A case study on severe damage at a tunnel in serpentinite rock mass

Face squeezing, floor heave, and buckling of invert were found after a 10-day holiday in 2014 around the serpentinite face of a tunnel in Hokkaido, Japan. The damage continued for over 2 months, extending 400 m toward the entrance causing a massive roof fall. The tunnel was excavated again with a circular section and extra-thick shotcrete, and the face had crossed the damaged part 6 years after the damage occurred. Uniaxial and triaxial compression tests were carried out to obtain the mechanical properties of the serpentinite to clarify the severe damage mechanism at the tunnel. The main experimental findings are as follows. The uniaxial compressive strength of the serpentinite samples was very low, and the ratio of the strength to the estimated overburden pressure was extremely low. The parameter n indicated that the time-dependent deformation of the serpentinite was not large but the same as ordinary rocks. All specimens showed strain-hardening in the triaxial compression test, and the friction angle was very low by the brucite content. Only primary creep was observed in the multistage triaxial creep test. The pressure on the shotcrete from rock mass for the damaged tunnel was enough to cause creep deformation and failure of shotcrete. From the above findings, designing the concrete lining that can support the earth and water pressure is recommended for tunnel excavation in such a weak serpentinite rock mass, particularly with a very low friction angle by brucite. Highlights Face squeezing, floor heave, and buckling of invert were found after a 10-day holiday around the serpentinite face in Hokkaido, Japan. The time-dependent deformation of the serpentinite was not large but the same as ordinary rocks. All specimens showed strain-hardening in the triaxial compression test, and the friction angle was very low by the brucite content. Only primary creep was observed in the multistage triaxial creep test. The severe damage to the tunnel was not a brittle creep failure of the serpentinite rock mass itself but the shotcrete lining.

Investigation on the Failure Mechanism of Weak Floors in Deep and High-Stress Roadway and the Corresponding Control Technology

Large deformation of roadway and floor burst are the two major geotechnical hazards encountered with high mining stress in deep mines. In this paper, the stress and energy conditions generated by the impact damage on the rock surrounding a roadway are analyzed, and UDEC software was used to study the deformation characteristics of the roadway, as well as its failure mechanism under the influence of superimposed dynamic and static loads. The results indicate that the soft floor of a deep-buried roadway has a high damage degree and an obvious stress release effect, high static load leads to slow floor heave, and strong dynamic load disturbance is the principal trigger leading to floor burst. In addition, the anisotropy caused by the bedding surface weakens the cooperative characteristics of the support system, resulting in serious instability of the whole rock surrounding the roadway. Full-section anchor cables and inverted arches were adopted to maintain the stability of the rock surrounding the roadway. The monitoring results obtained from field tests show that the adoption of the combined support system effectively avoids floor burst caused by the superposition of dynamic and static loads; the maximum floor heave is 67.9 mm, which is 95% lower than the original value, ensuring safety in coal mining operations.

“Relief-Retaining” Control Technology of Floor Heave in Mining Roadway with Soft Rock: A Case Study

The floor heave problem is one of the important factors affecting the stability and safety of surrounding rocks of roadways, especially in deep high-stress mining roadway with soft rock. The return airway of no. 130203 working face in Zaoquan Coal Mine of Ningdong Mining Area in Northwest China is the research object in this study. Firstly, an innovative “relief-retaining” control scheme of floor heave is proposed, which is the comprehensive measure of “cutting groove in floor + drilling for pressure relief at roadway side + setting retaining piles at the junction of roadway side and floor.” Then, the specific parameters suitable for floor heave control of no. 130203 return airway are determined using numerical simulation method. Finally, the yield monitoring results show that both the deformation of surrounding rocks and the cable force are significantly reduced. The roof falling capacity, floor heave displacement, and thickness increasing value of 0–2 m floor strata are 596 mm, 410 mm, and 82 mm, respectively, which are 43.67%, 67.49%, and 75.38% less than those of the control section. The maximum force of cables at roadway sides is 140.13 kN, about 32.54% less than that of the control section. The results verify the reliability of the proposed “relief-retaining” control scheme and can provide some reference for the floor heave control of similar roadways.

