Coal Mine Roadway Stability in Soft Rock: A Case Study

Roadway instability has always been a major concern in deep underground coal mines where the surrounding rock strata and coal seams are weak and the in situ stresses are high. Under the high overburden and tectonic stresses, roadways could collapse or experience excessive deformation, which not only endangers mining personnel but could also reduce the functionality of the roadway and halt production. This paper describes a case study on the stability of roadways in an underground coal mine in Shanxi Province, China. The mine was using a longwall method to extract coal at a depth of approximately 350 m. Both the coal seam and surrounding rock strata were extremely weak and vulnerable to weathering. Large roadway deformation and severe roadway instabilities had been experienced in the past, hence, an investigation of the roadway failure mechanism and new support designs were needed. This study started with an in situ stress measurement programme to determine the stress orientation and magnitude in the mine. It was found that the major horizontal stress was more than twice the vertical stress in the East–West direction, perpendicular to the gateroads of the longwall panel. The high horizontal stresses and low strength of coal and surrounding rock strata were the main causes of roadway instabilities. Detailed numerical modeling was conducted to evaluate the roadway stability and deformation under different roof support scenarios. Based on the modeling results, a new roadway support design was proposed, which included an optimal cable/bolt arrangement, full length grouting, and high pre-tensioning of bolts and cables. It was expected the new design could reduce the roadway deformation by 50 %. A field experiment using the new support design was carried out by the mine in a 100 m long roadway section. Detailed extensometry and stress monitorings were conducted in the experimental roadway section as well as sections using the old support design. The experimental section produced a much better roadway profile than the previous roadway sections. The monitoring data indicated that the roadway deformation in the experimental section was at least 40–50 % less than the previous sections. This case study demonstrated that through careful investigation and optimal support design, roadway stability in soft rock conditions can be significantly improved.