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RI 9533 STlGATlONS/1995

Field Evaluation of Cable Bolts for Coal Mine UBRARV

Roof Support \ 9I'OKAtlE~~~~WiTi:R
MAR 2') 1995
By John P. McDonnell, Stephen C. Tadolini, and Paul E. DiGrado

-)

UNITED STATES DEPARTMENT OF THE INTERIOR

BUREAU OF MINES
 U.S. Department of the Interior
Mission Statement
As the Nation's principal conservation agency, the Department of
the Interior has responsibility for most of our nationally-owned
public lands and natural resources. This includes fostering
sound use of our land and water resources; protecting our fish,
wildlife, and biological diversity; preserving the environmental
and cultural values of our national parks and historical places; and
providing for the enjoyment of life through outdoor recreation.
The Department assesses our energy and mineral resources and
works to ensure that their development is in the best interests of
all our people by encouraging stewardship and citizen participa-
tion in their care. The Depaliment also has a major responsibility
for American Indian reservation communities and for people who
live in island territories under U.S. administration.

Cover: U.S. Bureau of Mmes researchers in fully cribbed

tQl7gate entry of a longwml (upper right) and tailgate entry
utilizing onlyc~le bolts (no wood cribs) for secondory
support (lower left).
Report of Investigations 9533

Field Evaluation of Cable Bolts for Coal Mine

Roof Support

By John P. McDonnell, Stephen C. Tadolini, and Paul E. DiGrado

UNITED STATES DEPARTMENT OF THE INTERIOR

Bruce Babbitt, Secretary

BUREAU OF MINES I, ,

Rhea L. Graham, Director

 I

International Standard Serial Number

ISSN 1066-5552
 CONTENTS
Page

Abstract. . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cable support design ...............................................................•. 3
Installation methods ................................................... . . . . . . . . . . . . . . . 6
Cement grout installation procedures ................................................... 6
Resin grout installation procedures ..................................................... 7
Field evaluations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Case study 1 ..................................................................... 8
Site description ................................................................. 9
Instrumentation ................................................................. 10
Test site results ................................................................. 10
Discussion ................................................ . . . . . . . . . . . . . . . . . . •. . 12
Case study 2 ...............................................................•..... 12
Site description ................................................................. 12
Cable system design . . . .. .. .. .. .. .. .. .. .. .. .. . . . . . . . . . . .. . . . . . . . . . . . .. .. . . .. . . . . .. 13
Instrumentation ............................................. . . . . . . . . . . . . . . . . . . . . 13
Test site results ......................................•.......................... 14
Discussion .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Case study 3 ..................................................................... 17
Site description ................................................................. 17
Cable system design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Instrumentation ...•...................................• :':. . . . . . . . . . . . . . . . . . . . . . . 17
Test site results ................................................................. 19
Panel 2 mining ............................................................... 19
Panel 3 mining ............................................................... 19
Discussion .............................................................. . . . . . . . 29
Future research •.................................................................... 29
Summary and conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
References . . . . . . . . . . . . . . . . • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

ILLUSTRATIONS

1. Detached block failure supported by cables ............................................. 4

2. Formation of pressure arch of failed mine roof material .................................... 4
3. Formation of yield zone in coal pillars ................................................. 4
4. Design chart to determine yield zone width in coal pillars .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Cable support design chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. Components of concrete-grouted cable support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7. Specific components of resin-grouted cable bolt .......................................... 7
8. Tensionable nut for resin-grouted cable bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9. Cross section of 1.52-cm diam cable installed in 2.5-cm diam hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10. General mine layout showing case study loeations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11. Gate roads showing cement-grouted cable test area and instrumentalion layout at a Western U.S.
underground longwall mine ........................................................ 10
12. Geological column from test area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
13. Crib stiffness at different intervals of face advance ........................................ 11
14. Individual and accumulated roof anchor displacements ..................................... 11
15. Pressure pad loading behavior with face advance in crosscut 11 . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . 12
16. Pressure pad loading behavior with face advance in crosscut 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
17. Entry closure and roof response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
18. Bleeder entry configuration and resin-grouted cable test area ................................ 13
19. Cross section of test area showing primary and cable support spacing and resin grout lengths . . . . . . . . . 14
 ii

ILLUSTRATIONS-Continued

Page

20. Bleeder site 1 proftles duriug panels 2 and 3 mining ............•...............••..••...•. 15

21. Bleeder site 2 profiles during panel 3 mining ...............•...............•......•••.•. 16
22. Case study 3 test area examining three different types of resin-grouted cable supports and respective
instrumentation types and locations ...•......••.................•.....•.........•..•• 18
23. Generalized cross section of cable spacing and lengths used in gate road test areas .•..........•... 19
24. Resin-grouted cable test area immediately after cable support installation ...............•....... 20
25. Resin-grouted cable test area after first panel passed test area and loads were redistributed onto pillars
and next panel ................................................................. . 20
26. Resin-grouted cable test area when panel 3 face was 243.8 m inby test area .............•...•.•.. 22
27. Results from differential sag station being located in first intersection of passive test area ..••....... 22
28. Floor heave in passive support system test area .............•..................•...•...•.. 23
29. Results from differential sag station being located in first intersection of stiff support system test area ., 23
30. Stiff support system test area condition during panel 3 mining ...............••...•...•....... 24
31. Roof condition inby panel 3 longwall face ......•.......•................•....•.......... 24
32. Tensionable support system test area condition during panel 3 mining .............•..••..•....• 25
33. Results from differential sag station being located in second intersection of tensionable support system
test area •...........•...........•........................................•...• 26
34. Closure-rate instrumentation and condition of tensionable support system test area ...•.•.......... 26
35. Roof integrity and stability of tensionable support system test area ...............•.......•.... 27
36. Pillar and panel loading during panel 2 extraction ......•............•......•...••.....••.. 28
37. Pillar and panel loading during panel 3 extraction .........................•...•..••..••..• 28

UNIT OF MEASURE ABBREVIATIONS USED IN THIS REPORT

Metric Units

em centimeter kN kilonewton

cm/h centimeter per hour kN/cm kilonewton per centimeter

GPa gigapascal kPa kilopascal

h hour m meter

ha hectare MPa megapascal

kg/m kilogram per meIer tim' metric ton per square meter

kg/m' kilogram per cubic meter

!.l.S. Cusloman: Units

ft foot Ib/ft' pound per cubic foot

in inch Ib/in pound per inch

in/h inch per hour lbf pound (force)

Ib pound Ibf/in' pouud (force) per square inch

lb/ft pound per foot st/ft' short ton per square foot

Reference to specific products does not imply endorsement by the U.S. Bureau of Mines.
 FIELD EVALUATION OF CABLE BOLTS FOR COAL MINE ROOF SUPPORT

By John P. McDonnell,l Stephen C. Tadolini,l and Paul E. DiGrado2

ABSTRACT

Cable supports offer several advantagcs over traditional secondary support methods by enhancing
stress redistribution to pillars and gob arcas, minimizing or eliminating timbers and cribs that reduce
ventilation, eradicating material-handling injuries related to placement of crib supports, and providing
a cost-effective alternative to secondary support. The U.S. Bureau of Mines, in researching alternatives
to traditional roof support methods, designed and installed high-strength cable supports to improve the
stability of longwall gate road and bleeder entrics in a Western U.S. coal mine. With the cooperation
of industry, methods were developed to install cable supports in a tailgate and bleeder entry test area
using traditional resin cartridges. Resin-grouted cable bolts were also installed and evaluated in
additional longwall gate road and bleeder entry systems at the study mine. The cable-bolted areas
successfully maintained roof support throughout the tailgate and bleeder entries. Cable supports
replaced wood cribbing as secondary support in the bleeder entry system and minimized the use of
cribbing in the longwall tailgate entries.
This report describes the theory, application, and advantages of cable supports and prescnts mine
measuremcnts made to assess the cable performance during the retreat process of longwall mining.

