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By Sun Henghu

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

Jan 1, 1992

By C. Srinivasan

Microseismic emissions are generated by deformation and cracking of rock around an opening inside a mine. The rock tends to achieve equilibrium in a new geometry under changing stress conditions was found to provide useful clues to the impending roof falls and ground instability. The typical characteristics of these microseismic event patterns is shown to be of diagnostic value in sensing in advance rook fall that invariably follow such events. In most of the longwall faces, the main problem faced was due to strata behavior in the presence of massive sandstone bed, which is generally difficult to cave. Microseismic monitoring system was used to monitor strata behavior during longwall mining operation at Rajendra underground coal mine of South Eastern Coal Fields limited (SECL). More than 44,000 microseismic events with local magnitude between -3.4 and 0.5 were recorded during the monitoring period from September, 2001 to March 2003. Analysis of these events was correlated with respect to roof falls. The time series of range of source parameters such as Radiated energy, seismic moment, Energy Index, Seismic Schmidt number, time of occurrence and location of fractures before and during roof fall exhibit qualitatively distinct patterns about six hours before roof falls. &ong the several seismic parameters investigated the microseismic event rate as precursor was found to be most significant indicator of an impending roof fall. The results are discussed as case study in this paper.

Jan 1, 2005

By Jun Lu

The Pittsburgh seam is the most extensively mined coal bed in the Appalachian Basin. Unlike most other prominent coal seams, the Pittsburgh seam typically includes a sequence of immediate roof coals and intervening rock binders (or ?draw slate?), most of which are within mineable horizons. Furthermore, unlike the main bench, the thickness of the overlying roof coals and their intervening rock binders can vary significantly. For instance, in southwestern Pennsylvania, the Pittsburgh seam main bench typically ranges from about 5.0 to 6.0 feet thick with minimal variation over short distances. On the other hand, the Pittsburgh seam roof coals and immediate roof binder typically range from a few inches to several feet, and in certain geologic settings can vary significantly over short distances. Additionally, in some locations, very thick draw slate can totally replace the roof coals. Since the draw slate, which typically consists of claystone or clayladen shale, is relatively weak, the presence of thick and variable draw slate in the roof and rib can significantly affect mine safety and productivity. This paper presents the adverse effect of thick draw slate on a 1500-foot-wide longwall face in a southwestern Pennsylvania coal mine. Mapping of the thick draw slate, numerical models which illustrate stress distribution and failure associated with thick draw slate, and operational adjustments instituted to mitigate the negative impact of thick draw slate will be discussed in detail.

Jan 1, 2013

By Ryan Garvey

A numerical investigation is made into unstable failures of coal pillars (i.e. coal bumps) using the finite difference software FLAC3D. A static energy balance is first derived to calculate the excess energy released as a consequence of unstable failure in rock. Two- and three-dimensional mining layouts are then assessed on their bump-potential based on the magnitudes of excess energy released during simulated pillar failures. A three dimensional pillar model is developed to represent tributary area loading of an infinite room-and-pillar layout. Pillar strength and brittleness characteristics are calibrated using a Mohr-Coulomb strain-softening constitutive law to simulate width-to-height ratio coal pillars ranging from 1:1 to 5:1. Width-to-height ratio pillars 1:1 to 3:1 release large magnitudes of excess energy as the pillars fail, representing massive collapse of room-and-pillar layouts. The larger pillars maintain their residual strength during failure; however significant excess energy is still released during temporary reductions in pillar strength. A two-dimensional model is then constructed of a gate road pillar failing due to elastic rebound of the surrounding rock mass. Soft loading conditions initiate unstable failure for all pillar widths, while the total magnitudes of excess energy increase with the size of pillar being modeled. The results from these tests indicate that excess energy may be used as a direct assessment of the bump potential of simulated mine layouts.

