Theory,technology and application of grouted bolting in soft rock roadways of deep coal mines

The grouted bolt,combining rock bolting with grouting techniques,provides an effective solution for controlling the surrounding rock in deep soft rock and fractured roadways.It has been extensively applied in numerous deep mining areas characterized by soft rock roadways,where it has demonstrated remarkable control results.This article systematically explores the evolution of grouted bolting,covering its theoretical foundations,design methods,materials,construction processes,monitoring measures,and methods for assessing its effectiveness.The overview encompassed several key elements,delving into anchoring theory and grouting reinforcement theory.The new principle of high pretensioned high-pressure splitting grouted bolting collaborative active control is introduced.A fresh method for dynamic information design is also highlighted.The discussion touches on both conventional grouting rock bolts and cable bolts,as well as innovative grouted rock bolts and cables characterized by their high pretension,strength,and sealing hole pressure.An examination of the merits and demerits of standard inorganic and organic grouting materials versus the new inorganic–organic composite materials,including their specific application conditions,was conducted.Additionally,the article presents various methods and instruments to assess the support effect of grouting rock bolts,cable bolts,and grouting reinforcement.Furthermore,it provides a foundation for understanding the factors influencing decisions on grouted bolting timing,the sequence of grouting,the pressure applied,the volume of grout used,and the strategic arrangement of grouted rock bolts and cable bolts.The application of the high pretensioned high-pressure splitting grouted bolting collaborative control technology in a typical kilometer-deep soft rock mine in China—the soft coal seam and soft rock roadway in the Kouzidong coal mine,Huainan coal mining area,was introduced.Finally,the existing problems in grouted bolting control technology for deep soft rock roadways are analyzed,and the future development trend of grouted bolting control technology is anticipated.

Failure mechanism and safety control technology of a composite strata roadway in deep and soft rock masses:a case study

The construction of coal mines often encounters deep composite soft rock roadways,which is characterized by significant deformation and poor stability.To deeply study the failure mechanism and large deformation challenges of a composite strata roadway in deep and soft rock masses,a numerical model of 3DEC tetrahedral blocks was established based on the method of rock quality designation(RQD).The results showed that original support cannot prevent asymmetric failure and large deformation due to the adverse geological environment and unsuitable support design.According to the failure characteristics,a coupling support of“NPR bolt/cable+mesh+shotcrete+steel pipe”was proposed to control the stability of the surrounding rock.The excellent mechanical properties of large deformation(approximately 400 mm)and high constant resistance force(bolt with 180 k N;cable with 350 k N)were evaluated by the tensile tests.The numerical results showed that the maximum deformation was minimized to 243 mm,and the bearing capacity of the surrounding rock of the roadway was enhanced.The field test results showed that the maximum deformation of the surrounding rock was 210 mm,and the forces of the NPR bolt and cable were stable at approximately 180 k N and 350 k N,respectively.This demonstrated the effectiveness of the coupling support with the NPR bolt and cable,which could be a guiding significance for the safety control of large deformation and failure in deep composite soft rock roadways.

Surrounding Rock Control Technology of Strong Dynamic Pressure Roadway in Hudi Coal Industry

Aiming at the problems of large deformation and difficult maintenance of deep soft rock roadway under the influence of high ground stress and strong dynamic pressure, taking the surrounding rock control of 1105 lane in Hudi Coal Industry as an example, the deformation characteristics and surrounding rock control measures of deep soft rock roadway are analyzed and discussed by means of geological data analysis, roadway deformation monitoring, rock crack drilling and field test. The results show that the main causes of roadway deformation are high ground stress, synclinal tectonic stress, advance mining stress, roadway penetration and surrounding rock fissure development. Based on the deformation characteristics and mechanism of lane 1105, the supporting countermeasures of “roof synergic support, layered grouting, anchor cable beam support, closed hardening of roadway surface” are proposed, which can provide reference for the control of deep roadway surrounding rock under similar conditions.