IMining engineer.
2Engineering technician,
Denvel' Research Centel', U.S. Bureau of Minell, Denver, CO.
2

INTRODUCTION

Gate road entries remain the most hazardous areas in Cable bolts were introduced to the U.S. mining industry
longwall mines, and keeping them stable is a challenging in the early 1970's as a method to reinforce ground prior
task. Gate roads provide access and escapeways for the to mining; discarded wire rope was the preferred choice by
miners, coal transportation, and ventilation (intake and most ground control engineers. Today, the basic cable
return). Headgates are supported primarily with roof bolts bolt support consists of a high-strength steel cable installed
during development mining and, during longwall face re- and grouted with cement in a 4.1- to 6.4-cm (1.625- to
treat, require secondary reinforcement for a nominal dis- 2.5-in) borehole. Recent advancements in resin and cable
tance outby the face, arouud 152 m (500 ft). Generally, technology permit the use of resin as an anchorage ma-
wooden posts, hydraulic jacks, or spot roof bolts are used terial in a 2.5- and 3.5-cm (1- and 1-3/8-in) diam hole.
to cope with the front and side abutment pressures caused Traditional cables have an ultimate strength of 244.7 to
by mining. Headgate entries must stay unobstructed and 266.9 kN (55,000 to 60,000 Ibl) and a modulus of elasticity
completely open, with minimum convergence, for access of of about 203.4 GPa (29.5 million Ibf/in,). Cables are 1.52
personnel and equipment and for coal b·ansport. The tail- to 1.59 em (0.6 to 0.625 in) in diameter and consist of sev-
gates, however, are used for return air, sometimes intake en individual wires. Driven by the demand for high capac-
air passages, and travelways. Much higher ground pres- ity and large deformations in coal mine gate roads, high-
sures exist around the tailgate entries, making them dif- strength cables measuring 1.78 em (0.70 in) diam with a
ficult to support. Moderate entry closure or partial yield strength of 244.7 kN (55,000 Ibl) and an ultimate
blockage of the tailgate entry is tolerated. Generally, strength of 378.1 kN (85,000 Ibl) are being introduced.
wood or concrete cribbing materials are used for second- These cable material characteristics provide large amounts
ary supports in the tailgate entries, where cribbing pat- of deformation at a high degree of loading and ultimate
terns and densities are varied to support difficult ground strength. These steel cables are flexible and can be coiled
pressures. to about 1.2 m (4 ft) diam for handling. This flexibility is
A recent analysis on the number of reported accidents one of the primary advantages of cable supports since the
related to cribbiug, timbering, and blocking revealed that support length is not limited or restricted by the opening
in U.S. underground mines in 1991 and 1992, a total of734 height.
accidents pertinent to these activities were reported. The For a cable support system to be effective, it is neces-
majority of the serious accidents occurred in Western U.S. ,ary for the loads to be successfully transferred from the
underground longwall mines. These accidents directly re- rock to the cable through the grouting materiat Labora-
late to the height of the coal seam, which requires the use tory and field investigations have determined that to
of ladders to build the cribs with heavy and cumbersome achieve a load of 258.0 kN (58,000 Ibf) when resin prod-
materials (1_2).' Use of cable bolts in lieu of cribbing in ucts are used, 1.2 m (4 ft) of grout is required to develop
tailgates reduces the exposure of the worker to the hazards the ultimate capacity of the cable. Of conrse, adequate
of cribbing. anchorage should be evaluated on a site-specific basis by
Using less crib material will also help minimize the ven- performing standard pull tests. Laboratory and field re-
tilation resistauce in air passages, which results in savings sults indicate that at least 6% elongation for the ungrouted
in air pressure and increases airflow at the working face, portion of the cable can be expected (4-5). This permits
while removing gas and dust more efficiently (3). This the designer to vary the amount of grouted and ungrouted
creates a safer and cleaner mine environment for under- portion of cable to obtain various degrees of stiffness,
ground workers, while saving on mine ventilation costs to depending on the specific strata to be supported.
the mine operator. Additionally, subject to the availability From 1992 to 1994, the U.S. Bureau of Mines (USBM)
of a reliable source of quality timber, the amount required investigated the use of cable supports at Mountain Coal
to support a single 2,530-m (8,3oo-ft) gate road with 1.8-m Co.'s West Elk Mine, Somerset, CO, to evaluate the po-
by 20.3-cm by 20.3-cm (6-ft by 8-in by 8-in) crib blocks in tential to supplement or replace conventional headgate and
a 2.9-m (9.5-ft) high opening would be 613 ha (248 acres) tailgate secondary supports. The results indicated that
of select-cut prime timber.' Consequently, eliminating or given the pillar layout and site-specific roof conditions and
minimizing crib supports can reduce accidents related to strengths at the test mine, the use of cable bolt systems
support iustallation, improve ventilation, and reduce wood was successful in maintaining the longwall tailgate entries
consumption. (6-7). The effective application of this technology indi-
cated the potential for several mining benefits. A direct
3ltalic numbers in parentheses refer to items in the list of references benefit of cable systems is the installation of a support sys-
at the end of this report. tem capable of strengthening and reinforcing roof mem-
4Data provided by the U.S, Forest Service. bers, transferring high pressures into the main and
 3

immediate roofs and onto supporting structures away from applications (8). The success of this investigation prompt-
the periphery of the entries. The major disadvantages of ed the mine operator to investigate the application of
the cement-grouted cable systems are the amount of time resin-grouted cable supports in a longwall gate road and
required to pack and grout the holes, the additional step assess support performance during the extraction of the
required to install the bearing plates, and the system adjacent longwall panels.
component costs. The ultimate goal of this investigation is to provide en-
The USBM, with the cooperation of industry, has de- gineered and economically feasible support systems and
veloped methods to install cable supports using traditional designs that provide safe work areas under diverse and
roof bolt resin cartridges. The first resin-grouted cable hazardous ground conditions while enhancing production
bolts were employed to support coal mine bleeder entries in U.S. coal mines.
directly behind a longwall panel at the West Elk Mine. This report presents results from the initial <;ement-
Resin-grouted cable-supported bleeder entries have proven grouted cable test area and subsequent cable support sites
to be an effective alternative for secondary support when in the bleeder and gate road entries.
compared with wood timbers and cribs in bleeder entry

CABLE SUPPORT DESIGN

Although cables have been used in U.S. hard-rock (1)

mines, the procedure is new for underground coal mines,
and applications are significantly different from hard-rock where Fw = weight of rock per lineal meter (foot),
employment. Wire rope and cable supports have been kg/m (Ib/ft),
used in Australian coal mines for about 8 years. However,
Australian mining methods differ from U.S. methods in = effective width of opening, m (ft),
that large barrier pillars, approximately 61 to 122 m (200
to 400 ft), are left between two entries and cables are = distance from coal mine roof to parting
frequently supplemented with steel arches and beams (9- plane, m (ft),
10). The analytical and theoretical approach, ongoing
during the invesligation, is initially simplistic in nature, but and -y = rock density, kg/m3 (lb/ft3).
is being constantly modified based on field measurements.
The first step of the design procedure requires a de- This method is conservative since it is more likely that
tailed data gathering 10 determine the ground conditions the coal pillars will provide additional support to the de-
in the underground mining environment. This includes a tached roof structure, forcing the formation of a pressure
general estimation of the rock mass quality, the geological arch of the failed material. As shown in figure 2, the
structure, and the strengths of the immediate and main cables must be capable of supporting pnly the material
roof members. This information can be obtained from within the boundaries of the pressure arch. The height of
roof core samples and supplemented with a borescope or the arch can be correlated to the, vertical and horizontal
camera used in the borehole. Secondly, an estimate of the stresses acting in the immediate roof and is believed to
induced stresses calculated using empirical methods or increase as the in situ horizontal stress increases. A gen-
modeling should be included in the stability analysis. The erally used criterion for determining the height of the
weight of the rock mass should be expressed per lineal pressure arch is that the failure height is 0.5 to 2.0 times
meter (foot) of roof for mine entries to determine the the mined seam height, varying with the direction and
required cable spacing. The zone of rock material that magnitude of the stress field (11). The weight of the ma-
must be supported by the cable system can be determined terial within the arch can be estimated with respect to the
several ways, and design principles are constantly being opening width and the height of the arch by the following
updated. equation:
The simplest approach is to identify a parting plane
where separation above the roof bolted zone is likely to
occur. For the worst case scenario, it can be assumed that
the bolted strata will shear at the pillar boundaries of the where Fa = weight of rock within pressure arch per
opening and that the entire block must be supported by lineal meter (foot), kg/m (Ib/ft),
cables, as shown'in figure 1. The weight of the material
can be determined by using the equation and height of pressure arch, III (ft).
4

The behavior of the pillar under different loading con- Figure 1

ditions determines W., shown in figure 3. Wilson dermes
the depth of the yield zone as the depth at which the coal
strength in the entire pillar is exceeded by the loads im-
posed; therefore, Wilson's equations can be used to esti-
mate the depth of this yield zone for rigid roof-floor
conditions (equation 3) and yielding roof-floor conditions
(equation 4) (12).

