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By Steve Tadolini

Underground roof falls can have devastating effects on the safety of operations personnel, and equipment, and seriously impact production. Immediate steps are usually taken to danger off and secure the area while clean-up efforts are designed and implemented. A critical step, often overlooked due to production demand, is the determination of - why the roof fall occurred so that additional occurrences can be avoided in future developments or what measures can be taken to identify areas that have similar ?symptoms?? Forensic engineering includes the investigation of materials, products, structures or components that fail or do not operate/function as intended. The authors define forensics in ground control engineering as the study of evidence discovered while examining underground roof falls by applying expert observational techniques and established mining engineering principles to determine the probable cause, hypothesize solutions, and design engineering safeguards to prevent reoccurrences. Simply stated, the primary steps in the forensics of underground roof fall techniques are: ? Assess regional and local conditions prior to the event. ? Assess post-event conditions. ? Hypothesize plausible ways in which the pre-event conditions ? became the post-event conditions.Search for evidence that either denies or supports the various ? hypotheses.Apply engineering skill to relate the various facts and evidence into a cohesive scenario of how the event may have occurred. This paper details the proposed technique by utilizing a roof fall case study that required the examination of five primary factors: mine design parameters, excavation geology, method of excavation, method of support, and mining cycle times.

Jan 1, 2009

By Tim Ross

Several shear failures were observed in Shaft #1 at the Mountain Coal Company, LLC, West Elk Mine, after mining longwall Panel 23, 1,100 ft to the east of Shaft #1. It was speculated that this shear damage could be related to differential ground movement caused by in situ stress relief from the ?stress shadow? of the caved zone above longwall Panel 23. A numerical study was conducted to assess the possibility of the shaft shear damage being caused by in situ stress relief and the potential for additional damage to Shaft #1 and two other nearby shafts, due to mining nearby longwall Panel 24. Three-dimensional (3D) models were built in FLAC3D to simulate past and future mining near shafts, the estimated local anisotropic and directional horizontal stresses, and the overlying variable surface topography. The numerical analyses indicated that stress relief due to mining Panel 23 caused the shear damage to Shaft #1and that additional damage to Shaft #1 and the other two shafts, would likely result from mining longwall Panel 24. Additional shear damage was documented in Shaft #1 when longwall Panel 24 was mined, confirming the results of the numerical analyses.

Jan 1, 2006

By Anastasia M. Suchowerska

The design of effective ground support requires a sound understanding of the pre-mining state of stress in the stratum to be mined. Irregularities in the stress field encountered during multiseam mining are governed primarily by the previous mining in the surrounding strata. The aim of this study is to quantify the effects of rock mass transverse isotropy on the vertical stress redistribution in the rock strata beneath supercritical longwall panels. Wilson?s equations for determining the stress distribution induced in and beyond a single longwall panel after it has been mined have been adopted, and a plane strain finite element analysis of an elastic medium, together with the stress changes predicted by Wilson, was used to calculate the final pre-mining stresses in the underlying strata. Values of the independent shear modulus (G¢) of the rock strata, ranging from 0.1 to 1 times the isotropic shear modulus (Giso) in the plane of the strata, and a Poisson?s ratio (?) of 0.25 have been investigated. The key finding of this study is that the predicted magnitude of vertical stress in the transversely isotropic strata beneath a mined supercritical longwall panel is larger and changes more quickly with horizontal distance than is the case for an isotropic rock mass. This finding is of significance for the design of ground support measures in multi-seam mining operations.

