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.

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.

Deformation characteristics of surrounding rock of broken and soft rock roadway

A similar material model and a numerical simulation were constructed and are described herein. The deformation and failure of surrounding rock of broken and soft roadway are studied by using these models. The deformation of the roof and floor, the relative deformation of the two sides and the deformation of the deep surrounding rock are predicted using the model. Measurements in a working mine are compared to the results of the models. The results show that the surrounding rock shows clear theological features under high stress conditions. Deformation is unequally distributed across the whole section. The surrounding rock exhibited three deformation stages： displacement caused by stress concentration, theological displacement after the digging effects had stabilized and displacement caused by supporting pressure of the roadway. Floor heave was serious, accounting for 65% of the total deformation of the roof and floor. Floor heave is the main reason for failure of the surrounding rock. The reasons for deformation of the surrounding rock are discussed based on the similar material and numerical simulations.

Application of a combined supporting technology with U-shaped steel support and anchor-grouting to surrounding soft rock reinforcement in roadway

Soft rock surrounding deep roadway has poor stability and long-term rheological effect. More and larger deformation problems of surrounding rock occur due to adverse supporting measures for such roadways, which not only affects the engineering safety critically but also improves the maintenance costs. This paper takes the main rail roadway with severely deformation in China＇s Zaoquan coal mine as an example to study the long-term deformation tendency and damage zone by means of in-situ deformation monitoring and acoustic wave testing technique. A three-dimensional finite element model reflecting the engineering geological condition and initial design scheme is established by ABAQUS. Then, on the basis of field monitoring deformation data, the surrounding rock geotechnical and theological parameters of the roadway are obtained by back analysis. A combined supporting technology with U-shaped steel support and anchor-grouting is proposed for the surrounding soft rock. The numerical simulation of the combined supporting technology and in-situ deformation monitoring results show that the soft rock surrounding the roadway has been held effectively.

Instability mechanism and control technology of soft rock roadway affected by mining and high confined water

Based on deformation and failure characteristics of the second belt conveyor roadway at level II of Zhuxianzhuang coal mine, laboratory experiments, numerical calculation and field test were adopted to analyze the composition and microstructure of mudstone, the law of mudstone hydration and its strength weakening induced by water, the characteristics of surrounding rock deformation and failure under the action of confined water. Results showed that montmorillonite clay minerals accounted for as much as 76% of mudstone, with a large number of pores existing in the microstructure. Besides, as the molecular structure of montmorillonite changed, mudstone microstructure damage occurred with the macroscopic manifestation of its theological instability. Weakening degree of confined water on residual strength of mudstone was almost 50%. The instability mechanism of soft rock roadway caused by high confined water is that surrounding rock circulates the process of ＂fracture-seepage-mud ding-closed＂ twice, which weakens its strength and leads to roadway instability. A combined support technology, namely the, ＂high-toughness sealing layer ＋ hollow grouting cables ＋ full-length anchoring bolts with deep borehole＂ was proposed. Based on field observation, the soft rock roadway was controlled effectively, which also verified the effectiveness of new control technology for surrounding rock.

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.

Response models of weakly consolidated soft rock roadway under different interior pressures considering dilatancy effect

Surrounding rocks of weakly consolidated soft rock roadway show obvious strain softening and dilatancy effects after excavation. A damage coefficient concerning modulus attenuation was defined. Response models of stress and displacement of surrounding rock of soft rock roadway and analytical expressions to calculate plastic zones under different interior pressures and non-uniform original rock stresses were derived based on damage theories and a triple linear elastic-plastic strain softening model. Influence laws of dilatancy gradient on damage development, distributions of stresses and displacement in plastic region were analyzed. Interior pressure conditions to develop plastic region under different origin rock stresses were established and their influences on plastic region distribution were also discussed. The results show that the order of maximum principle stress is exchanged between ~0 and trr with the increase of interior pressure P0, which causes distributions of plastic zone and stress shift. Dilatancy effect which has great influences on the damage propagation and displacements in plastic region has little effect on the size of plastic region and stress responses. The conclusions provide a theoretical basis for a reasonable evaluation of stability and effective supporting of weakly consolidated soft rock roadway.

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.