Wilson's equations are

w = 2~ln
F
[~)
p+p
(3)
Detoched block failure suppotted by cables.

and w=m [[-

q
-
P +p"
J1/k-1_]1 ,
(4)
Figure 2
where w pillar width, m (ft),

F k -_1 + ____
_ (k - li tan-11i:'
Vk, where
.fk k
tan -1.fk is expressed in radians,
m seam height, m (ft),

q overburden load, t/m2 (st/ft2),

p = artificial edge restraint, 0 t/m2 Fonna/ion ofpressuro =h offailed mine roof ma/erial.
(st/ft2)

p' = uniaxial strength of fractured coal, Figure 3

1 t/m2 (st/ft2),

and k " I factor = l+sinql , were

tn3X1a h
1 - sinql
qI = angle of internal fric-
tion, deg. (5)

The depth of this yield zone can be calculated or approxi-

mated using the charts shown in figure 4. The charts were
created using a value of 35' for the angle of internal fric-
tion. W, can then be calculated by using the following
equation: Fonnalion of yield zone in coal pillars. (w., = effective
width of openin/!i Ypl = yield zone for pillar 1; YpZ = yield
(6) zone for pl7lar 2; W = mined width of opening.)
Figure 4 where W = mined width of opening, m (ft),
COVER DEPTH, ft
500 1,000 1,500 2,000 YpI = yield zone for pillar 1, m (ft),
10.0
A 30
and Yp2 = yield zone for pillar 2, m (ft).
7.5
E Once the volume and weight of the material to be sup·
W 5.0 w ported with cables has been determined, it is then possible
z z to determine the number and spacing of the required ca·
o L -__ ~ ____- L____i -____L -_____ J 10 N
0
bles to support the gate road entry. Using a cable capacity
N 2.5
o of 258.0 kN per cable (58,000 Ib per cable) and varying the
I
0

iii i
~ ~

i, i : 4
number of cables across the opening, the best design can

~ 5.0 IB 10 ~ be determined for a specific application and operation.

Figure 5 shows a design chart calculated for two, three,
2.5 and four cables installed for W, of 7.6 m (25 ft) and a mao
100 200 300 400 500 600 terial weighing 2,403 kg/m3 (150 Ib/fl'). For example,
COVER DEPTH, m drawing a line up from the x·axis, spacing distance along I
the entry to the cable number line, and going left from
KEY that point to the y.axis indicates the thickness of a failed
Seam height, m (ft) beam member that can be entirely supported with the in·
" 3 (10) stalled cables. In the example, two, three, and four cables
o 2.4 (8) spaced across the width, at 2.1·m (7·ft) spacing along the
o 1.8 (6) entry, would have the capacity to support 1.4, 2.0, and
Design chait to detennine yield :wne width in coal pillars. 2.7 m (4.5, 6.7, and 8.9 ft) of separated material,
A, Yielding roof; B, rigid roof. respectively.

Figure 5
DISTANCE BETWEEN CABLE BOL TS, ft
5 6 7 8 9
4.0
KEY 12
3.5
" 4 cables
E o 3 cables ,-
+'

3.0 10
vi
(f)
o 2 cables (f)"
(f)
w w
z 2.5 z
8 :.::
:.::
u u
:r: 2.0 :r:
I- I-
6
~ ~

w 1.5
<{ <{
w
m 4 m
1.0
2
0.5
1.5 2.0 2.5 3.0
DISTANCE BETWEEN CABLE BOLTS, m
Cable suppmt design chmt, where effective width of opening (WJ = 7.6 m (25ft) muJ
rock density (y) = 2,403 kg/m 3 (150 Ib/[i'). For example, a 21-111 (70-ft) cable bolt
spacing along entry could support 1.4, 2~ and 27 m (4.5, 6.7, and 8.9 ft) of separated
material using two, three, and four cables, rospec/ively.
 I" '
1
i

1 '
6
"I'
!;' ,
i!l:
I' ,
I' INSTALLATION METHODS

Cable supports have been successfully installed using viscosity. This can be partially overcome by adding a
both the "traditional" cement grout and resin grout. Both chemical plasticizer, which makes the grout slicker and
systems have advantages and disadvantages, but a close ex- easier to pump without adversely impacting the final
amination of both systems indicates that resin-grouted ca- strength.
ble bolting is superior for most coal mine applications 7. After the hole is filled, the ends of the two tubes
from a productivity and cost standpoint. However, there are folded over and tied off to prevent the grout from
may be circumstances when a cement cable system would draining.
be preferred. For example. if large voids or washout of 8. The next day, or after approximately 24 h, the tubes
the roof rock was present, the concrete would completely can be cut off to allow the installation of a bearing plate
fill the voids and develop the required anchorage, whereas and cable grips. A hydraulic cable jack can be used to
the resin would be lost in the voids and may not develop tension the cable to the desired preload condition.
enough anchorage to develop the strength of the cables.
Another example of when cement grout would be pre- A completed cement installation and the required com-
:' I
ferred is when a full column of grout is used to increase ponents, without the bearing plate and the cable grips, are
',.i; the system stiffness. The volume of resin is currently shown in figure 6.
constrained by the diameter of the tubes, and obtaining a
full column of resin is extremely difficult.
Figure 6
CEMENT GROUT INSTALLATION PROCEDURES

Cement -grouted cable bolts can be installed at any

angle in the rock. To install the cables with concrete
grout, the following steps are taken:

1. A hole is drilled, with a diameter of 4.1 cm (1-

5/8 in), to a depth of at least 5.1 cm (2 in) deeper than
the desired cable length.
2. The cable, with the appropriate retaining anchor,
plastic breather tube, and grouUube, is inserted into the
hole. The breather tube is almost as long as the cable and
allows the air being displaced by the grout to escape. Al-
so, grout running out of the tube indicates to the cable
bolt crew that the hole is filled.
3. Water is sent through the breather tube to flush the
hole and clear debris from the breather tube.
4. A plastic grout tube is pushed approximately 45.7 cm
(18 in) into the hole.
'" I
ii,
5. The bottom 20.3 cm (8 in) of the hole is plugged,
I sealing the area around the cable, grout, and breather
tubes. This can be accomplished by stuffing shredded cot-
ton waste material around the tubes or using an expansive
foam. The combination of both provides an excellent seal.
6. The hole is then filled with a cement-based grout
through the grout tube. The grout commouly used con-
sists of a water and cement mixture at a ratio of 0.35 part 1.27-cm-ID
of water to 1 part of cement by weight. Several laboratory (O.5-in-1Dl----...
studies have been completed that investigated the effects
of water-to-cement ratios. The strength selected is site
breather tube
specific and related to the available pumping equipment. Components of concrete-grouted cable support. (ID = in-
The greater the cement-to-water ratio, the higher the final side diameter.)
•