Jan 1, 2012

By Bill Kyslinger

In underground mining, machine design is predominantly dictated by mine conditions and individual customer desires. In partnership with Boart Longyear Poland and KGHM, J. H. Fletcher & Company was tasked to design and manufacture a single-boom, single operator drill module for installation of 1.2 meter expansion bolt in a 1.6 meter height mine. The objective was to produce a machine to provide ergonomic improvements for the operator while working in the mine environment. This dictated the requirement for a small easily controlled, maintenance friendly design with a remote operator?s control station. The selected design method was to use starter and finisher drill steels. This combination, requiring a number of mechanized machine motions, provides the ability to drill the required depth in the specified mine height. To accomplish the task from a remote location, a conscious decision was made to employ current technology in the form of small pressure compensated hydraulics and electronic controls. The result of the design method is a modular assembly with each sub-component designed to be replaceable and adjustable independently from other machine components. The low profile remote roof bolting module is made up of six major sub-components. Each major component is painted a different color to help the operator make the visual connection from the drill module to the operator?s control/display monitor. The Stabilizer (White) secures the module between the mine top and floor. The Drillhead (Orange) produces the drilling rotation and torque but also must slide out of position to allow the machine to manipulate the drill consumables. The Drill Steel Carousel (Blue) holds and indexes the starter and finisher steel from position to position. The Manipulator Arm (Green) moves and guides the drill steels and drill consumables from position to position during installation. The Roof Reference Guide (Yellow) locates the mine roof and guides the drill steels and drill consumables into position. The Linear Bolt Carousel (Purple) holds the drill consumables. The low profile remote roof bolting module allows the operator to drill and install a roof bolt manually or automatically with the push of a button. This design substantially reduces the operator?s exposure in the mine environment, as well as inherent pinch points and rotary hazards. Positioning the operator safely in the confines of the air conditioned cab.

Jan 1, 2006

By Takashi Sasaoka

Chain Conveyor Cutter (CCC) is a chainsaw-type machine and originally developed for the construction of underground walls and/or ground improvements. CCC was developed from the accumulated technology of coal mining, combining the cutting technology of a shearer and the fuctions of chain conveyor. The CCC can cut harder soils and soft rocks, and vertically mixes the cut soils/rocks with cementing material selected through the discharging port installed at the bottom of the machine. In Indonesia, highwall mining trials have already been conducted in several coal mines. However, full-scale and regular operations have not been done yet due to the ground and machine control issues from their geological conditions. In order to overcome these problems, the application of CCC to highwall mining systems was proposed, and its applicability and technical issues to be solved were investigated in this research. This paper discribes the characteristics of CCC system and discusses the application of CCC to highwall mining systems.

Jan 1, 2012

By Stephen Tadolini

A unique circumstance created by monitoring a pre-driven longwall recovery room permitted measuring the stresses of a coal pillar throughout its entire life cycle in less than a week. A fender pillar, created in approximately the middle of a longwall panel at a depth of 650 ft, transformed from a solid barrier pillar - to a yielding pillar - to a residual pillar as 3 ft slices were methodically removed with the longwall shearer. The complete transformation, or life cycle, took place in less than 12 hours. The stresses were quickly transferred from the pillar onto the standing pumpable concrete supports and into the outby pillars. Roof to floor closure measurements, combined with the timing of the pillar behavior, provides a detailed look at the uncontrollable convergence of underground mine openings. Pillars remain the most important form of ?primary support? and understanding these life cycles is vital for safe and efficient mine design, in both room and pillar and longwall panel extractions.

Jan 1, 2007

By Gary B. Petersen

The author has developed a seven-step process called the Applied Rock Mechanics (ARM) Protocol that the author has used to solve numerous roof stability problems in mines throughout North America since 1975. It is a practical evaluation process using trained observation, innovative data collection instrumentation, video borehole cameras, analytical processes, and controlled testing methods that have become highly effective in solving ground control problems in every type of underground mine. This paper will describe each of the steps of the protocol and how the rock mechanics engineer applies them to resolve a typical ground control problem.

Jan 1, 2012

By Greg Smith

This paper documents the use of bench testing equipment developed to enhance the understanding of, and improve upon, common roof bolt support systems. Most roof bolt systems consist of components that are covered within the scope of ASTM (American Society for Testing and Materials) standards. However, ASTM does not specify testing methods or performance standards for complete roof bolt ?systems?. It only designates testing methods and minimum performance standards for roof bolt ?components?. Improved understanding and continuous improvement of these systems is essential given the enormous impact that they have on the safety and profitability of underground mining operations. Bench testing equipment has been developed that effectively measures and records multiple points of deformation in a rock bolt support system while load is being applied. With this testing capability, an improved understanding of component and system stress distribution can be obtained and devices and methods for visual load indication can be developed. This paper is formatted as case studies where testing was performed to demonstrate load versus deformation profiles and to develop system improvement products.