A post-peak dilatancy model for soft rock and its application in deep tunnel excavation

The dilation angle is the most commonly used parameter to study nonlinear post-peak dilatancy(PPD)behavior and simulate surrounding rock deformation;however,simplified or constant dilatancy models are often used in numerical calculations owing to their simple mathematical forms.This study developed a PPD model for rocks(rock masses)based on the Alejanoe-Alonso(A-A)dilatancy model.The developed model comprehensively reflects the influences of confining pressure(σ_(3))and plastic shear strain(γ^(p)),with the advantages of a simple mathematical form,while requiring fewer parameters and demonstrating a clear physical significance.The overall fitting accuracy of the PPD model for 11 different rocks was found to be higher than that of the A-A model,particularly for Witwatersrand quartzite and jointed granite.The applicability and reliability of the PPD model to jointed granites and different scaled Moura coals were also investigated,and the model was found to be more suitable for the soft and large-scale rocks,e.g.deep rock mass.The PPD model was also successfully applied in studying the mechanical response of a circular tunnel excavated in strain-softening rock mass,and the developed semi-analytical solution was compared and verified with existing analytical solutions.The sensitivities of the rock dilatancy to γ^(p) and σ_(3) showed significant spatial variabilities along the radial direction of the surrounding rock,and the dilation angle did not exhibit a monotonical increasing or decreasing law from the elasticeplastic boundary to the tunnel wall,thereby presenting the σ3-or γ^(p)-dominated differential effects of rock dilatancy.Tunnel deformation parabolically or exponentially increased with increasing in situ stress(buried depth).The developed PPD model is promising to conduct refined numerical and analytical analyses for deep tunneling,which produces extensive plastic deformation and exhibits significant nonlinear post-peak behavior.

Grouting theories and technologies for the reinforcement of fractured rocks surrounding deep roadways

Grouting is an effective method to improve the integrity and stability of fractured rocks that surround deep roadways.After years of research and practice,various theories and a complete set of grouting technologies for deep roadways with fractured rocks have been developed and are widely applied in Chinese coal mining production.This paper systematically summarizes and analyzes the research results concerning the theory,design,materials,processes,and equipment for the grouting and reinforcement of fractured rocks surrounding deep roadways.Specifically,in terms of grouting methods,pregrouting,groutingwhile-excavation,and postgrouting methods are explored;in terms of grouting theory,backfill grouting,compaction grouting,infiltration grouting,and fracture grouting theories are studied.In addition,this paper also studies grouting borehole arrangement,water-cement ratio,grouting pressure,grouting volume,grout diffusion radius,and other grouting parameters and their determination methods.On this basis,this paper explores the physical and mechanical properties of organic and organic-inorganic composite grouting materials,and assess grouting reinforcement quality testing methods and instruments.Taken as the field cases,the application of pregrouting in front of heading faces,groutingwhile-excavation,and postgrouting in the Kouzidong coal mine are then introduced,and the effects of the grouting reinforcements are evaluated.This paper proposes a development direction for grouting technology based on problems existing in the grouting reinforcement of fractured rocks surrounding deep roadways.

Study on Asymmetric Deformation Law and Surrounding Rock Control Technology of High Stress Soft Rock Crossing Roadway

In order to solve the problem of asymmetric large deformation of high-stress soft rock crossing roadway under complex geological conditions in deep mines, taking the 2# total return airway of 76.2# section of Wuyang Coal Mine as the engineering background, the causes of asymmetric deformation and failure of soft rock crossing roadway in deep mines were summarized and analyzed by means of field investigation, theoretical analysis and numerical simulation, and the asymmetric high-efficiency support technology with large row spacing was studied. The results show that the lithology of roadway strata is the main cause of asymmetric deformation and failure of roadway. The shape change of roadway is not the main influencing factor of asymmetric deformation of roadway, but for the control of roadway surrounding rock, the straight wall semi-circular arch roadway is better than the rectangular roadway. The field industrial test shows that after adopting the new support design scheme, the displacement of the roof and floor of the roadway is reduced by 86.39% compared with the original support design scheme, and the displacement of the two sides of the roadway is reduced by 86.05% compared with the original support design scheme, which can ensure the normal and safe production of the roadway during the service period, and provide reference for the support design of other similar geological conditions.

Bolt-grouting combined support technology in deep soft rock roadway

Analyzing the mineral composition, mechanical properties and ground stress testing in surrounding rock,the study investigated the failure mechanism of deep soft rock roadway with high stress. The boltgrouting combined support system was proposed to prevent such failures. By means of FLAC3D numerical simulation and similar material simulation, the feasibility of the support design and the effectiveness of support parameters were discussed. According to the monitoring the surface and deep displacement in surrounding rock as well as bolt axial load, this paper analyzed the deformation of surrounding rock and the stress condition of the support structure. The monitor results were used to optimize the proposed support scheme. The results of field monitors demonstrate that the bolt-grouting combined support technology could improve the surround rock strength and bearing capacity of support structure, which controlled the great deformation failure and rheological property effectively in deep soft rock roadway with high stress. As a result, the long term stability and safety are guaranteed.