RESIN GROUT INSTALLATION PROCEDURES Figure 7

Resin-grouted cable bolting was initiated in the United

States in 1992. Several required installation parameters
were identified to make cable bolting with a resin anchor-
age system as routine as headed rebar. Numerous design
evolutions were investigated before resin-grouted cable
bolts were fabricated on a production level. An example
of the cable bolt used in several USBM investigations is
shown in figure 7. Each component serves a specific func-
tion that contributes to the overall success of the cable
bolt system.
The end of the cables are clamped together using a
swedged-on fitting, as shown in figure 7A. This ties all the
cable strands together, including the king wire, which is
the center cable strand. The next swedged-on buttons
serve two functions (figure 7B) . First, they provide addi-
tional anchorage and resistance to pullout forces. It is
extremely difficult, if not impossible, to pull the cable out
of the resin when these buttons are imbedded in the bore- Specific components of rnsin-grouted cable bolt A,
hole. Secondly, the buttons help mix the resin during Swedged-on fiUing to tie all cable strands together; B,
placement by forcing the resin around the tight opening;
the turbulence enhances the mixing and helps to detach
c:
swedged-on buttons for additional ancluJTages; shott but-
ton to hold p/Qstic seal in place; D, cable stiffener rod; E,
the cartridge cover. The short button (figure 70 generally installation head or caIJ/e nut
pserves the same functions as the large button and also
holds a plastic seal (dam) to restrict the flow of resin
down the hole. Laboratory and field results indicate that
keeping the resin at the top of the hole can be the differ- Figure 8
ence between adequate and inadequate anchorage for
resin-grouted cables. Any resin loss for a critical length of
anchorage may allow the cable to pull out of the hole be-
fore developing ultimate strength. Because the cables are
flexible, they may bend when the back pressure from the
resin becomes too high, causing the cable to bend or kink.
The cable stiffener (figure 7D) provides stiffness to the
bottom portion of the cable to ease the installation of the
last 1.2 to 1.5 m (4 to 5 ft) of cable. The length of the
stiffener can be adjusted to the mining height and the ef-
fective resin column length desired. It eases installation to
have the stiffener in the hole before any back pressure
causes the cable to bend or kink. Additionally, during the
process of mixing the resin, the bearing plates, placed on 0 4 S
the cable before installation, tend to spin rapidly. Field
observations indicate that this spinning can cause the bear- I I -- ~
I

".
ing plate to nick the cable, which may lead to premature
failure. The cable stiffener eliminates cable nicking. The 0 1 ~ 5 [I

final component of the resin-grouted cable bolt system is

the installation head or cable nut (figure 7E). This makes Scale
the cable easy to rotate and install with conventional roof
Tensionable nut for rnsin-grouted cable boIL
bolting machinery. The nut is capable of handling loads in
excess of the ultimate bearing capacity of the cable.
Several variations of this system are becoming available. an important consideration in a laminated roof material
One system of particular interest allows tension to be ap- where any separation may lead to progressive-type failures.
plied to the cable after the resin has cured. This compo- If a high-tensioned system is desired, it is important to
nent is shown in figure 8. High degrees of tension may be realize that the resulting ultimate support capacity is
 •

lowered by the tensioned amount. For example, if the sys- Figure 9

tem is pretensioned 44.5 kN (10,000 Ib), the remaining ca-
pacity of the system to support roof loads is 213.5 kN
(48,000 Ib). To install the cables with resin grout, the
following steps are taken:

1. Drill the prescribed hole 2.5 to 5.1 cm (1 to 2 in)

longer than the cable to be installed. The holes can be
drilled with a water or vacuum drilling system. Hole di-
ameters ranging from 2.5 to 3.5 cm (1 to 1-3/8 in) have
been used successfully.
2. Place the resin cartridges into the borehole. An in-
stallation technique that appears to be working well, espe-
o 4 8 em
cially in the case where more than one cartridge of resin
is required, is the placement of a faster setting cartridge at I 1 1
the top of the hole. This permits fast installation, instan-
taneous anchorage, and immediate support.
3. As the cable is pushed up through the resin car-
o 1 2 3
•
In
tridges, it is rotated slowly to enhance the mixing of the
resin. When the cable is approximately 7.6 to 10.2 cm (3
to 4 in) from the back of the hole, the rotation is in-
Sc a l e
creased and the resin is mixed the total amount of time Cross section of I.52-cm (O.60-in) diam cable instIllled in
recommended by the manufacturer. (Care should be tak- 25-cm (I-in) diam ho1L
en not to overspin the bolt.) The mixing time begins when
the cartridges are punctured by the insertion of the cable.
Field investigations have revealed that the cable should be provides an active bearing plate pressure and pretensions
rotated counterclockwise. This tends to screw the cable the cable (13).
into the hole, getting a positive contact between the bear- 5. If a tensionable unit has been installed, the cable is
ing plate and the roof. Rotating the cable clockwise will then ready for jacking to a predetermined load, using spe-
pull up the resin, creating back pressure after the resin has cial equipment.
been mixed and the cable is pushed up against the roof.
When the bolting stinger is removed, the cable relaxes and A cross section of a 1.52-cm (0.60-in) diam cable is shown
pushes out of the hole, voiding any plate roof contact that in figure 9. The resin is tight against the six outer strands
may allow separation and progressive failure to occur. and there are traces of resin around the center strand.
4. When the resin has been adequately mixed, the ca- This demonstrates how resin grout provides an excellent
ble is pushed up against the roof with the full force of the mechanical interlock, creating a high degree of cable
bolter and held in place until the resin has cured. This anchorage.

FIELD EVALUATIONS

Several long-term field evaluations were undertaken at CASE STUDY 1

various locations in the West Elk Mine. In each of the
three case studies, the cables were being used as secondary Cable supports were installed to assess their effects on
support systems in gate roads and bleeder entries. Case the stability of tailgate entries in an underground Western
study 1 involved cement-grouted cables in a bleeder and U.S. coal mine. Two entries closest to the longwall panel
gate road entry; case study 2 involved advancing to resin- were supported with high-strength cables installed with ce-
grouted cables installed in a bleeder entry system; and case ment grout. Instrumentation was used to monitor and as-
study 3 was an evaluation of resin-grouted cables as the sist in the evaluation of the effectiveness of the support
sole means of secondary support in a longwall tailgate en- system and the general response of the mine openings.
try. Figure 10 shows the general mine layout with the
location of the three case study areas.
 9

Figure 10

Case study 2 orea

ponel 1
Ponel 2
Panel 3
Panel 4
Panel 5

Direction Case
of study 3
area
mining
Case
study 1
area

General mine IayoUl shoWing case sllldy locations.

76.2 m (250 ft) of the second entry, longwall bleeder entry
2, was supported with S.5-m (18-ft) long cables iusta\led on
Site Description a 2.1-m (7-ft) spacing, as shown in fignre 11. The differ-
ence in cable length was attributed to the different loading
The longwall gate roads and the test area are shown in
conditions that the supports would be subjected to as th
figure 11. The final pUla! dimensions for the pillar nearest
panel was extracted. The primary support system in tb
the panel were 39.6 by 39.6 m (130 by 130 ft), and the pil-
area, installed on initial development, was 1.8-m (6-[t
lar between entries 2 and 3 was 39.6 m (130 ft) long and
full-column, resin-grouted bolts on a l.5-m (5-ft) patter
30.5 m (100 ft) wide. Basically, with modifications in the
installed with pans and complete wire meshing.
intersections, 109.7 m (360 ft) of roadway nearest the long-
wall panel, entry 1, was supported with 6.7·m (22-ft) long
cables installed on a 2.1-m (7-ft) spacing. Approximately
 10

An examination of the mining horizon indicated 4.2 m indicated bed separation and subsequent roof movements.
(14 ft) of minable coal seam, but the gate road entries The sag station was located at approximately construction
were driven only 2.9 m (9.5 ft) high. A generalized sum- station 19 +48. The roof strata remained stable until the
mary of the immediate roof in the area included about 1.1 panel face was approximately 2.4 m (8 ft) inby. The im-
m (3.5 ft) of top coal overlain by about 0.45 m (1.5 ft) of mediate roof then began to show signs of movement and
a silty shale. The roof above. the silty shale grades ver- separation. The largest separations occurred between the
tically into interbedded units of siltstone, shale, and sand- 0.61- and 1.22-m (2- and 4-ft) anchors, the top coal and
stone. This unit coarsens upwards in grain size, and the
top portion consists of sandstone. The thickness of the Figure 11
sandstone in the test area was approximately 4.9 m (16 ft)
thick. A geological column of the test area, obtained with
a borehole television camera, is shown in figure 12.

