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.

Mechanical mechanism and support design analysis on bolt-beam-net support in soft rock roadway in Qigou Coal Mine

The deformation and failure mechanical mechanism in soft rock roadway is related to the stability of supported tunnels, which is important to coal mine production and construction. By physical mechanics experiments and X-ray diffraction （XRD） tests, the engineering mechanical properties of soft rock, as well as main mineral composition of the surrounding soft rock of Qigou Coal Mine, were obtained. Based on analysis results, a method using bolt-beam-net combination to support was put forward. Mechanical analysis of the support form was done by using the calculation software FLAC3D. Results show that clay minerals of this mine are kaolinite and illite mixed layer, of which the water absorption is relatively obvious and presented mudding characteristic after absorbing water, with the plasticity index of 0.35, with small expansibility, which is weakly consolidated colloid with strong connected force in unit cell. The rock blocks have the characteristics of moisture absorption softening, and the deformation mechanical mechanism of which is with the coexistence of molecular expansive mechanism, colloid expansive mechanism, and weak layer trend type. The calculation results show that the bolt-beam-net support structure makes the bolt, beam, and roof deform compatibly. The beams make the force in the bolt relatively homogeneous, which restricts the displacement of the tunnel roof as well. Finally, using in situ monitoring, the numerical results were verified.

Surrounding rock control of gob-side entry driving with narrow coal pillar and roadway side sealing technology in Yangliu Coal Mine

Gob-side entry driving can increase coal recovery ratio, and it is implied in many coal mines. Based on geological condition of 10416 working face tailentry in Yangliu Coal Mine, the surrounding rock deformation characteristics of gob-side entry driving with narrow coal pillar is analysed, reasonable size of coal pillar and reasonable roadway excavation time after mining are achieved. Surrounding rock control technology and effective roadway side sealing technology are proposed and are taken into field practice. The results showed that a safer and more efficient mining of working face can be achieved. In addition, results of this paper also have important theoretical significance and valuable reference for surrounding rock control technology of gob-side entry driving with narrow coal pillar under special geological condition.

Research on space-time coupling action laws of anchor-cable strengthening supporting for rock roadway in deep coal mine

In order to obtain space-time coupling relationship of anchor-cable to improve supporting effect for deep coal mine rock roadway, FLAC3D was used to investigate into mechanical characteristics of the roadway whose crosssection shape was vertical wall and semi-circular arch when the roadway was supported by bolts and metal mesh. The results show that the extent of stress concentrations, the range failure zone, and the deformation at the roof center and two spandrels of roadway are greater than those at other positions, except at the floor. The reasonable positions of anchor-cable supporting are the roof center and two spandrels of roadway. The anchor-cable should be installed at good time with bolts supporting after roadway driving be- cause it can improve the stress states of deep surrounding rock around the roadway and control the roadway deformation effec- tively. The engineering practice has proven that the sustained deformation of deep surrounding rocks is effectively controlled when the anchor-cable supporting is adopted at reasonable positions of the roadway at good time.

Analysis of soft rock roadway deformation mechanism in Zhangshuanglou Mine

On basis of ground stress surveying and analysis of physical nature and mechanics character of rock, the deformation mechanism of west main roadway in Zhangshuanglou Mine is studied. It is put forward that engineering mechanics nature, infiltration of water and concentrated stress on pillar are the main factors to affect stability of the west main roadway. The overall thinking used to restore the roadway is raised.

Study on creep deformation and energy development of underground surrounding rock under four‐dimensional support

There is an urgent need to develop optimal solutions for deformation control of deep high‐stress roadways,one of the critical problems in underground engineering.The previously proposed four‐dimensional support(hereinafter 4D support),as a new support technology,can set the roadway surrounding rock under three‐dimensional pressure in the new balanced structure,and prevent instability of surrounding rock in underground engineering.However,the influence of roadway depth and creep deformation on the surrounding rock supported by 4D support is still unknown.This study investigated the influence of roadway depth and creep deformation time on the instability of surrounding rock by analyzing the energy development.The elastic strain energy was analyzed using the program redeveloped in FLAC3D.The numerical simulation results indicate that the combined support mode of 4D roof supports and conventional side supports is highly applicable to the stability control of surrounding rock with a roadway depth exceeding 520 m.With the increase of roadway depth,4D support can effectively restrain the area and depth of plastic deformation in the surrounding rock.Further,4D support limits the accumulation range and rate of elastic strain energy as the creep deformation time increases.4D support can effectively reduce the plastic deformation of roadway surrounding rock and maintain the stability for a long deformation period of 6 months.As confirmed by in situ monitoring results,4D support is more effective for the long‐term stability control of surrounding rock than conventional support.

Support technologies for deep and complex roadways in underground coal mines:a review

Based on geological and mining characteristics,coal mine roadways under complex conditions were divided into five types,for each type the deformation and damage characteristics of rocks surrounding roadways were analyzed.The recent developments of roadway support technologies were introduced abroad,based on the experiences of supports for deep and complex roadways from Germany,the United States and Australia.The history and achievements of roadway support technologies in China were detailed,including rock bolting,steel supports,grouting reinforcement and combined supports.Four typical support and reinforcement case studies were analyzed,including a high stressed roadway 1,000 m below the surface,a roadway surrounded by severely weak and broken rocks,a chamber surrounded by weak and broken rocks,and a roadway with very soft and swelling rocks.Based on studies and practices in many years,rock bolting has become the mainstream roadway support form in China coal mines,and steel supports,grouting reinforcement and combined supports have also been applied at proper occasions,which have provided reliable technical measures for the safe and high effective construction and mining of underground coal mines.

Floor heave in the west wing track haulage roadway of the Tingnan Coal Mine: Mechanism and control

Floor heave of a roadway is a dynamic phenomenon that often happens in the roadways of coal mines. It seriously affects safe production in the coal mine. Floor heave has long been one of the most difficult problems to be resolved during coal mining. An analysis of floor heave in the soft rock surrounding the roadway, and the factors influencing it, allowed the deformation mechanism in the west wing double track haulage roadway of the Tingnan Coal Mine to be deduced. Three types of floor heave are observed there: intumescent floor heave, extrusion and mobility floor heave, and compound floor heave. Control measures are proposed that have been adopted during a recent repair engineering project. Control of the floor heave in the west wing track haulage roadway was demonstrated. The reliability and rationality of a combined support technology including floor anchors, an inverted arch, and anchoring of both sides was verified by mine pressure data and the field observations. Waterproofing measures were also under-taken to assist in the control of floor heave.

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.

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.

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.

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.

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.

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.

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.