Jan 1, 2012

By Andre Zingano

The objective of this paper is to study the effect of annulus thickness on the quality of resin mixture for fully grouted resin bolt. Pullout and mixture tests were made in underground coal mines for the following arrangements: (a) borehole diameter 1.14 in. (29 mm), and roof bolt diameter 0.75 in. (19 mm) with steel wire around the roof bolt; (b) borehole diameter 1.14 in. (29 mm), and roof bolt diameter 0.75 in. (19 mm) with no wire around the roof bolt; and (c) borehole diameter 0.95 in. (24 mm) and a roof bolt diameter 0.75 in. (19 mm) with no wire around the roof bolt. The mixture test in steel pipe showed that the best resin mixture is for borehole with 0.95 in. (24 mm). The arrangement (b) produced big voids around the bolt. But for the 0.95 in. (24 mm) hole, arrangement c, the mixture was the best. It was corroborated with the pullout tests results where there is a difference in grout stiffness: the 0.95 in. (24 mm) borehole is about 10 times higher than a borehole with diameter 1.14 in. (29 mm). On the other hand, for the cohesive strength the difference is not significant. Numerical models were built to simulate the pullout tests, and also to simulate the roof support at an intersection. Convergence at two underground intersections, consisting of an immediate roof with laminated sandstone, was monitored to evaluate the performance of the roof supports, using the 1.14 and 0.95 in. (29 and 24 mm) diameter boreholes (i.e. arrangements ?a? and ?b?). The convergence readings showed that the 0.95 in. (24 mm) borehole diameter resulted in a smaller, although it was not significantly different.

Jan 1, 2008

By Gabriel Esterhuizen

Observations of pillar conditions in limestone mines showed that the presence of weak bands in the limestone can result in pillar damage at stresses that are lower than one would otherwise expect. The objective of this National Institute for Occupational Safety and Health study was to investigate the mechanism of failure caused by the presence of weak bands by using a series of numerical models based on realistic physical properties. The effect of the weak bands on pillar strength was also investigated by developing a series of pillar models with different width-to-height ratios and determining their strength by simulating a servo-controlled loading condition. The material properties of the bands and the limestone were varied and their effects on pillar strength were determined. Model results demonstrated failure development similar to the pillars observed in the field. The weak bands were seen to develop tensile stresses in the limestone as they extrude under increasing stress. The limestone fails in tension at a much lower stress than its expected uniaxial compressive strength. The results showed the load bearing capacity of the pillars can be reduced significantly by the presence of multiple thin weak bands. The degree of strength reduction is largely dependent on the compressive strength, the frictional resistance and the thickness of the weak bands. Single weak bands do not affect pillars as severely as multiple bands. However, the model results show that a single thick weak band, which comprises more than about 2 percent of the pillar height, can cause a significant reduction in pillar strength. The weakening effect of the bands become less severe as the pillar width-to-height ratio is increased. Field observation of spalling and failure associated with weak bands in limestone pillars show that the failure mechanism in the models resembles the observed failure. The model results provide insight into the important factors affecting pillar strength in the presence of weak banded materials.

Jan 1, 2007

By Navid Hosseini

Several empirical equations to estimate coal pillar strength have been presented in academic studies. The development processes of these equations are similar and are usually obtained by fitting the mathematical function (curve) to field data. One of the best criteria to evaluate the quality of fitting for such equations is the correlation coefficient R2, which has limited applicability. It is necessary to calculate the correlation coefficient access to the initial data for which the equation is presented; this is impossible for many coal pillar strength formulas. This paper presents a new approach based on the analysis of uncertainty amplitude to compare the coal pillar strength. This approach utilizes a combination of parameters such as Mean Squared Error (MSE), Root Mean Squared Error (RMSE), function type and degrees of freedom. The confidence level of constants is subsequently formed and the correlation coefficient becomes more comprehensive. Therefore, for an effective comparison, the efficiency and accuracy of coal pillar strength formula can be used. Keywords: Coal Pillar Strength, Correlation Coefficient, MATLAB, Uncertainty Criterion