Instrumentation
20+00
Individual cable loads were monitored with hydraulic U-
cells and Goodyear pressure pads. The mine roof behav- 20+50
ior was simultaneously monitored with differential mag-
netic sag stations and closure meters on 7.6-m (25-ft)
spaciugs along the entty axis during the development of
the longwall panel to evaluate the response of the im-
mediate and main roofs. Additioually, hydraulic flatjacks
and closure gauges were installed on wooden cribs on the
inby and outby sides of the test areas to determine the crib
stiffnesses.

Test Site Results

23+00
The test area was installed 229 m (750 ft) outby the
longwall panel face to ensure that the instrumentation and 23+50
cables had properly stabilized and cured before mining. Entry 1 Entry 2 Entry 3
The last crib (C-3) set to maintain abutment and tailgate Gate roads showing cement-grouted cable test area and m-
loads was installed near station 19 +35. Hydraulic flatjacks stn/mentation layout at a Westem US_ undetground longwall
were installed between the 20.3- by 20.3-cm (8- by 8-in) minee
timber blocks, and the closure of the crib was monitored
to establish the in situ stiffness of the crib supports and to
determine a baseline for the amount of load the cables Figure 12
would be subjected to during panel extraction. The cribs
remained virtually unloaded until the face was approxi- 7.6 (25)
mately 15.2 m (50 ft) inby the crib. The crib was sub- Sandstone
jected to a calculated load of approximately 138 kN
~ 6.1 (20) Interbedded siltstone,
(31,000 Ib) before becoming inaccessible for subsequent ~ shale, and sandstone
readings. The stiffness of the crib changed as a function
E
of time and subsequent increases in loading. Figure 13 4.6 (15)
shows how the calculated stiffness started at 126 kN/cm w
u
(72,000 Ib/in) and then decreased to a final value of about z
61 kN/cm (35,000 Ib/in). This clearly indicates that tim- ~ 3.0 (10) Roof line
ber supports are a soft system and do not provide resist- o
ance to subsequent main roof loading. Coal
1.5 (5)
The roof movement was carefully monitored using mag-
netic anchors, established at various locations of the test
area at approximately 0.61-m (2-ft) intervals along the o (0) Interbedded siltstone.
shale, and sandstone
length of a 3.7-m (12-ft) borehole. Sag station 3, located
in entry 1 of the tailgate (figure 11), is the only one that Geological column from test area.
 11

shale interface, and the 1.8- to 2.4-m (6- to 8-ft) anchors, 6.1 m (20 fl) in front of the face. Face ventilation was
the transition zone between the interbedded siltstone and never disrupted, and the panel was mined through the fall
the sandy shale. The roof between the 2.4- and 3.0-m (8- area without major additional incidence. The mine oper-
and 10-ft) levels experienced minor separation. Individual ator elected to provide additional supplementary support
anchor displacements and an accumulation of the total dis- in the form of two 20-cm (8-in) diam timber posts, from
placement are shown in figure 14. The entire roof was station 21+50 to station 22+50, spaced on l.5-m (S-ft)
subjected to approximately 5.7 em (2.25 in) of total sep- centers for the remainder of the test area. Five timber
aration over a 3.6-m (l2-ft) length. posts were instrumented with hydraulic flatjacks to assess
Two pressure pads were loeated near the intersection their contribution to the total support of the entry. Again,
in crosscut 11 of bleeder entry 2, shown in figure 11. at a distance of about 23 m (75 ft) outby the face, the
Again, the installed loads remained constant until the face posts began taking load. When the face was approximately
was outby approximately 4.6 m (15 ft). As the panel was 6.1 to 9.1 m (20 to 30 ft) inby, the instrumented posts were
mined to station 20+ 88, approximately 36.6 m (120 ft) out- carrying an average of 48.9 kN (11,000 Ib), which translates
by crosscut 11, pressure pad P-5, near the right rib, loaded to about 1,550 kPa (225 Ibf/in') on the timber post. When
to about 28.9 kN (6,500 Ib), and then maintained that load the face was directly adjacent to the posts, the load
for the duration of the test. Pressure pad P-4, loeated in reached approximately 125 kN or 3,860 kPa (28,000 Ib 01'
the intersection in crosscut 11, experienced only minor 560 Ibf/in') and then the posts failed.
changes, 2.7 kN (600 lb), during the entire panel ex-
traction. The behavior of pads P-4 and P-5 is shown in Figllre 13
figure 15. 130
The loading behavior of the pressure pads located in
70,000
bleeder entry 2 at crosscut 10 (figure 16) showed a profile
that included minor roof dilation until the face was ap- E 110
u c
proximately 15.2 m (50 ft) inby the crosscut. The cables "- 60,000 '-
z
then loaded approximately 4.5 kN (1,000 lb), and then un-
~

vi 90 - 50,000
'vi"
V1
loaded as the face was mined past the intersection and the "'z
w w
z
abutment loads and pressures dissipated. The differential "-
"-
"-
"-
F= 40,000 F
sag stations in the same area indicated only a minor sep- 70 V1

aration, 0.381 cm (0.15 in), between the coal and siltstone "'
interface. 50
30,000
Closure meters were positioned at 7.6-m (25-ft) inter- 19+01 19+05 19+11
vals along the length of entry 1. The data were fairly
SURVEY STATION FACE POSITION
consistent; an example is shown in figure 17. The entry
showed only minor signs of closure, less than 1.27 cm enD stiffness at different intervals of face advance.
(0.5 in), until the face was approximately at 23 m (75 ft)
inby. At that time, the closure increased to about 5 cm
(2 in). This pattern remained fairly consistent unless the
face sat idle for extended periods of time. The data indi- Figure 14
cated that the closure, 15.2 m (50 ft) outby the face, ex- ANCHOR LOCATION, in
ceeded a total of 10.2 cm (4 in) when the face sat idle for 0 24 48 72 96 120
more than 2 days. Another interesting observation in the 1
data was the roof response, consistently recorded between
E 0 0.0
closure stations up to 15.2 m (50 ft) apart. As shown in 0 .C
figure 17, the closure on inby station 20 + 00 corresponded f-C
z -1 f-C
w -0.5 z
to an upward movement at station 20 + 50. This occurred :2
w
:2
w -2 w
when the 10ngwaU face sat idle for an extended period of u -1.0 u
time and may be related to time-dependent deflections of
the immediate roof.
'"
..J
"-
V1
-3
KEY '"
..J
"-
V1
0 -4 -1.5 0
As the panel was extracted to approximately construc- 0 Individual
tion station 19+98, excessive forward abutments and side -5 <> Accumulated
-2.0
loading caused two cables installed near the pillar side of
-6
entry 1 to fail at a height of approximately 2.7 m (9 ft). 0 50 100 150 200 250 300
Cable anchorage was strong enough to cause the cable to
fail about 0.3 m (1 ft) below the faU of ground. The faU ANCHOR LOCATION, em

extended at an angle to construction station 20+ 18, about Individual and accumulated roof anchor displacements.
 12