Mechanics model and numerical analysis of floor heave in soft rock roadway

The mechanism of floor heave was analyzed by establishing mechanics models and solving differential equations. The amount of floor heave is proportional to the abutment pressure of surrounding rock, roadway width, and the distance of support pressure peak to the roadway and is inversely proportional to the elastic modulus of floor rock. Using FLAC2D to simulate floor rock grouting in soft rock roadway verifies the active role of floor rock grouting in the floor controlling of soft rock roadway; floor rock grouting and grouting range directly impact on the stability scope of surrounding rock, namely, with the increase of grouting range, the subsidence of roof, the approach of both sides, and the amount of floor heave decreased gradually, the stability of surrounding rock is enhanced

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.

Mechanism of rock deformation and failure and monitoring analysis in water-rich soft rock roadway of western China

Aiming to get the strata behavior and stability rules of surrounding rock of the main return airway of Yushujing Coal Mine, convergence deformation of two sides and force of U-shaped steel yieldable support and bolt were monitored, and deformation of surrounding rock and mechanical characteristics of support structure were timely obtained to guide the informa- tion construction and optimize supporting parameters in water-rich soft rock roadway. The field monitoring results indicate the following. （1） Convergence displacement of rock surface increases with time continuity and shows surrounding rock＇s intense theological behavior. The original support scheme cannot control the large deformation and strongly theological behavior; （2） Without backfilling, the U-shaped steel support begins to bear load after erecting for 4-7 days and increases rapidly in the first 30 days. The U-shaped steel support at the right shoulder and top of roadway bears a larger force and the left side and shoulder bears a smaller force; （3） The stress of bolt increasing over time and at the right shoulder of roadway has larger growth and value. The mechanism of rock deformation and the failure and strata behavior in water-rich soft rock roadway are revealed based on the results of the measured relaxation zone of surrounding rock, measured stresses, and the rock mechanics tests.

Study on strata control by delay grouting in soft rock roadway

The properties of broken rock before and after grouting reinforcement are studied. Testing results show that grouting can raise the residual strength of broken rock, and the broken rockness by grouting can keep the steady supporting capacity within a relatively large deformation range. Revealing of the characteristics of stage deformation and damage process comes to the conclusion that the supporting of soft rock roadway should be analyzed in a dynamic view, and the grouting should be delayed at a proper occasion. Based on the above, the stepwise reinforcement technology characterized by immediate shotcreting, timely bolting and delay grouting is put forward and illustrated with a successful engineering practice.

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.

Theory of SCSTKP in Soft Rock Roadway

The secondary coupling supporting technique on key parts (SCSTKP) is put forward. Based on the coupling state between supporting structure and surrounding rock of roadway, the key parts are divided into four types, and the characteristics of each type are described. The method to determine the optimum supporting time is also presented.

Principle and practice of coupling support of double yielding shell of soft rock roadway under high stress

In order to ensure the safety and stability of the soft rock roadway under high stress, based on the char- acteristics of the surrounding rock deformation and failure, this paper presented the support technology“coupling support of double yielding shell”, then gave the design method of inner and outer shells and analyzed the principle and requirements of the support technology by taking the -850 meast belt mad-way of Qujiang coal mine as the background. The field application results show that the support technol- ogy can control the soft rock roadway deformation better under high stress. The displacement between roadway sides was 851 mm, the displacement of the roof was 430 mm, and the displacement of the floor was 510 mm.

Development of fractures in soft rock surrounding a roadway and their control

As the excavation of roadway, new fractures will be formed and the pre-existing fractures extend with the redistribution of stress in surrounding rocks. Eventually, fracture zone and bed separation are formed in rocks because of the developed fractures. Therefore, mastering the fracture evolution of surrounding rocks is very important to maintain the stability of roadway. The surrounding rocks of main haulage road- way in a certain coal mine is so broken and loose that the supporting is very difficult. Based on compre- hensive anal[ysis of the engineering geological conditions, a sight instrument was used to observe the fractures of internal surrounding rocks, Four indices, i.e., the width of fracture zone W, the number of fractures n, the width of fractures d and rock fracture designation RFD, are put forward to evaluate the fracture dewelopment. According to the evolution rules of the soft rock roadway from this paper, control principles by stages and by regions are presented through the research. At the same time, the best time of grouting reinforcement is determined on the basis of fracture saturation. Field practice shows that the roadway can satisfy normal production during service periods by suitable first support and grouting reinforcement.

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.