force acceptance. The impact of shear deformation on bolt loading is described. Bolts longer than the working height have been required at Angus Place to achieve a suitable bolt anchorage horizon. Details of the long hole drilling and the benefits of a two stage grouting procedure are outlined. Improvements in roof conditions which have resulted from the inclusion of FLEXIBOLTS into the overall roof support strategy at Angus Place are described. Their importance to the viability of the Angus Place operation is also highlighted.

Jan 1, 1994

By David J. Reddish

Longwall systems are inflexible in layout, intolerant of disruption and represent a substantial investment. It is therefore essential drat all understanding of the likely strata behaviour and support requirements is obtained prior to panel development. For many tears rock mechanics engineers have applied numerical modelling based kill finite element techniques to the design of the support and layout of underground excavations. Whilst such design methodology has worked well in civil engineering and hard rock situations, it has been less reliable when applied to excavation design in the soft rocks of the coal measures. This lack of reliability has been identified largely as being the result of the utilisation of unsatisfactory input data, This paper describes the results of an ongoing research programme at the University of Nottingham in which a novel rock mass rating system known as the UK Coal Mine Classification system was developed to enable the prediction of the strata properties that are required as input parameters for use in numerical modelling of the deformation of soft rocks around excavations such as roadways and longwall faces in coal mines. The paper describes the development of the system. the way in which classifications are applied to derive input data for numerical models and gives two case studies ill which deformations and stress re-distributions around coal mine excavations have been simulated by numerical modelling using the FLAC finite difference code.

Jan 1, 2000

By Andre Vervoort

The roof in coal room and pillar panels is normally stratified and can be thought of as beams or plates supported by the pillar sides in the roadways and by pillar corners in the intersections Underground measurements showed the effect of the face advance on the additional total movement of the roof skin and on the relative movement between various layers in the roof. The latter consists of the opening of bedding planes and of the lateral sliding of layers over one another. Both phenomena increase locally the axial load along full column anchors. Four models have been used to come to a better understanding of the roof behavior: a beam either clamped above the pillar side or laying on the pillar sides and a three-dimensional boundary clement model with and without bedding planes. The shape ref the curvature of the roof deflection is host approached by a clamped beam: the other models overestimate the movement at the sides. The largest roof deflection for a given Young's modulus is estimated by the model incorporating bedding planes. This model estimates that the bed separation occurs close to the face (within the first meter) and within 0.2 m of the sidewalk. In some simulations, openings are even recorded just ahead of the face. Further underground measurements should focus on these findings, as the effectiveness of the support is directly related to the amount of bed separation and sliding, which have occurred prior to the support installation and which still cart occur abler installation.

Jan 1, 2000

By Gexin Sun

This paper presents the physical modelling results of subsurface fracture development associated with longwall mining operations and an application of image processing techniques to interpretion of the results. Physical modelling results have been obtained by employing a large sand and plaster model loaded purely by gravity as a means of fracturing the subsurface strata above the longwall excavation. The results have shown fracture development and crack propagation as a longwall face advances and demonstrated that the strength of stratified rocks, the presence and position of a weak band-, and the extraction thickness, have significant effects upon the overall fracture patterns above the excavation. Binary images of fracture patterns were scanned from the black and white photographs of the tested models using an image analyser coupled to a video camera. These images were manipulated by a custom written C program which allows the images to be processed in both vertical and horizontal direction. The images were filtered to quantitatively differentiate between vertical and horizontal fracture intensities. The vertical fracture intensity is particularly important as vertical fractures are considered to provide the main avenues for surface and subsurface water inflow into the excavation. The use of the image analysis techniques has shown a promising improvement in image enhancement and in model results interpretation in a quantitative manner. The numerical nature of the image analysis results will allow further statistical comparison with other modelling techniques to be undertaken and significantly increase the scope for use of the modelling technique results.