Jan 1, 2013

By Thomas R. Scotese

A rock mechanics instrumentation and monitoring program was implemented during pillar extraction at Gulf Mineral Resources' Mt. Taylor Mine, the deepest uranium mine in the U.S. Three types of monitoring were employed: (1) drift convergence around stopes (using a portable tube extensometer), (2) stress changes in pillars (using vibrating wire stressmeters in horizontal boreholes), and (3) load changes in haulage ways under stopes (using vibrating wire load cells in jack stands). Results include convergence-time graphs, convergence contour maps, stress-time graphs, a stress increase contour map, load-time graphs, and abutment load limit maps. Major factors influencing results include (1) size of pillars around the extraction area, and (2) presence and orientation of a major fault adjacent to one extraction area. These factors, combined with pillar extraction, produced evidence of load transfer over 120 m from a stope measuring only 55 m x 45 m. Vertical stress increases of 7 to 17 MPa (1000 to 2500 psi) within 60 m of the stope were obtained using the stress- meter manufacturer's method. The fault apparently prevented load transfer in the down-dip direction but increased load transfer in the up-dip direction. Convergence rates of up to 1.3 cm/day (0.5 in/day) were measured at two stations. Instruments were generally reliable despite adverse underground conditions. The instrumentation and monitoring program at Mt. Taylor provided a warning system against ground control problems and a characterization of ground behavior for future development and extraction of pillars. Recommendations are made for future mining and instrumentation practices.

Jan 1, 1984

Virtually all mineable Appalachian coal seams exist in a multi-seam environment. This makes it inevitable that most seams will eventually experience interaction induced ground control and mining problems. Indeed, it has been estimated that every working face will experience interaction effects from previous or current workings at least once during its lifetime (1), and that these problems are considerably exaggerated when seams are in close proximity -- a distance of less than 110 feet. The continued increase in multi-seam problems has resulted in considerable research activities over many years (2,3,4,1). Theoretical analysis, numerical and physical model studies, statistical and empirical analysis of numerous interaction related field data have been applied to multi-seam mining situations and have identified many useful trends and design criteria (4,5,6,7). To fully utilize research results and transfer multi-seam mining technology to field engineers, a design model -- USEAM was constructed (8). This model, designed for close seam under-mining situations, was computerized to facilitate utilization. In the current research, a new computer program "MSEAM" was developed to produce a model for both under- and overmining close seam situations. It is hoped that both of these software packages will aid field engineers in using important interactive design criteria to gain a better understanding of interaction mechanisms. Through advance planning with these programs, detrimental interaction may be avoided and minimized, and occasionally a design can be selected which will allow interaction effects to be utilized to the benefit of mining operations.

Jan 1, 1987

By Charles D. Albright

FMC built its first angle bolter in 1969. This was a single mast unit which could drill holes for conventional bolts or angle holes for installing roof trusses. From this drill we learned very quickie that the mast design was an important factor to the success or failure of any angle bolter. The first mast installed on this machine (EXHIBIT 1) was fixed in length with endless chain and hydraulic motor feed. It took less than a shift underground to determine that the fixed length was not going to work. The undulating top created conditions where the mast was too long to be positioned at a 450 angle. Several mast designs were tried and discarded before we felt we had the answer to our problems. (EXHIBIT 2} We developed a mast that would extend or retract without moving the position of the drill unit. This allowed the operator to "wedge" the mast between the floor and roof before starting his drill feed. This arrangement worked exceptionally well, but unfortunately the demand, as perceived by our Sales Department, for angle bolters did not materialize. This unit became an "orphan" and was used by many coal mines until it died a natural death. FMC did not decide to re-enter this market again until 1979. At this time many coal producers were contacted to determine what features should he incorporated into a dual mast angle bolter. From this information we were able to arrive at three main areas of concern that we should consider when designing a new machine. 1. Eliminate overturning moment on drill unit. 2. Provide some sort of steel support near roof line to aid in starting a 15° hole. 3. Dual mast units need a method of raising center of mast rotation to facilitate various mining heights and still maintain a 45° angle and proper distance from rib. I would now like to discuss each of these individually. EXHIBIT 3 indicates the overturning moment resulting from the feed cylinder thrust and the reaction of the drill hit against the roof. To eliminate this moment a mast was designed using two feed cylinders mounted in the plane of the drill center line, thus removing all overturning moments on the drill unit carriage. This mast has been used extensively in vertical drilling with no downtime attributed to wear on mast guides and drill unit supports. The cylinders are designed to provide uniform thrust and feed speed throughout the total stroke. For manufacturing and economic reasons, the final mast design on the first drill was not used for this new drill. A drill steel support mounted on the mast, and positioned by a hydraulic cylinder provides the needed guidance near the roof for starting a hole at a 45° angle. (EXHIBIT 4) This support does not surround the drill steel but simple cradles the drill steel for "collaring" the hole. Once the hole is started, the support can he lowered. The support plate is hinged to allow the drill mast to pass. The advantage of having vertical motion of the center of rotation on a dual mast drill is shown in EXHIBIT 5. Following the criteria recommended by Birmingham Bolt Company, the truss bolts should he at a 45° angle and one fifth of the width of the entry from the rib. Therefore, in an entry 20 ft. wide, the hole should be drilled 4 ft. from the rib and at the 45° angle previously mentioned. With the limitations inherent to dual boom drills, that is, the masts cannot pass each other nor can one mast pass the center line of the machine even if the other is positioned out of the way, it is impossible to accommodate much variation in seam height and maintain the recommended criteria. As shown in EXHIBIT 5, a center of rotation 17 inches above the floor will start a hole 4 ft. and 45°angle at a height of 67 inches. Any height above 67 inches