Influence of dynamic pressure on deep underground soft rock roadway support and its application

Due to high ground stress and mining disturbance, the deformation and failure of deep soft rock roadway is serious, and invalidation of the anchor net-anchor cable supporting structure occurs. The failure characteristics of roadways revealed with the help of the ground pressure monitoring. Theoretical analysis was adopted to analyze the influence of mining disturbance on stress distribution in surrounding rock,and the change of stress was also calculated. Considering the change of stress in surrounding rock of bottom extraction roadway, the displacement, plastic zone and distribution law of principal stress difference under different support schemes were studied by means of FLAC3D. The supporting scheme of U-shaped steel was proposed for bottom extraction roadway that underwent mining disturbance. We carried out a similarity model test to verify the effect of support in dynamic pressure. Monitoring results demonstrated the change rules of deformation and stress of surrounding rock in different supporting schemes. The supporting scheme of U-shaped steel had an effective control on deformation of surrounding rock. The scheme was successfully applied in underground engineering practice, and achieved good technical and economic benefits.

Failure analysis and control technology of intersections of large‑scale variable cross‑section roadways in deep soft rock

In deep underground mining,achieving stable support for roadways along with long service life is critical and the complex geological environment at such depths frequently presents a major challenge.Owing to the coupling action of multiple factors such as deep high stress,adjacent faults,cross-layer design,weak lithology,broken surrounding rock,variable cross-sections,wide sections up to 9.9 m,and clusters of nearby chambers,there was severe deformation and breakdown in the No.10 intersection of the roadway of large-scale variable cross-section at the−760 m level in a coal mine.As there are insufcient examples in engineering methods pertaining to the geological environment described above,the numerical calculation model was oversimplifed and support theory underdeveloped;therefore,it is imperative to develop an efective support system for the stability and sustenance of deep roadways.In this study,a quantitative analysis of the geological environment of the roadway through feld observations,borehole-scoping,and ground stress testing is carried out to establish the FLAC 3D variable cross-section crossing roadway model.This model is combined with the strain softening constitutive(surrounding rock)and Mohr–Coulomb constitutive(other deep rock formations)models to construct a compression arch mechanical model for deep soft rock,based on the quadratic parabolic Mohr criterion.An integrated control technology of bolting and grouting that is mainly composed of a high-strength hollow grouting cable bolt equipped with modifed cement grouting materials and a high-elongation cable bolt is developed by analyzing the strengthening properties of the surrounding rock before and after bolting,based on the Heok-Brown criterion.As a result of on-site practice,the following conclusions are drawn:(1)The plastic zone of the roof of the cross roadway is approximately 6 m deep in this environment,the tectonic stress is nearly 30 MPa,and the surrounding rock is severely fractured.(2)The deformation of the roadway progressively increases from small to large cross-sections,almost doubling at the largest cross-section.The plastic zone is concentrated at the top plate and shoulder and decreases progressively from the two sides to the bottom corner.The range of stress concentration at the sides of the intersection roadway close to the passageway is wider and higher.(3)The 7 m-thick reinforced compression arch constructed under the strengthening support scheme has a bearing capacity enhanced by 1.8 to 2.3 times and increase in thickness of the bearing structure by 1.76 times as compared to the original scheme.(4)The increase in the mechanical parameters c andφof the surrounding rock after anchoring causes a signifcant increase inσt;the pulling force of the cable bolt beneath the new grouting material is more than twice that of ordinary cement grout,and according to the test,the supporting stress feld shows that the 7.24 m surrounding rock is compacted and strengthened in addition to providing a strong foundation for the bolt(cable).On-site monitoring shows that the 60-days convergence is less than 30 mm,indicating that the stability control of the roadway is successful.

Comparative study on bearing mechanism and design parameters of confined concrete arch joints in deep soft rock roadway

Square confined concrete arch is increasingly used in deep soft rock roadway support because of its advantages of high strength and construction convenience.However,the design of confined concrete arch in underground engineering still remains in experience-based method and lacks quantitative analysis.As a connecting component between arch sections,the connection joints have an important influence on the internal force distribution and failure mechanism of support arch.Therefore,a reasonable design of arch joints is the premise of rational support design.Taking Liangjia Coal Mine,a typical deep soft rock mine in China,as research background,this paper fully compared the most widely used joint types of confined concrete arch as analytical objects:flange joints and casing joints.The main failure modes of these two kinds of joints under bending moment are defined.Laboratory and numerical tests are carried out to study the mechanical characteristics of joints.Based on the M-θ curve,the influence law of different design parameters is analyzed,and the design principles of joints are proposed.The research results could provide a theoretical basis for the design and application of confined concrete arch in related projects.