Jan 1, 1992

By K. Y. Haramy

Strong roof helps minimize roof fall problems in coal mine entries. However, the Inability of strong roof to cave readily may contribute to major ground control problems In Iongwall and retreat mining operations. The concern expressed by mine operators prompted this Bureau of Mines study to analyze the effects of strong roof members on ground stability around Iongwall openings. The problem was approached from three directions: development of a theory to analyze the strain energy conditions In the coal and surrounding strata, modeling the effects of different thicknesses and strengths of Coal and roof strata, and field Instrumentation of powered supports In two Iongwall mines. Results from the theoretical and modeling analysis confirm the accepted belief that a strong roof does, In fact, play a major role in high stress concentration problems In and around the Iongwall panel. Analysis of the effect of different roof overhang dimensions and properties on relative strain energy buildup In the coal and roof Is presented. Shield pressure data Indicate possible methods for detecting noncaving roof behind the shields. Strategies to monitor roof overhang and control dangerous conditions caused by the noncaving roof are also presented.

Jan 1, 1988

By Gift Makusha

Pre-feasibility work at Goedehoop Colliery indicated that stooping of the undersized pillars could be undertaken safely and economically. In light of the findings a decision was taken in may 2003 to undertake the project in the 600 area where three panels (628, 630 and 632) were identified for pilot test sites. The findings of the pre-feasibility studies were presented in a paper to the 22nd International Conference on Ground Control in Mining held at Morgantown in 2003 (1). This paper is a progress report for the project 12 months down the line. Work commenced to prepare the sites for mining including, acquisition of equipment, equipping the panels, selecting and training people to undertake the project. Three monitoring sites were set up distributed evenly along panel 628. Each site comprised of a surface extensometer station in the overburden strata adjacent to a pillar underground containing hard inclusion vibrating wire extensometer cells. This combination would be used to record pillar loading ahead of stooping as well as the depth of caving and strata deformation in the goal zone behind the stooping face. In July 2003, support work began to secure the roof and rib sides. The support was required to be at least three-pillar center distances ahead of the mining front to ensure that the effective stooping zone is secured at all times. The NEVID method of pillar extraction developed at Sasol and described in detail by Ismet and Moolman (2) in a Coaltech 20-20 report was adopted for the pilot project. As part of training the selected stooping team was send for a week to Sasol's Bosmanskrans Colliery to familiarize with the NEVID method of stooping. Further training sessions were carried out on site especially on the use of Mobile Roof supports. The first cut was taken on 20 August 2003 by implementing a form of chequerbord mining taking every second row of pillars. Three rows were mined this way which period was considered training to get workers familiar with the new equipment and mining method. On the fourth row the full design span equivalent to mining 4 pillars in a row was implemented taking out all the pillars in successive rows. Production figures gradually increased from 300 to more than 1,000 tons run of mine coal per shift. Panel 628 was mined out at the end of December 2003 and the second of three panels (630) is being mined. Substantial data from the monitoring set up has been recorded since the start of the project. Monitoring will continue to the end of the pilot project and the data will be analysed and fed back into the design tools to improve the design in future undertakings. The pilot project has been a success so far and other old workings are being evaluated for stooping.

Jan 1, 2004

By William J. Gray

The Roof Control Division of MSHA's Pittsburgh Safety and Health Technology Center has been conducting a program to evaluate methods employed by the U.S. coal mining industry during recovery of longwall faces. The objective of this effort is to provide information on safe and efficient roof control methods currently being used to recover longwall faces. In addition to a literature review and extensive contacts with MSHA and industry personnel, 14 mines were visited to observe firsthand various aspects of longwall recovery. It is hoped that the dissemination of this information will aid in the prevention of accidents and a reduction in costly downtime during recovery.

Jan 1, 1993

By Z. T. Bieniawski

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

Jan 1, 1981

By Liang Yinhuai

The hydraulic-stowing mining method is most effective for mining thick coal seams. It is superior to the sliced cover-caving and artificial mining method and the fully mechanized sublevel-caving mining method for the following reasons - a much higher recovery rate is achieved, there is much less surface subsidence and roof pressure, there is no hidden danger of gob fire, and much less methane emission and coal dust problems, etc.. However, its superiority is overshadowed by its backward stowing technique which makes mechanisation of mining and stowing difficult, causes bleed water interference to production and to the environment and is uneconomic because of the high cost of stowing material. These disadvantages limited its application to coal seams that are difficult and not suitable to be mined by other mining methods. The remedy is in reforming it thoroughly to permit mining of otherwise unminable seams and this paper presents the reformation.

Jan 1, 1992