Jan 1, 1982

By Keith Heasley

In this paper, a state-of-the-art, three-dimensional, full waveform, microseismic system was used to analyze the rock failure around a deep (> 750 in (2500 ft) of cover) bump-prone longwall panel. The microseismic system consisted of both underground and surface geophones coupled through radio telemetry and a fiber-optic network to produce pseudo real-time detection and location of seismic events surrounding the coal seam. This was the first microseismic installation of this scope at a U.S. coal mine, and the system was intended to help determine the exact strata mechanics associated with the redistribution of stress and the associated gob formation at one of the U.S.'s deepest longwall mines. Overall, 5,000 calibrated seismic events were recorded during the mining of one panel, including a Richter magnitude 4.2 event which occurred inside of the array. Analysts of these events provides a number of notable insights into the rock mass behavior. For instance, the longwall panel was widened during the retreat process, and the mining-induced seismicity shows a distinctly different behavior between the start of the panel, the mining of the narrow part of the panel and the mining of the wider part of the panel. Also, in itself, the acquisition of the ML 4.2 event was a major milestone in geomechanical and bump research. This is the first time that such an event has been recorded with this detail and accuracy at a bump-prone coal mine in the U.S. `The analysis of this single event has set distinct new limits on the relationship between mining seismicity and coal bumps.

Jan 1, 2001

By Jaco J. van Vuuren

Modikwa Platinum Mine, in the Eastern Bushveld of South Africa's Limpopo Province, is a new operation employing a hybrid mining method where mechanised methods are used for the main developments and the narrow, 60cm reef is conventionally stoped using a down-dip conventional mining method. Throughout the mine, the hanging wall immediately above the reef comprises 3 jointed and laminated layers of varying thickness, commonly known as the triplets, below a non-cohesive leuconorite parting plane. At North shaft, using pre-stressed standing support and mechanically anchored rockbolts, it was found difficult and hazardous to hold all three triplets in the hanging wall, however bringing them down caused a significant increase in dilution and therefore cost of mining. A novel solution was conceived whereby two of the triplets are kept up using short, stiff resin anchored rockbolts installed systematically within 0.5 m of the face. This resulted in both safety and productivity benefits. The rockbolts create a stable and safe hanging wall and allow the mine to extract UG2 reef more economically. New drilling equipment, developed locally from available drilling technology, can be operated from a safe position, and in situ tests and measurements are made to confirm effective support. The technology and underlying concepts were successfully tested in a trial stope prior to rolling out the new support system across all the stopes at North Shaft. This has involved an extensive training programme to ensure that the rockbolt system is installed correctly and that the conditions are appropriate for this technology. The paper describes the motivation behind the project, the underlying technology and its application to Modikwa, and the benefits now being realised.