Numerical simulation study of the failure evolution process and failure mode of surrounding rock in deep soft rock roadways

Based on the safety coefficient method,which assigns rock failure criteria to calculate the rock mass unit,the safety coefficient contour of surrounding rock is plotted to judge the distribution form of the fractured zone in the roadway.This will provide the basis numerical simulation to calculate the surrounding rock fractured zone in a roadway.Using the single factor and multi-factor orthogonal test method,the evolution law of roadway surrounding rock displacements,plastic zone and stress distribution under different conditions is studied.It reveals the roadway surrounding rock burst evolution process,and obtains five kinds of failure modes in deep soft rock roadway.Using the fuzzy mathematics clustering analysis method,the deep soft surrounding rock failure model in Zhujixi mine can be classified and patterns recognized.Compared to the identification results and the results detected by geological radar of surrounding rock loose circle,the reliability of the results of the pattern recognition is verified and lays the foundations for the support design of deep soft rock roadways.

Deformation mechanism of roadways in deep soft rock at Hegang Xing’an Coal Mine

Engineering geomechanics characteristics of roadways in deep soft rock at Hegang Xing'an Coal Mine were studied and the nature of clay minerals of roadway surrounding rock was analyzed. This paper is to solve the technical problems of high stress and the difficulty in supporting the coal mine, and provide a rule for the support design. Results show that mechanical deformation mechanisms of deep soft rock roadway at Xing'an Coal Mine is of ⅠABⅡABCⅢABCD type, consisting of molecular water absorption (the ⅠAB -type), the tectonic stress type + gravity deformation type + hydraulic type (the ⅡABC -type), and the ⅢABCD -type with fault, weak intercalation and bedding formation. According to the compound mechanical deformation mechanisms, the corresponding mechanical control measures and conversion technologies were proposed, and these technologies have been successfully applied in roadway supporting practice in deep soft rock at Xing'an Coal Mine with good effect. Xing'an Coal Mine has the deepest burial depth in China, with its overburden ranging from Mesozoic Jurassic coal-forming to now. The results of the research can be used as guidance in the design of roadway support in soft rock.

Deformation mechanism and excavation process of large span intersection within deep soft rock roadway

The FLAC3D software was used to simulate and analyze numerically the displacement, stress and plastic zone distribu-tion characteristics of a large span intersection in a deep soft rock roadway after the surrounding rock was excavated. Our simula-tion results show that there are two kinds of dominating factors affecting roadway stability at points of intersection, one is the angle between horizontal stress and axial direction of the roadway and the other are the angles at the points of intersection. These results are based on a study we carried out as follows: first, we analyzed the failure mechanism of a large span intersection and then we built a mechanical model of a rock pillar at one of the points of intersection. At the end of this analysis, we obtained the failure characteristics of the critical parts on the large span intersection. Given these failure characteristics, we proposed a new supporting method, i.e., a Double-Bolt Control Technology (DBCT). By way of numerical simulation, DBCT can effectively control the deformation of the surrounding rock at the points of intersection in roadways.

A study of support strategies in deep soft rock:The horsehead crossing roadway in Daqiang Coal Mine

Geomechanics in deep mines becomes more complex and structural support in soft rock can be very difficult.Highly stressed soft rock subject to expansion deformation is particularly difficult to control.The Tiefa Coal Industry Group Daqiang Coal Mine is used as an example.A ventilation shaft,à550 horsehead,is located in tertiary soft rock.Analysis of the reasons for deformation shows an intumescent rock,which is easily damaged.Field observations and theoretical analysis led to a design capable of stabilizing the rock.A combination of spray,anchors,anchor bolts,and soft corner coupled truss supports allowed the deformation to be controlled.This provides a model for similar designs when support of a horsehead roadway is required.

