For large underground coal mines producing 10 million tons a year, rapid excavation and stability of deep roadways are pivotal to ensure sustainable, safe, and efficient production. This paper provides a case study of Hulusu Coal Mine in Inner Mongolia, where roadway excavation speed was insufficient to meet production needs. Moreover, deformation in the roofs of the roadways was severe. To achieve rapid excavation and control the stability of deep roadways, a new support system was proposed and constructed in a roadway at a depth of 640 m. The system consisted of long flexible bolts pretensioned to high levels and spaced at large intervals. Roadway excavation and construction of a support system were conducted simultaneously. Field measurements indicated that the new support system effectively controlled deformation and fracture development during excavation and mining. Maximum displacements of the roof during excavation and mining were 10 and 30 mm, respectively. The axial load on bolts surged during excavation as a result of slight deformations caused by excavation operations. This active response of the bolts is beneficial to the prevention of roof deformation during excavation and mining. During mining, fissures propagated up to only a depth of 1.4 m into the surrounding rock mass. The new support system formed a thick reinforced anchorage zone, which greatly improved the bearing capacity of the roof. Compared with the previous support system, the new system allowed the maximum excavation speed (31.5 m/day) to increase by 85.3%. This successful case provides a practical reference for similar roadway projects.
The stability of a deep composite roof is a powerful guarantee for the safe and efficient production of a coal mine. The coal–rock combination, the single rock or coal bodies have different bearing capacity; thus, we can accurately obtain the deformation field evolution and failure mechanisms of the combination, which is useful in the deformation control of a composite roof. In this study, based on the digital speckle correlation method (DSCM), a uniaxial compression test was applied to coal–rock combinations with different height ratios. The results revealed that the compressive strength, elastic modulus, and secant modulus of the combination gradually decreased, while the decreasing amplitude weakened with the increase of coal height. Additionally, the strain field map of the combination had different characteristics in different stages. As the height of the coal body continuously increased, the gradient of the strain cloud and the area of local strain increase moved upwards. Moreover, the cracks caused by the failure of the coal body in the combination triggered the failure of the rock body. According to the test results, two principles are proposed for the deformation control of the composite roof, and are expected to be useful in applications for the similar geological conditions.
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