Jan 1, 2004

By Gift Makusha

The Witbank Coalfield in South Africa contains up to five economically viable coal seams. These seams have been mined continuously for over 100 years and the reserve in now becoming depleted. The normal mining method has been bord and pillar with examples of stooping. The situation now occurs where the formed pillars, left to maintain stability, have a higher quality than the coal that is left in the unmined reserves. Where the reserves are less than 70m deep and continuous over several kilometers, opencast mining is being successfully applied. After several years of investigation, Anglo Coal has identified blocks of coal that warrant investigation with regard to pillar extraction by underground methods The proposed method is pillar extraction using Mobile Roof Supports (MRS) It is proposed to mine three panels at a depth of 120m, by keeping the panels narrow and sub-critical. The sub-critical layout does not allow caving to surface and more stress is thrown onto the barrier pillar rather than the face pillars. The sub-critical span is anticipated to be 100m. The paper describes the full geotechnical investigation, including numerical modelling, instrumentation and drawing on the local South African experience of shortwall mining. The project will be unique in that pillars were not designed for pillar extraction and have low factors of safety (l.4 - 1.8) and width to height ratios of less than 4. The mining height will be approximately 4-4 5m, and this represents "new" operating heights for Mining Roof Supports. The required equipment was ordered in late 2002 and pillar extraction is anticipated to begin in June 2003.

Jan 1, 2003

By Andrew P. Schissler

Cyprus Shoshone is an underground coal mine in southern Wyoming owned by Cyprus Coal Company, a subsidiary of Cyprus Minerals Company. To date, seven longwall panels have been extracted from the pitching seam under increasing depth of cover from 150 ft to 1200 ft. The purpose of this paper is to describe the geology, rock mechanics needs identification, design, testing and successful application of the current headgate/tailgate cribbing system. The immediate roof of the Shoshone is unique in that the first 50 ft of lithology is interbedded mudstones. The mudstone is slickensided, highly friable and has characteristics of unconsolidated fill relative to self-spanning and beaming abilities. Finite element modelling analysis of the overall geomechanical environment showed the mudstone to yield under applied longwall abutment stress. Roof bolt system design methodology also pinpointed the relative weakness of the mudstone roof. In-mine entry vertical convergence and weight response from the mudstone identified the need to design a crib which had superior weight capacity over a wide range of convergence. Design of a structure ensued to achieve the superior strength properties of wood parallel to the grain and the displacement properties of wood perpendicular to the grain. Testing of the prototype structure along with other alternative wooden cribs was done at the U.S. Bureau of Reclamation facility in the Denver Federal Center, Colorado. The test results verified the design. Crib placement pattern was chosen to maximize support with a confined core crib under the high convergence area. The design has been successfully installed in over 5,000 ft of headgate entry in the 11 left panel.

Jan 1, 1993

By Christopher Mark

After the United States and Australia, South Africa has the largest. modern underground coal mining industry in the world. Historically, South Africa has been the cradle of many innovations in ground control, particularly in the area of pillar design. Today, South African mines are grappling with many of the same issues faced by their U.S. counterparts, including safety during pillar retreat operations, selecting the proper roof support, and maintaining long-term pillar stability. The author recently visited seven underground mines in the Mpumalanga, Free State, and KwaZulu-Natal provinces. Mining methods included longwall, room-and-pillar with continuous miners, and drill-and-blast. The mines represented a cross-section of geology and ground support practices. At each mine evaluations were made of the Coal Mine Roof Rating (CMRR), roof support practices, pillar design methods, and general ground control experience. The coal seams observed were generally thick (2-5 m), the depths of cover moderate (less than 200 m), and the roof rocks relatively strong (CMRR greater than 45). Unfortunately, the South African roof fall fatality rate is approximately three times greater than in U.S., perhaps in part because roof bolts seem to be more widely spaced in most South African mines. Roof bolting equipment was generally outdated, and the quality of bolt installation was a major concern. Pillar design, on the other hand, is quite advanced, and pillar failures are rare. Several novel partial pillaring techniques are employed, including "checkerboard" mining in which every other pillar is removed, 3-cut systems, and high-extraction mining where engineered final stumps are left by design. The paper also offers observations on ground control management techniques (including recently introduced Codes of Practice), the role of the mine inspectorate, and the status of the research community.