An experimental study of a yielding support for roadways constructed in deep broken soft rock under high stress

A rationally designed support for deep roadways excavated in broken soft rock under high stress was investigated. The deformation and failure characteristics and the mechanism of ''yielding support'' was studied for anchor bolts and cables. The rail roadway of the 2-501 working face in the Liyazhuang Mine of the Huozhou coal area located in Shanxi province was used for field trials. The geological conditions used there were used during the design phase. The new ''highly resistant, yielding'' support system has a core of high strength, yielding bolts and anchor cables. The field tests show that this support system adapts well to the deformation and pressure in the deep broken soft rock. The support system effectively controls damage to the roadway and ensures the long term stability of the wall rock and safe production in the coal mine. This provides a remarkable economic and social benefit and has broad prospects for fur- ther application.

Deformation failure and countermeasures of deep tertiary extremely soft rock roadway in Liuhai coal mine

In view of failure phenomena with nonlinear large deformation including extensive damage,whole section destruction in short time,high rate of repair,most destruction forms occurred in the tertiary roadway of soft rocks engineering in Liuhai mine,according to the methods of geological survey,theoretical analysis,numerical calculation and in-situ test,the composite failure mechanism of molecular expansion,tectonic stress,gravity stress and engineering deviatoric stress,faults and random joint in this area is analyzed deeply,then an coupling support of double-layer-truss is proposed.The research results show that the first wave of deformation energy was released by bolt-mesh-cable fixed into the roof,floor and two sides of the roadway.While the second wave of deformation energy was released through the interface function between double-layer-truss and the surrounding rock.The double-layer-truss that characterized by high strength,good integrity can absorb high deformation energy of surrounding rocks,which led to the uniform distribution of the stress.Engineering practice shows this technology has been successfully applied to control the deformation failure of the tertiary extremely soft rock roadway.

Creep characteristic simulation of deep soft rock roadway and long-term mechanical analysis of lining support

By the generalized Kelvin creep model,rheological characteristics of deep softrock and long-term mechanical behaviors of support structures were simulated.Mechanicaldeformation characteristics of support structures under different lining circumstanceswere also analyzed on the basis of deducing the relationship between the generalizedKelvin creep model and implicit creep equations in ANSYS FEM software.The resultsshow that high stress of deep tunnels is the main factor in creep damage;the surroundingrock's deformation binding effect due to lining increases as the thickness increases but theeffect becomes very weak when it increases to a certain value;contact pressure on thelining decreases as its thickness decreases.

Numerical modeling of large deformation and nonlinear frictional contact of excavation boundary of deep soft rock tunnel

Roadways excavated in soft rocks at great depth are difficult to be maintained due to large deformation of surrounding rocks, which greatly influences the safety and efficiency of deep resources exploitation. During the excavation process of a deep soft rock tunnel, the rock wall may be compacted due to large deformation. In this paper, the technique to address this problem by a two-dimensional (2D) finite element software, large deformation engineering analyses software (LDEAS 1.0), is provided. By using the Lagrange multiplier method, the kinematic constraint of non-penetrating condition and static constraint of Coulomb friction are introduced to the governing equations in the form of incremental displacement. The numerical example demonstrates the efficiency of this technology. Deformations of a transportation tunnel in inclined soft rock strata at the depth of 1 000 m in Qishan coal mine and a tunnel excavated to three different depths are analyzed by two models, i.e. the additive decomposition model and polar decomposition model. It can be found that the deformation of the transportation tunnel is asymmetrical due to the inclination of rock strata. For extremely soft rock, large deformation can converge only for the additive decomposition model. The deformation of surrounding rocks increases with the increase in the tunnel depth for both models. At the same depth, the deformation calculated by the additive decomposition model is smaller than that by the polar decomposition model.

Anchoring mechanism and application of hydraulic expansion bolts used in soft rock roadway floor heave control

Comparing with the resin bolt, the hydraulic expansion bolt has different anchoring mechanism and application advantage. According to the working mechanism of the hydraulic expansion bolt, its anchoring force is expressed in four forms including support anchoring force, tension anchoring force, expansion anchoring force and tangent anchoring force, and their values can be obtained on the basis of each calculation formula. Among them, the expansion anchoring force, which is the unique anchoring force of the hydraulic expansion bolt, can provide confining pressure to increase the strength of rock. Aiming at solving the problem of stability control in the soft rock roadway in Jinbaotun Coal Mine which has a double layer of 40 U-type sheds and cannot provide enough resistance support to control floor heave, the study reveals the mechanism of floor heave in the soft rock roadway, and designs the reasonable support parameters of the hydraulic expansion bolts. The observed results of floor convergence indicate that the hydraulic expansion bolts can prevent the development and flow of the plastic zone in the floor rock to control floor heave. Research results enrich the control technology in the soft rock roadway.