Large Deformation Characteristics of Surrounding Rock and Support Technology of Shallow-Buried Soft Rock Roadway: A Case Study

The coal resources in the coal-rich area of western China are mostly located in the late diagenetic Cretaceous and Jurassic strata. In this paper, a study on the support of soft rock roadways was carried out in the background of the soft rock track roadway in the Jiebangou coal mine. The field investigation showed that the surrounding rocks of the roadway were weak, soft, and broken, and the surrounding rocks were cemented, with the roadway local deformation exceeding 1 m. The borehole television results showed that the surrounding rocks were mainly weak sandy mudstone and yellow mudstone. The average uniaxial compressive strength of the surrounding rock was 15.49 MPa. The roadway is a shallow buried soft rock roadway; site investigation revealed that the original U-shaped steel shed had an extremely low resistance to slip, the filling body behind the U-shaped steel shed fell off, the interaction between the U-shaped steel shed and the surrounding rock was poor, the U-shaped steel shed could not provide sufficient timely support resistance, and the bearing capacity of the U-shaped steel shed was far from consideration. The floor was not effectively supported. The floor had different degrees of the bottom drum, and frequent undercover caused new stress disturbances, which loosened the bottom corners of both rock types and made the shed legs move continuously inward, reducing the bearing capacity and actual support resistance of the bracket. Numerical calculations were performed to study the deformation characteristics of the surrounding rock of the tunnel and the yielding damage characteristics of the brace. The results showed that the current U-shack support strength was insufficient, the two sides were deformed by 950 mm, the bottom of the roadway bulged by 540 mm, and the surrounding rock was mainly shear damaged. The fall of the filler behind the shed caused damage to the U-shaped steel shed spire. Through site investigation results and numerical calculations, the deformation and damage characteristics of the soft rock roadway and its damage causes were analyzed, and the support technology system of ‘strengthening support for weak structural parts’ was proposed. This improved the mechanical properties of the weak structural support body, the stress state of the local surrounding rock, and the bearing capacity of the support structure, and effectively controlled the deformation, damage, and instability of the surrounding rock of the roadway, and deformation, damage, and destabilization of the roadway, thereby achieving overall stability for the surrounding rock of the roadway.

Determination of loading capacity index of a continuous miner in soft rock roadway and virtual test method

To improve the loading efficiency and reduce energy consumption of a continuous miner in soft rock roadway, a seven-arm star wheel designed with Gaussian fitting method was proposed, and a coal loading model of the continuous miner star wheel loading mechanism was reconstructed with EDEM software. The loading capacity of the seven-arm star wheel and the three-arm star wheel of the EML340 continuous miner at different working speeds were studied respectively. The scientific and reasonable identification index was formulated and the index evaluation system of loading star wheel was established. It has been found that the performance of the loading star wheel is a collection of various identification indicators, the coal returning mass reducing the loading efficiency and increasing unnecessary energy consumption, therefore, it is difficult to identify by a single index. Loading coal and rock by the star wheel is a process that consumes energy and pays attention to output, therefore, the identification index should include two kinds of efficiency parameters and energy parameters. Rake coal torque and loading specific energy consumption have reflected the degree of energy utilization, which can be comprehensively used for preliminary design of the star wheel. The performance parameters such as loading power and loading efficiency are reliable indicators for designing and performance evaluation of the star wheel. Based on the statistical analysis of the test data, compared with the three-arm star wheel of the EML340 continuous miner, the loading efficiency of the seven-arm star wheel has been significantly improved. The loading power for coal loading has been reduced by 46%. The feasibility of the Gaussian design method of loading star wheel has been verified.

Stabilization of Rock Roadway under Obliquely Straddle Working Face

A floor rock roadway under an oblique straddle working face is a typical dynamic pressure roadway. Under the complex disturbance of excavation engineering works, the roadway often undergoes stress concentration and severe deformation and damage. To solve the problem of surrounding rock stability control for this roadway type, this study considered the East Forth main transport roadway in the floor strata of the 1762(3) working face of the Pansan coal mine. In situ ground pressure monitoring and numerical simulation calculation using the FLAC2D software were carried out. The influence laws of the surrounding rock lithology, the vertical and horizontal distance between the roadway and overlying working face, the positional relationship between the roadway and the overlying working face, and the support form and strength of the rock surrounding an oblique straddle roadway were obtained. Within the range of mining influence, the properties of the rock surrounding the roof and floor were very different, and the deformation of the rock surrounding the two sides exhibited regional difference. The influence range of the mining working face on the rock floor of the roadway was approximately 30–40 m, and that of horizontal mining was approximately 50–60 m. The mining influence on the rock surrounding the side roadway of the working face is large, but the mining influence on the roadway below is small. Using FLAC2D, the stress and displacement characteristics of the rock surrounding the obliquely straddle roadway were compared and analyzed when the bolt support, combined bolt and shed support, and bolt–shotcreting–grouting support were adopted, the proposed support scheme of bolting and shotcreting was successfully applied. The deformation of the rock surrounding the roadway was satisfactorily controlled, and the results were useful as a reference for similar roadway maintenance projects.

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.