Jan 1, 1999

By N. P. Kripakov

This paper presents a brief overview of current bump mechanics theories and pillar design methodologies, and relates these concepts to experiences at two mines located in a north-central Utah coalfield where different pillar designs were used to control mountain bumps. Experiences gained at the first mine demonstrated the successful implementation of a two-entry, 9.8 m (32 ft)-wide, yield-pillar design. A U.S. Bureau of Mines field study quantified the timing of chain pillar yielding and resulting load transfer from the gateroad. In-mine pillar response, although apparently sensitive to site-specific conditions, compared favorably to estimates derived using two yield-pillar design methods. A second study conducted at another mine located in the same district, but subjected to different geologic conditions, documents the unsuccessful attempts to employ progressively narrower three-entry pillar designs based on successes achieved at the first mine site. This second mine never achieved a true yield-pillar design. Use of pillar widths ranging between 9.1 m (30 ft) and 27.4 m (90 ft) always resulted in violent bumps in the tailgate pillars. The pillars were either too large to yield, or too small to support peak operational loads. Hypothetical gateroad systems were evaluated using both analytical and empirical approaches for configurations comprised of two rows of conventional pillars, and systems incorporating both yield and abutment pillars. Analysis concluded that yield pillars less than 6.1 m (20 ft) wide and abutment pillars ranging between 30.5 m (100 ft) and 39.6 m (130 ft) square would be required to achieve a stable gateroad design. However, results of a field study conducted on a two-entry, 36.6 m (120 ft)-wide abutment pillar concluded that abutment pressures from the first panel overrode the pillar, and that a still larger pillar may be required to preclude bumps in the tailgate during second panel mining. Without the benefit of a demonstrated in-mine success, it is not clear which design would ensure elimination of gateroad bumps.

Jan 1, 1992

By Michael Gauna

In 2010, the number of fatal rib falls in U.S. underground coal mines exceeded fatal roof falls for the first time ever. While recent trends have seen roof fall fatalities reduced by about 62% since the 1990s (from an average of 9.6 per year in the 1990s to 3.6 per year during the last five years), the incidence of rib fall fatalities has remained approximately constant (about 1.5 per year). In addition, injury incidents associated with pillar rib failure have been steady at approximately 100 per year. The persistence of rib fall injuries, underlined by the recent increase in rib fall fatalities, has led to this investigation of the coal rib failure parameters and methods available to mitigate rib failure in U.S. underground coal mines A detailed study of the 21 fatal rib fall incidents that have occurred since 1995 (excluding coal burst incidents) indicates that the two most important risk factors are the mining height and the depth of cover. The depth of cover was 700 ft (213 m) or greater in 81% of the fatalities, and the mining height was at or exceeded 7 ft (2 m) in every instance but one. Other risk factors included multiple seam interactions, rock partings in the seam, and retreat mining. The accident history reveals that joints or slickenside features within the rib increase the hazard. Approximately threequarters of the rib fatality victims were roof bolting machine operators and continuous mining machine operators. This paper includes a brief overview of techniques for rib control; including bolts, standing support, bent steel straps, and rib strapping. The available mining equipment features for installing rib support and protecting operators from rib falls are also discussed. A proactive approach to rib control using available technologies will lower the risk to miners and is an endeavor that must be pursued to reduce rib fall accidents.