The cable test area in entry 1 was successfully mined Discussion

through without further incidence of caving or roof falls
ahead· of the face. Bleeder entry 2 showed only minor Given the pillar layout and site-specific roof conditions
signs of loading, and differential roof sag stations indicated and strengths at the test mine, cable bolt systems were
insignificant movements or separation in the roof. successfully used to maintain the longwall tailgate entries.
The installed instrumentation indicated that very little ac-
Figure 15 tive support can be expected from installed crib systems.
30,------,------,------,-----, Even with the stiff cable support system, differential mag-
KEY 6,000 netic sag stations indicated that roof bed separations still
25
0 Pad P-4
occurred between geological interfaces, which eventually
z
~ 5,000 led to loading beyond the designed capacity. Timber
ci 20
<> Pad P-5
"ci posts, installed as additional secondary support in the
'"
0
~
4,000
'"
0
~
tailgate entry, were subjected to loads of approximately
0 15 0 125 kN (28,000 lb) and then subsequently failed. The
'"
"-
3,000
""
"- loading on the timber posts, while appearing substantial,
10
2,000 could have been supported by an additional cable installed
in the roof of entry 1. Adding another cable with a
5
258-kN (58,000-lb) capacity in the middle of the entry may
19+00 20+00 21+00 22+00 2.3+00
have compensated for these extra loads. A review of the
SURVEY STATION FACE POSITION
design chart shows that a three-cable system, spaced on
Pressure pad loading behavior with face advance in crosscut 2.1-m (7-ft) centers, would have been sufficient to carry
11. the loads generated by the observed roof separation at a
height of 9 ft above the coal seam.
Figure 16 CASE STUDY 2
18 4,000

1. 3,500
The first resin-grouted cable test area was established
14 KEY in a bleeder entry system immediately behind a longwall
3,000
1I panel. A longwall bleeder system is a designated set of
ci
'2
0
<>
Pad P-l
Pad P-2 2,500
"ci special entries developed and maintained as part of the
0
~'" 10
• Pad P-J
2,000
"0
~ mine ventilation system. These entries are designed to
0 8 0
continuously move air-methane mixtures from the gob,
""- • 1,500 "
"-
away from the active workings, and deliver the mixtures to
1,000
4 the return air courses. Because these systems are critical
2 500 to safe ventilation and provide emergency escapeways, they
19+00 20+00 21+00 22+00 23+00 must be maintained to permit adequate airflow and travel.
SURVEY STATION FACE POSITION To accomplish this, most mines elect to install crib sup-
Pressure pad loading behavior with face advance in crosscut ports along the entire length of the bleeder entry system.
10. As an alternative secondary support system, approved by
the U.S. Mine Safely and Health Administration (MSHA),
resin-grouted cables were selected to support the bleeder
Figure 17 entry.
6
Site Description
5f- - 2.0
-t}- A three-entry system was driven behind the longwall
E 4 system. The first entry was used as the longwall setup
.0 KEY - 1.5 .,;;
W W room. The second set of entries were the bleeder entries.
3 - 0 20+00
'"
iil <> 20+25 - 1.0 '"<n
=> The two entries were separated by pillars that measured
g 57.9 m (190 ft) in length and 45.7 m (150 ft) in width. The
()
2 - • 20+50
0
~
()
6.1-m (20-ft) wide entries were primarily supported with
- 0.5
2.4-m (8-ft) full-column, resin-grouted bolts and steel
I
"" mesh. The third set of entries, adjacent to virgin coal, re-
0 0.0 sulted in a final pilIar dimension of 57.9 m (190 ft) in
19+30 19+40 19+50 19+60 19+70 19+80
length and 47.5 m (150 ft) in width. An examination of
SURVEY STATION FACE POSITION
the mining horizon indicated 4.3 m (14 ft) of minable coal
Entry closure and roof response. seam, with the entries driven only 2.9 m (9.5 ft) high. A
 13

generalized summary of the immediate roof in the area in- Mine management decided to move the bleeder entry
cluded about 0.8 m (2.5 ft) of top coal overlain by about to the third entry for panel 4. The intersection for this
0.5 m (1.5 ft) of a silty shale. The roof above the silty transfer is where bleeder site 2 is located. The general
shale grades vertically into interbedded units of siltstone, arrangement of the cable bolt supports in the bleeder
shale, and sandstone. This unit coarsens upwards in grain entries is shown in figure 18B, and the details of the two
size, and the top portion consists of sandstone. The test bleeder instrumentation sites are shown in figure 18, C and
area location is shown in figure 18. D. Cable supports were installed in the second entry
along the entire width of panels 2 and 3 and in the third
Figure 18 entry behind panel 4.
A Cable System Design
JL rBleeder site 2 Based on the caving resnlts from a previous panel, the
site lithology, and the loading generated on the crib sup-
H /Bleeder site 1 ports in the previous bleeder, a cable system was designed
1(/ to support the loads generated on the roof when the panel
was extracted and the immediate and main roofs caved.
I
J I The entries were protected by the abutment-size pillars,
Panel 3 Panel 2 Panel H.. but the transfer of stress Over those pillars warranted sec-
ondary support to ensure an adequate ventilation and es-
Direction
D
of
mining -hF- capeway entry. It was believed that if separation did oc-
cur, it would most likely be in the layers of silty shale that
I e9 '9 occurred about 1.2 m (4 ft) up from the roof. Additional-
ly, the interbedded siltstones and shales could separate if
the abutment forces became large enough or the immedi-
B ate roof was lost. Yield zones on the pillars, both cal-

~~
culated and observed in the mine, indicated that the ef-
fective roof span would be approximately 7.9 m (26 ft).
With these facts, the mine operator elected to install a
4.9-m (16-ft) long cable, which would intersect the sand-
stone 1.8 m (6 ft). The cables were installed with 3.7 m
(12 ft) of resin grout to ensure a strong cable anchorage
and also to help hold the lower silty shale member intact.
The design specified three cables across the entry on a
l.5-m (5-ft) spacing. The cable supports would support a
complete roof separation-the worst case scenario-if it oc-
C D curred at a depth of 2.7 m (9 ft). A cross section of the

~
support system is shown in figure 19. In addition to 15.2-

0
0
L
0
~
o 0 0 L by 15.2-cm (6- by 6-in) bearing plates, the cables and pri-
mary support were also installed in conjunction with Mon-
0 000 ster Mats.' The mats provide excellent roof support
0 0 000 between the cables and maintain any failed material. Mats

I 0

I I r help prevent unraveling or progressive roof-type failures.

Instrumentation
LEGEND
0 Pressure pad location Hydraulic V-cells and Goodyear pressure pads were
(] U-cell location installed throughout the test areas on individual cables to
determine the aetualloading that occurred during variolls
===- Mat and cable bolts
phases of panel extraction. Differential sag stations were
installed to monitor any roof separations that occurred in
Not to scale the first entry to establish the expected failure surface and
Bleeder entry configuration and resin-grouted cable test area.
A, Location of bleeder sites; B, general layout of cable bolt 5-fhcsc mats arc DAS-em (3/16-in) thick steel pans that arc 35.6 em
supports in bleeder entries; C; bleeder site 1 detail; D, (14 in) wide and 4.9 m (16 ft) long, manufactured by Rocky Mountain
bleeder site 2 detail Doll Co., Salt Lake City, UT.
 14