Evaluation Method of Floor Heave Damage Degree and a Case Study in Zaoquan Coal Mine, China

With the continuous increase of mining depth and complex mining geological conditions, the mileage of roadways in underground engineering such as coal mine is increasing year by year. Complex conditions lead to different floor heave failure laws, and the control technology and strategy should be changed accordingly. How to evaluate the damage degree of floor heave under different conditions has become an urgent problem. Firstly, this paper makes a statistical analysis on the main evaluation indexes of the damage degree of roadway floor heave. Then, the fuzzy comprehensive clustering method is used to establish the classification method of floor heave damage degree, taking the floor heave amount, floor rock fragmentation degree, coal pillar size, buried depth, and floor lithology as evaluation indexes. The damage degree of floor heave can be divided into five types: light type, obvious type, severe type, destructive type, and extremely severe type. Finally, the rationality and accuracy of the method are verified by the measured value and evaluation value of No. 130203 roadway in the Zaoquan coal mine. The results can provide reference for the evaluation of the damage degree of the floor rock in similar condition mine and provide guidance for the design of the support and stability control of the failure of the roadway floor heave.

Innovative Control Technique for the Floor Heave in Goaf-Side Entry Retaining Based on Pressure Relief by Roof Cutting

To solve the difficulty in controlling floor heave of a retained goaf-side roadway, a new control technique was investigated from the perspective of the pressure relief by roof cutting by combining mechanical analysis, numerical simulation, and engineering tests. The mechanical principle of controlling the floor heave based on pressure relief by roof cutting was attained by analyzing the movement of overlying strata and mechanical characteristics of key blocks before and after the roof cutting. A new technique for controlling the floor heave based on pressure relief by roof cutting was proposed. Research results have shown that after performing pressure relief by roof cutting, the caved gangues in the goaf can support the overlying strata and, thereby, change the movement law thereof and weaken the abutment pressure on the coal wall. Furthermore, the pressure exerted on the roadway floor by the coal wall is lowered to prevent plastic deformation of the floor, thus controlling floor heave in the roadway; a new integrated technique for controlling the floor heave based on pressure relief by roof cutting, flexible yielding, controlling with double-direction-control anchor bolts, and controlling with reinforcing anchor cables is developed, and the technological processes of support, cutting, and protection are summarised. The results of field testing showed that, after applying the new technique, the average floor heave amount of the roadway declines by 64% and the average speed of the floor heave up to 231 m behind the working face decreases by 61%.

Stress and deformation analysis of gob-side pre-backfill driving procedure of longwall mining: a case study

At present, non-pillar entry protection in longwall mining is mainly achieved through either the gob-side entry retaining (GER) procedure or the gob-side entry driving (GED) procedure. The GER procedure leads to difficulties in maintaining the roadway in mining both the previous and current panels. A narrow coal pillar about 5–7 m must be left in the GED procedure; therefore, it causes permanent loss of some coal. The gob-side pre-backfill driving (GPD) procedure effectively removes the wasting of coal resources that exists in the GED procedure and finds an alternative way to handle the roadway maintenance problem that exists in the GER procedure. The FLAC3D software was used to numerically investigate the stress and deformation distributions and failure of the rock mass surrounding the previous and current panel roadways during each stage of the GPD procedure which requires "twice excavation and mining". The results show that the stress distribution is slightly asymmetric around the previous panel roadway after the “primary excavation”. The stronger and stiffer backfill compared to the coal turned out to be the main bearing body of the previous panel roadway during the "primary mining". The highest vertical stresses of 32.6 and 23.1 MPa, compared to the in-situ stress of 10.5 MPa, appeared in the backfill wall and coal seam, respectively. After the "primary mining", the peak vertical stress under the coal seam at the floor level was slightly higher (18.1 MPa) than that under the backfill (17.8 MPa). After the "secondary excavation", the peak vertical stress under the coal seam at the floor level was slightly lower (18.7 MPa) than that under the backfill (19.8 MPa); the maximum floor heave and maximum roof sag of the current panel roadway were 252.9 and 322.1 mm, respectively. During the "secondary mining", the stress distribution in the rock mass surrounding the current panel roadway was mainly affected by the superposition of the front abutment pressure from the current panel and the side abutment pressure from the previous panel. The floor heave of the current panel roadway reached a maximum of 321.8 mm at 5 m ahead of the working face; the roof sag increased to 828.4 mm at the working face. The peak abutment pressure appeared alternately in the backfill and the coal seam during the whole procedure of "twice excavation and mining" of the GPD procedure. The backfill provided strong bearing capacity during all stages of the GPD procedure and exhibited reliable support for the roadway. The results provide scientific insight for engineering practice of the GPD procedure.