Jan 1, 2011

By Al Campoli

One of the critical variables affecting resin bolt performance is the size of the resin annulus, defined as the difference between the hole and bolt radius. The vast majority of the millions of resin roof bolts installed each year in the United States employ an annulus between 0.125 and 0.188 inch. As the annulus size decreases the resin flow around the bolt becomes more difficult, increasing the resin pressure induced by bolt insertion. As the resin pressure increases the loss of resin into bedding planes and vertical fractures in the rock increases. As the annulus size increases the mixing of the resin paste and mastic becomes less efficient. Thus, the lower and upper limits of the optimum annulus size is determined by insertion pressure and mixing considerations, respectively. Previous U.S. Bureau of Mines researchers have concluded that a 0 125 inch annulus is optimal. However, others have recently reported that a 0.095 inch annulus with special rolled deformation (SRO) bolts provide superior anchorage to standard rebar with a very large 0.250 inch annulus, attributing SRD resin loss in weak ground to oversized holes. The effect of annulus size on unit length pull strength and resin loss to fractured rock was investigated. Short encapsulation pull tests with resin annuluses of 0.125 and 0.095 inch resisted an average of 2.25 tons per grouted inch, with no significant variation. However, annulus size has shown a dramatic effect on the magnitude of resin lost to simulated rock fractures. No. 5 standard . No. 6 standard, and No 7 J-Bar rebar were inserted into two different viscosity resin cartridges designed for 4 foot boll encapsulation into a one inch inside diameter metal tube, To simulate a rock fracture, a 0.250 inch diameter orifice was located near the capped end of the tube Resin loses increased as annulus size decreased, with a minimum loss of 35% and a maximum loss of 60% associated with 0.125 and 0.095 inch annuluses, respectively.

Jan 1, 1999

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

By Daniel Su

Following several roof falls in the E3 longwall development of a Consol Pennsylvania Coal Company underground coal mine, an underground roof geology reconnaissance program consisting of twenty-nine 20-foot deep roof holes had identified the presence of thick sandstone layers with abundant shale and micaceous streaks. The base of the sandstone was 4 to 8 feet above the roof line within the fall areas. The presence of micaceous streaks created extremely pronounced planes of weakness in the sandstone. A structural irregularity, which extends into the E4 and E5 developments, exists between crosscuts I 1 and 30,where all roof falls occurred. Immediately to the east of this structural irregularity lies a huge syncline. The presence of thick sandstone units within the typically all shale environment and within such a structural irregularity helps to maximize stress concentration and creates closely spaced joints in the sandstone, which explains why many cracks are present in the macroscopically massive sandstone upon development. The approaching E2 longwall gob to the south and on the down-dip side, on the other hand, provided horizontal stress relief in the sandstone, which helps to explain the many roof falls in the E3 development that occurred during or immediately after the formation of the E2 gob. Finite element modeling confirmed the presence of such horizontal stress relief. Since the E3 longwall was a right-handed face, stress concentration was expected at the longwall headgate T -junctions, and further delamination of the sandstone was expected upon arrival of the E3 longwall face. Based on the results of the roof geology reconnaissance program and a roof stability analysis that took into account up to eleven parameters, supplemental headgate and track roof support consisting of 16-foot and 20-foot long cable bolts was successfully implemented within the zone of thick sandstone with micaceous streaks and structural irregularity and at other potential roof instability areas along the E3 development. The cable bolts were designed to be anchored at least 4 feet above the sandstone unit into the mostly competent sandy shale layers. No headgate roof control problem was reported within the sandstone and structural irregularity zone during E3 and the subsequent E4 longwall extractions.

Jan 1, 2002

By Alan A. Campoli

"Pumpable crib support for longwall gates and ventilation bleeder entries is becoming more prevalent in United States coal mines (Figure 1). The pumpable crib selection and spacing design has been greatly refined by the full-scale testing conducted at the National Institute for Occupational Safety and Health (NIOSH) Mine Roof Simulator. The peak load on 24-, 27-, 30-, and 36- inch diameter J-Cribs is, on average, 300, 400, 450, and 650 kips, respectively. Standard J-Cribs have useful deformation of approximately 8 inches. The maximum useful deformation can be extended to 18–20 inches with an exterior reinforcement layer or an interior double wall, for all four J-Crib diameters. J-Crib diameter is primarily limited by a maximum 4.5:1 height-to-diameter aspect ratio. Spacing is controlled by immediate roof stability, anticipated pillar deformation, and roof bolting practice. Approximately 500,000 J-Cribs have been successfully placed in 18 different United States longwall coal mines. The selection and spacing of the J-Crib utilized to date is summarized for each mine.IntroductionLongwall productivity and safety depend on ground stability in gate and ventilation bleeder entries. Numerous support technologies have been developed and employed in United States longwall mines since the 1990s to replace traditional wooden cribbing. Many, if not all, of these technologies have been evaluated at the NIOSH Pittsburgh Research Laboratory since the mid-1990s (Mucho, et al., 1999). The NIOSH Mine Roof Simulator has a 3,000-kip vertical load and 24-inch displacement capacity, which has facilitated in-depth analysis of complex multimaterial support technologies like the pumpable crib. The extreme cost and human exposure risk associated with modern longwall mining prevent the trial and error development that would have been required absent the Mine Roof Simulator research. As a direct result of this research, pumpable cribs are becoming a major component of the standing support industry, providing the peak capacity and extended deformation characteristics necessary for successful gate and bleeder support. Recent research by Zhang, et al. (2012) and others have defined the required performance characteristics."