Figure 19 individual cables ranged from 14.7 to 149.0 kN (3,295 to

33,500 lbl), averaging 18.8 kN (4,225 Ibl) for the seven
hydraulic U -cells. Differential sag stations placed in the
roof indicated very little separation in the interface be-
tween the shale and sandstone. The entire bleeder entry
behind panel 2 remained extremely stable, with no roof
falls and very little signs of roof spalling or separation.
Additional recorded cable loads varied throughout the en-
tire panel 2 bleeder area, with higher readings mostly
related to geologic features that occurred in the cable·
supported area.
The behavior in bleeder site 2 area was very similar to
the behavior of bleeder site 1. The main difference was
that loading on the test area occurred shortly after panel
3 started mining and then stabilized as if the system had
reached equilibrium, with the cable supports experiencing
no additional load increases. The initial cable loads and
Cross section of test area showingprimary and cable support the subsequent loads recorded when the panel 3 face had
spacing and rosin grout lengths. been extracted to approximately 91 m (300 ft) and 365 m
(1,198 ft) are shown in figure 21. The pillars in this area
to estimate the volume of roof material that may have to showed more rib sloughage and spalling than the area be-
be carried by the cable supports. hind panel 2. However, the roof remained competent with
no visual signs or recorded loads that would indicate un-
Test Site Results anticipated separation. The loads measured on the eight
Goodyear pressure pads in bleeder site 2 ranged from 18.0
The test areas were monitored and evaluated 14 times to 119.2 kN (4,120 to 26,800 Ibl) and averaged 73.8 kN
throughout panels 2 and 3 mining. Panels 2 and 3 have (16,600 lbl). Subsequent measurements recorded in the
now been completely extracted. The cables installed be· panel 3 bleeder entry system showed little or no cable bolt
hind panel 2 have been subjected to increased loads as load increase as panel 3 was extracted. The results from
panels 2 and 3 mining created large spans of unsupported both bleeder test areas demonstrated the effectiveness of
ground. Data from bleeder site 1, shown in figure 20, cable supports as an alternative to other forms of second-
indicate the load profiles for the cable-supported inter. ary support. Ground conditions remained good in the
section during panel 2 and part of panel 3 mining. The bleeder entry during the mining of two complete longwall
initial measurements, shown in figure 20A, recorded ap· panels, and none of the cable loads exceeded 50% of fail-
proximately 35 days after the entry was supported with ure strength. The vast majority of the cables did not
cables but before panel 2 extraction began, show signs of exceed 10% of the ultimate cable load capacity.
general loading across the middle of the intersection.
More load was observed on the cables closest to panel 2. Discussion
When panel 2 had been mined to a distance of 337 m
(1,105 ft) from the setup room, shown in fignre 20B, the Results from this bleeder entry cable support study
loading pattern was nearly identical; overall load on the demonstrated the effectiveness of cable supports with
cables increased, with the largest loading still on the cables resin-grouted anchorage systems. The bleeder entry test
toward panel 2. The main cave for panel 2, as reported by area at the study mine, utilizing cable supports as the sale
the miners, took place when the panel 2 face had been ex- means of secondary support, experienced the effects from
tracted 37.5 m (120 ft). The cable loads in figure 20B, two longwall panels with very good results, no roof prob-
averaging 16.6 kN (3,730 lbl), represent the effects of main lems, and good bleeder entry conditions. A couple of
roof loading from panel 2 mining transferring to the bleed- areas in the bleeder entry experienced significant loading.
er abutment.pillars. Figure 20C shows the loading profile Still, the cable and Monster Mat' arrangement maintained
at bleeder site 1, resulting from the complete extraction of the roof integrity while keeping the entry clear of crib
panel 2 and 365 m (1,198 ft) of panel 3. Again, the load material.
pattern across the intersection is similar to that in fig-
ure 20, A and B, and the cable loads increased slightly
6See footnote S.
during the initial mining of panel 3. Loads measured on
 15

Figure 20

A
,,'"
,,"" .;:-
"'-""~.
~<v~
~
." ~0""
e,..4...--
G-,.s."
~~ LEGEND
U-cell location
B IiIII

c 1'10
1<0
~ 100
80
c)' 60

.;:-
C <10

<~ ~~ ~~~lliI~
..,
a.-(s-

" ~c~
~.
~=~~~~~~~
-9'0 --R
0..sC"oo
~
<"-v~
'-1"-,-
'..",
~~cp'-·~ ",..c. ~

~.-.'>.G~~
-"'-"""'
~=.
a ~~
~~

Bleeder site 1 profiles during panels 2 and 3 mining. A. Panel 2 face position 0 +00 with U-cell ulStrument
locations; B, panel 2 face position 11+05; C, panel 3 face position 11 +98.
 16

Figure 21

LEGEND
• Pressure pad location

B
:I
I
;!

; :i
I!
I, ;
, ,

Bleeder site 2 profiles during panel 3 mining. A, Panel 3 face position 0+00 with pressure pad in-
strument locotions; B, panel 3 face position 3 +00; C, panel 3 face position 11 + 98.
 17

CASE STUDY 3 install a 4.9-m (16-ft) long cable as the sole means of
secondary support, which would penetrate the sandstone
This last case study describes the most aggressive at- a distance of 1.S m (6 ft).
tempt at installing and evaluating resin-grouted cables for The tailgate test area is shown in figure 22. The cables
secondary support in a longwall gate road. Cable support installed in the first 91 m (300 ft) of the tailgate test area
systems were designed and installed to provide stability in (passive test area) utilized 1.7 m (5-ft-8-in) of resin, which
a gate road that will be utilized for two longwall panels, left approximately 3.1 m (10.3 ft) of the cable ungrouted.
first as a headgate and then a tailgate. This allowed the cable and the roof to yield and relax as
abutment loads were redistributed to the gate road. The
Site Description second 91-m (300-ft) area (stiff test area) used a 3.7-m
(12-ft) equivalent column of resin, leaving only 1.2 m (4 ft)
The instrumented test area, approximately 274 m (900 of the cable ungrouted. This provided a stiffer support
ft) long, was initially supported with 2.1-m (7-ft) full- system that would resist yielding, but still have enough
column, resin-grouted bolts. The three-entry system is ungrouted length to allow for separations at the interface
utilizing a yield-abutment pillar configuration to minimize between the coal, shale, and interbedded siltstone layers.
the pressure on the entries when they become tailgates The third and final zone (tensionable test area), also 91 m
and reduce the possibility of coal mine bumps or burst. (300 ft) long, was supported with a tension.ble cable
The final yield pillar dimensions, next to the panel during support system. The cables were installed utilizing 1.7 m
the second panel mining phase, measure 9.S m (32 ft) wide (5 ft-S in) of resin grout and pretensioned, using
and 39.6 m (130 ft) long. The fmal abutment pillar di- • specially designed jacking system, to about 35.6 kN
mensions, designed to absorb the first panel abutment (8,000 lb/). The tensionable system would help resist any
stresses and protect the integrity of the yield pillar, downward movements, but still have enough ungrouted
measure 30.5 m (100 ft) wide and 39.6 m (130 ft) long. portion of cable to accept large deformations before reach-
The geology was similar to the bleeder test area with one ing the ultimate capacity levels.
minor exception-the competent sandstone layer was lo- The support systems in both the passive and stiff sup-
cated about 3.0 m (10 ft) into the roof. The roof consisted port areas were preloaded by thrusting the bolt into the
of top coal, clay-shale, sandstone-shale, and a fine-grained roof, using the force of the bolter, before the resin had
competent sandstone layer. The laminated materials un- cured. After the resin cured and the load was removed,
der the sandstoue member were competent, and physical tension, ranging from 6.7 to 22.2 kN (1,500 to 5,000 Ib/),
property tests indicated a compressive strength of about was recorded on the instrumented bolts.
103.4 MPa (15,000 Ibfjin» for tested specimens. Five rock All of the cable systems were installed with 15.2- by
spars crossed the tensionable test area, which broke up 15.2-cm (6- by 6-in) bearing plates and Monster Mats.'
and weakened the immediate roof about 1.2 m (4 ft) on The mats provide excellent mine roof support between the
either side, as shown in figure 22. cables and maintain any failed material in place. Mats al-
so help prevent unraveling, rotation of failed blocks, or
Cable System Design progressive-type failures. The cables were placed four
across the 5.7-m (19-ft) wide opening at a row spacing of
After careful analysis of the anticipated pillar behavior 1.5 m (5 ft). The cables at the ends, dictated by the holes

i
\.
and the experience gained in the first cement-grouted test
area, it was decided to test three variations of resin-
in the mats, were installed as close to the pillar and panel
edges as possible and angled at approximately 80' from
horizontal. A cross section of the cable pattern is shown
grouted cables (6). Based on the caving results from a
previous panel, the site lithology, and the loading gener- in figure 23.
I, ated on the crib supports in the previous gate road, a cable
system was designed to support the loads generated on the Instrumentation

I roof when the longwall panels were extracted and the

immediate and main roofs caved. If roof-bed separation
The test area was instrumented with 36 hydraulic U-
cells and Goodyear pressure pads to evaluate individual
did occur, it would most likely be in the layers of silty
I shale that occurred about 1.2 m (4 ft) up from the roof.
cable loading trends and patterns. The extent of the test
I Additionally, the interbedded siltstones and shales could
area and the instrumentation locations are shown in fig-
iI separate if the abutment forces became large enough or
ure 22. The roof separations and movements were moni-
! tored with magnetic differential sag stations, wire-type
the immediate roof was lost. Initial yield zones on the
extcnsometers, and a closure-rate meter. In addition to
pillars, both calculated and observed in the mine, indicated
that the effective roof span would be approximately 7.9 m
(26 ft). With these facts, the mine operator elected to 7SCC footnote 5,
18

this instrumentation, crib loading inby the test area was redistribution and pillar performance were evaluated using
evaluated with hydraulic flatjack cells to measure the loads borehole pressure cells (BPC's). The BPC's will help eval-
and stiffness of the wooden material. Instrumentation was uate the effects and stresses generated by fIrst panel min-
concentrated in the intersections, where one would expect ing, determine the core of the yield pillar after fIrst panel
the highest degrees of loading, and approximately at the mining, and provide insight into the effects of a stiff sup-
midpoint of the entries between intersections. Stress port system on pillar behavior.