STUDY ON STABILITY CONTROL OF COAL MINE TUNNEL EXCAVATED IN WEAK ROCK MASS IN INDONESIA

This paper focuses on the stability analysis and support design of the coal mine tunnel excavated in weak rock mass in an Indonesian underground coal mine through numerical simulations using the FLAC3D software. The PT Gerbang Daya Mandiri (GDM) coal mine situated in Indonesia was selected as a mine site in this study. According to the results of a series of numerical simulations, the stability of the mine tunnel decreases by increasing the depth and stress ratio. Ground control problems, for example falling roof, sidewall collapse, and floor heave are expected unless an appropriate support system is anticipated. Three support systems, including friction rockbolt, steel arch, and shotcrete are discussed as methods to stabilize the roof and sidewalls of the mine tunnel. From the simulated results, the steel arch is considered to be the most effective support method when compared with other support systems. The steel arch which is installed with closer space and larger crosssection delivers a better stability control to the roof and sidewalls of the mine tunnel. Although the stability of the roof and sidewalls of the mine tunnel can be maintained effectively by the steel arch support, the occurrence of floor heave is expected when the mining depth is increased. To control the floor stability of the mine tunnel, three techniques by applying cablebolt, invert-arch floor, and grooving method are therefore investigated and discussed. Based on simulated results, the heaving of the floor is well controlled after the cablebolt, invert-arch floor, and grooving methods are applied. Nevertheless, it is found that controlling the floor heave by cablebolt support could be the most suitable method comparing with other support systems in terms of the installation process, providing flat and safe working conditions of the floor, and economy. Additionally, the cablebolt with closer row space and longer length works more effectively to control the heaving problem of the floor. Keyword

A Case Study of Optimization and Application of Soft-Rock Roadway Support in Xiaokang Coal Mine, China

The roadway of S2S2 fully mechanized caving face (FMCF) in Xiaokang Coal Mine is one of the most typical deep-buried soft-rock roadways in China and had been repaired several times. In order to figure out the failure reasons of the original roadway support, the geological conditions were investigated, the surrounding rock stress was monitored, the rib displacement, roof separation, and floor heave were in situ measured, and the performance of the U-shaped steel support was simulated. The above analysis results indicated that the support failure was mainly caused by (1) the unreasonable arch roadway section, (2) the high and complex surrounding rock stress, (3) the failure control of the floor heave, and (4) the inadequate self-supporting capacity of the surrounding rock. For optimizing, the roadway section was changed to circle and a new full-section combined support system of “belt-cable-mesh-shotcrete and U-shaped steel-filling behind the support” was adopted, which could specifically control the floor heave, allow the roadway deformation in control, and improve the self-supporting ability and stress field of the surrounding rock. To determine the support parameters, the selected U-shaped steel support was verified by simulation, and various bolt-cable support schemes were simulated and compared. Finally, such an optimized support scheme was applied in the roadway of the next replacement FMCF. The in situ monitoring showed that the rib-to-rib convergence and roof-to-floor convergence were both controlled within 600 mm, which indicated that the roadway was effectively controlled. This case study has important reference value and guiding function for the optimal design of the soft-rock roadway support with similar geological conditions.