Jan 1, 2012

By Alan A. Campoli

The mining industry has long been searching for an effective structural application that prevents weathering and falls of loose rock, debris, and sediment. J-Crete is a fiber-reinforced, engineered, cementitious composite rock application that is designed, tested, and successfully utilized as such a material. Laboratory evaluation of J-Crete material properties has shown the final compressive strength to be in excess of 7,300 psi (50.34 MPa), with 24 hour strength in excess of 1,500 psi (10.34 MPa). The flexural tensile strength is in excess of 600 psi (4.1 MPa) and is provided through a unique combination of polyvinyl alcohol (PVA) fibers activated by a proprietary liquid additive that prevents them from clumping and enables even distribution throughout the grout. Tensile bond strength in excess of 350 psi (2.4 MPa) at 28 day cure tightens the strata and holds loose material in place. Practically impervious to gas and liquids, J-Crete protects strata against long-term weathering, does not require screening to be effective, and has proven to be a successful waterproofing material. J-Crete has demonstrated the potential to alleviate coal mine roof cutters in soft, wet clay formations. J-Crete reinforces coal mine ribs by bonding directly to the rib, conforms to the strata, strengthens the rib, and eliminates sloughing due to long-term weathering; stabilizes coal mine entries by bonding directly to the brow and roof, and creates a monolithic shell with double reinforced corners.

Jan 1, 2012

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 Yi Luo

Multiple-seam mining operations induce surface subsidence basins different from those caused by mining in a single coal seam, and also disturb the mining operations in the other coal seams. A computer program, CISPM-MS (Comprehensive and Integrated Subsidence Prediction Model for Multiple Seam Mining), has been developed to predict the final surface movements and deformations as well as the interactions associated with multi-seam coal mining operations. The program applies a newly developed subsurface subsidence prediction model that is able to consider the geological stratification variations. In predicting surface subsidence, the surface movements and deformations caused by the individual mining operations as well as the interactive effects are all considered. A case study is conducted in this paper for validating the program.

Jan 1, 2012

By Kazem Oraee

Falls of ground have historically been the main cause for fatalities in underground mines. Although recent advances in technology have reduced the number of such accidents, when failures occur they usually result in severe consequences. Risks of rock falls, use of heavy machinery and electrical apparatus, entry to confined spaces, working in noisy and dusty environments, and working on unstable platforms are some of the hazards in ground control operations. Managing these risks requires a management regime involving strict adherence to operational codes of practice and an enshrined culture of safety. These should be subsequently reinforced through active participation of management, systematic training, and stringent internal and third party auditing. Accident reports show that the major contributing factor in most rock fall accidents is the failure to adequately manage known risks due to the lack of a systematic process. OHSAS 18001 (Occupational Health and Safety Assessment Series) is an international occupational health and safety management standard specification to develop occupational health and safety at the workplace. This standard is intended to help mine operators control occupational health and safety risks. Addressing the requirements of OHSAS 18001 can be a complex and demanding task. A comprehensive guide for efficient and accurate implementation of this standard is provided in this paper. The discipline can be used to establish an accountable management system foreground control activities in underground coal mines. The paper also provides guidelines for preparing necessary documents, devising safety policies, procedures, performing risk assessment, and handling instructions. Finally, the paper concludes by providing a sound analytical basis in terms of the creation of a robust safety management system foreground control operations in underground mines. Full benefits of implementing an effective and systematic operational health and safety management system are illustrated. The procedure adopted and prescribed in this paper can be used in all underground coal mines where lack of appropriate ground control practices can create deficiencies in both safety and productivity.

Jan 1, 2012

By Krzysztof Kotwica

The steady demand for rock materials leads not only to on increase in mining but to the need for decreasing the loss of material in the process of exploitation as well. It brings about an increase in using of explosives in open pits and as a result an increase of after blasting gases volume, vibrations, the scattering (dispersion) of stone ect. All these factors affecting the environment lead to the research work for applying the electrohydrodynamic methods both in open casts and underground mines. In the article the authors describe the concept of this method and construction of equipment which recently have been successfully introduced in mining, the results obtained determine the possibilities of using this method and the future directions. The results of combined method with high-pressure water jets cutting and prototype equipment for separating rock blocks from the rock mass using special head with high-pressure water jets are also described.