Jan 1, 2015

By John K. Wood

The development of an expanded cement product represents a major advance in the technology of roof control systems. Such a product is gaining recognition as a valuable tool in today's cost- conscious coal mines. The National Coal Board's Bretby Research Lab, in conjunction with Polement Ltd., developed the first lightweight cement for use in the mines of the United Kingdom. The product, Aqualight, is a low-density (about 12.5 PCF) cement with a typical compressive strength of about 19 p.s.i. The final product increases in volume by approximately 15 times its dry powder volume. Aqualight gels in about 2 minutes, becomes self-supporting in 15 minutes, and fully cur& in 24 hours. When subjected to a load, the "cells" within its bubble structure collapse so that the product gains in density and compressive strength while retaining its integrity. Traditional methods to contain and support roof fall cavities through cribbing and blocking are both dangerous and labor-intensive. Aqualight represents a significant advantage over such traditional methods. It is non-toxic, non-cmbustible, and very easy to install. Aqualight can be pumped to the worksite from re- mote locations (as much as 600 feet), thereby reducing danger to men and equipment. Addition- ally, the strength of the cured product can be varied by adjusting the expansion ratio and resulting density. A compressive strength of 150 p.s.i. can be obtained in this manner. Although primarily designed to fill cavities resulting from roof falls. Aqualight has found a wide range of applications in mining industries around the world. In addition to cavity- filling, Aqualight has been used for ventilation stoppings, fire stoppings and emergency fire control, backfilling between arches and the roof and ribs, and backfilling of old workings. Since its recent introduction into the United States. Aqualight has been used by MICON SER- VICES, INC. to fill several roof fall cavities along headgate entries. In all cases, the cavities were contained and the longwall moved through without problems. Roof Pall cavities along main haulage entries and at shaft/slope bottoms have been successfully filled. MICON has also installed Aqualight as backfill material around arches. A current major project is the installation of trial ventilation seals using Aqualight as an alternative to traditional block and mortar construction. Pending MSHA approval, MICON anticipates the use of Aqualight in the construction of both ventilation seals and stoppings. In addition to new construction, Aqualight can be employed to repair stoppings damaged by roof convergence and floor heave. In labor savings alone, this is very attractive for remote stopping repair. Among the many other uses of Aqualight is the backfilling of old auger holes, which will support the highwall and allow access to coal re- serves which are presently sterilized.

Jan 1, 1986

Tailgate pillar and tailgate-face corner humps have been a major threat to longwall coal mines where hump-prone conditions exist. The yield pillar design concept, in which the longwall chain pillars are designed in such way that they can yield in a nonviolent or controlled manner during longwall retreat, has been used in many longwall mines to prevent tailgate pillar humps. However, this practice often shifts the side abutment load onto the tailgate-face corner especially when a massive and strong sandstone member is present within the caving zone or in the vicinity of the coal seam. Therefore, the abutment pillar design concept has also been used in some hump-prone coal mines to minimize the stress concentration on the tailgate panel rib for the control of tailgate-race corner humps. The disadvantage of using the abutment pillar design concept is that it is more costly and puts additional pressure on mine operations for gate entry development and significantly reduces the recovery of coal reserve. In addition to pillar size, panel layouts. such as the panel width and panel orientation also play a critical role in pillar or face humps and should he taken into account. Based Upon the Cyprus mine design and operational experiences at Willow Creek and case studies at other bump-prone longwall nines in the U.S., the authors attempt to identify the critical factors causing coal mine bumps and to introduce some guidelines and criteria for the design of both yield and abutment pillar systems and panel layouts.

Jan 1, 1999