Jan 1, 2006

By Sandin E. Phillipson

The Mine Safety and Health Administration?s Roof Control Division responded to a massive ground failure at an underground marble mine in northern Georgia. The ground failure occurred in a benched area that had been abandoned in the early 1990s. It involved the failure of an estimated 19 pillars, in conjunction with a massive roof fall of an undetermined extent that was at least 60 ft high. Pillars in the benched area had been mined nominally 40 x 40 feet to a height of 50 feet ft, with 40-ft mining widths, although it seems likely from measurements and accounts from mining personnel that pillars were even smaller than intended. Average overburden depth was 500 ft, and the rock mass was characterized by three sets of intersecting geological discontinuities that not only defined very blocky conditions that were conducive to pillar spalling and volume loss, but they were also adversely oriented in such a way as to cut diagonally through pillars at a high angle. The recently released S-Pillar software from NIOSH was used to determine pillar safety factors in the failure area and indicated that pillars were undersized for the conditions. S-Pillar was used to assess pillar stability in active areas to evaluate the likelihood of experiencing similar collapses in the future. S-Pillar correctly identified the pillars in the bench area as having been at risk for instability, in light of their ultimate failure. A two-dimensional finite element model was used to evaluate the possible stages of failure and to assess the likelihood of continued failure in the benched area that might affect more distal mine openings. Although stone mines are generally characterized as having more forgiving conditions than those found in softer sedimentary rocks, the failure shares some characteristics with domino-style massive pillar collapses experienced in coal and trona mines. First, the minimum dimension of the benched area approached 350 ft; second, the pillars defined by benching had small width-to-height ratios (0.8), and; third, the pillar failure area was slightly greater than 4 acres. The massive pillar collapse and associated roof fall illustrate the importance of incorporating pillars that have been properly sized for depth and for the final bench height. Furthermore, the designed dimensions must be adhered to during the actual mining process. Finally, the importance of understanding the geological conditions and their effect on the rock mass is critical.

Jan 1, 2012

By Yi Luo

Subsidence events occurred over inactive room and pillar (R&P) mines, including abandoned mines or sealed portions of active mines, are classified as unplanned subsidence because of their timing and distribution are unpredictable. When investigating such subsidence cases, many uncertainties exist and disputes often focused on whether the observed structural damages are caused by mine subsidence or other natural or artificial causes. However, solid evidences to identify the causes are often lacking. In order to conduct a thorough and impartial investigation, good knowledge in subsidence theories and other ground control subjects and broad experience are required.

Jan 1, 2009

By Lixun Kang

Bedded structure is the characteristics of coal measures strata. Bedding planes, coal streaks and soft rock bands existing in roof strata destroyed its continuity in the direction perpendicular to the coal seams. The statistics from a large number of long wall faces in which serious roof fall accidents occurred in Datong coal mining area suggest that beddings planes, coal streaks, soft rock bands, especially the first layer thickness of immediate roof have a great influence on its stability. As the first layer thickness increases, the probability of serious roof fall accidents decreases. Based on the investigations finite element method is used to analyze stress and displacement in the first layer of immediate roof. The results indicate that the thicker the first layer is, the less the roof convergence in the unsupported area is. Stress and strain features in stratified immediate roof are quite different f7om those in non- bedded immediate roof. In stratified immediate roof, every stratum has each own tensile zone in the upper portion and compressive zone in the lower portion, while tensile zone in the first layer is less, the tensile stress is the greatest.

Jan 1, 2005

By Rajagopala Reddy Kallu

After the Sago and Darby No. 1 mine incidents, the new regulatory standards for the design of mine seals in underground coal mines of the United States require the mine seals to withstand higher explosion standards. This necessitated for the development of new design approaches and standards. For development of any new design standards or approaches a detailed understanding of effect of key influencing parameters on the stability of mine seal is a must. This paper attempts to address one of the factors, i.e. roof convergence, that play an important role in the stability of mine seal under explosion loading. Initially a couple of three dimensional numerical models were built and tested for different levels of roof convergence. These models confirmed that roof convergence has great influence on seal stability. A detailed study is undertaken, with some simple assumptions, to establish typical influence of roof convergence on the stability of mine seal under different levels of static explosion pressures. Three dimensional distinct element code 3DEC is used for this purpose.

Jan 1, 2007