Figure 22

(11 +45 survey station) loC

U
U LEGEND

t:. Sag station

o U-cell

>
Q)

'iii
DO o Pressure pad
• BPC
/ ' Rock spar
i\~ Broken weak top

>~O
en
o
a..

o
I
Q)
....

····~EJ .
o
..., o 16 32 m
en
...,
Q) I I I
o 50 100 ft
Scale

o
....Q)
o
...,
en
Panel 3 / Panel 2
...,
r--~V
Q)

Q)
.n
o
c V "')1 Directian
o ~'JL-_-'
~.-/
'iii of mining
c
~
I Finish - - - - - '>

~ -/*~
Entry 13
ntl Ir---
L.Entry 3
Entry 2
Case S/IJdy 3 test area exmnining three different types of resin-grouted cable supports and respective instru-
mentation types and locations.
 19

Test Site Results sloughage caused by increased pillar loading, the areas
were extremely stable, and no roof control problems were
The instrumentation in the test area was read and eval- noted. Figure 24 shows the resin-grouted cable test area
uated eight times during critical phases of panel 2 mining after installation. Figure 25 shows the cable test area after
and daily during panel 3 longwall production shifts, starting panel 2 mining and prior to panel 3 mining.
when the test area was 15.2 m (50 ft) inby the cable sup-
I
~'"
port test area and ending when the face was mined past
the test area.
Panel 3 Mining

Panel 3 mining progressed for approximately 40 days

Panel 2 Mining before the longwall face entered the test area. The tail-
gate entry, apart from the test area, was typically sec-
I At the conclusion of panel 2 mining, the instrumenta-
tion indicated that the cables loaded an average of 24.2 kN
ondary supported with two staggered rows of l.8- by 1.2-m
(6- by 4-ft) cribs installed with a l.2-m (4-ft) wide walkway
(5,450 lbl). The minimum recorded cable load was 0 kN between rows. Crib spacing in each row was 3.6 m (12 ft),
(0 lbl), where roof dilation actually caused the cable to center to center. In anticipation of the forward and ad-
unload, and the maximum load was 148.6 kN (33,400 lbl), jacent abutment loads and to quantify crib loading in the
where a localized separation above the primary support cribbed portion of the tailgate, two cribs located 25.9 and
caused the two adjacent cables to support the entire rock 6.1 m (85 and 20 ft) inby the test area were instrumented
mass. The differential sag stations indicated minor roof with hydraulic flatjacks. The flatjack pairs were installed
separations between the coal and clay-shale interfaces and at opposite corners of individual cribs between the timber
at the shale and sandstone-shale interfaces; this was ex- material to determine the amount of load subjected on the
pected. Minor floor heave, less than 15.2 em (6 in), was cribs. Both crib supports performed similarly. After panel
present in all three test areas, predominantly in the 2 was extracted, the cribs averaged 266.9 kN (60,000 lbl)
intersections. Basically, with the exception of minor of total load. When the face on panel 3 was 91.4 m

Figure 23

. . .
-.~
· ..._.-
~-. ~-
. . ...--.
-;- .
. . . .
~
_.
. ......
.
I---- --;-
.
-.-. -.-.
~ -. ~-.
.
.- · ..
. ..
~-. ~- ..- . . . . . .
~-. ~-. _.
....... .
---.
. ~-. ~-

• (12-ft) :
resin gr.out. . -.- . - . -.-.
. ..-.-.
·
~-.
.. ~- ...-. ..-
-... '.. --. .. ~

-.

GeneraJiud cross section of cable spacing and lengths used in gate road test areos.
20

Figure 24

Resin-grouJed cable rest DTea immediaJely after cable support ins/aJJalion (be/ore first panel mining).

Figure 25

Resin-grouted cable test DTea after flTSt panel passed test DTea and loads were redistributed onto pillars and
next panel.
 21

(300 £I) inby the cribs, the load had increased to about immediately across from or just inby the test area, were
445 kN (100,000 lbl). As the panel 3 face advanced to 71.2 and 115.6 kN (16,000 and 26,000 lbl), respectively.
within 7.6 m (25 ft) of the cribs, the load increased to This indicates that a separation, combined with forward
1,112 kN (250,000 lbl) and remained at that level when the and side abutments, loaded the cable supports to
longwall passed and the cribs were inby the panel 3 face approximately 50% of their ultimate capacity.
approximately 7.6 m (25 ft). The large loads were also The differential sag stations indicated that a minor
attributed to the floor heave that occurred throughout the separation occurred between the first and second exten-
area, but the values still served as an indication of the someter anchors, which would have placed it between the
loads that could be anticipated on the cable support coal and clay-shale interface. Typical roof bebavior, shown
systems. in figure 29, as observed from a sag station located in the
first intersection, indicated that a slight separation also
Passive SUpp01t System Test Area occurred between the 135- and 178-cm (53- and 70-in) an-
chors. The yield pillar and panel sloughed as the forward
At the conclusion of panel 2 mining, the instrumenta- abutment of panel 3 approacbed within 91.4 m (300 ft), as
tion in the passive support system test area was read and shown in figure 30. Similar to the first test area (passive
evaluated; the loads on the 14 hydraulic U-cells ranged area), floor heave forced the floor to within 1.8 m (6 ft) of
from 0 to 31.1 kN (0 to 7,000 lbl) and averaged 13.2 kN the roof, starting approximately in the middle of the entry
(2,975 lbl). The four differential sag stations, instalIed in and propagating toward the yield pillar, indicating a stiff
the intersections and entries, showed very few signs of roof panel edge transferring stress into the floor. The stiff test
separation. As the panel 3 longwall face approached the area was mined through without problems, and the roof
test area, minor separations began to occur between the remained intact until the panel was well past the support
coal-shale interface. Figure 26 shows the condition of the system. Figure 31 shows the caving profile of the roof as
test area when panel 3 was approximately 243.8 m (800 ft) it remains standing approximately 30.5 m (100 ft) behind
inby the test area. When the face entered the test area, the panel 3 longwall face, shown on the left side of the
the loads on individually monitored cables ranged from 0 photograph.
to 106.8 kN (0 to 24,000 lbl), and the average increased to
18.8 kN (4,227 lbl). The roof remained intact and very Tensiollable Support System Test Area
little roof separation occurred. The differential sag station
located in the frrst intersection (figure 27) showed a The tensionable support system test area provided the
maximum of 0.6 em (0.25 in) of total separation in the most difficult test conditions because the rone with cables
roof when the active face was only 2.7 m (9 ft) inby. contained several geologic features that created roof in-
The roof remained extremely stable in the passive stability prior to panel extraction. A zone containing rock
support test area throughout the retreat of panel 3. The spars and sedimentary dikes had disrupted the continuity
only difficulty encountered was the floor heave adjacent to of the immediate roof, weakening it. Additionally, the dis-
the yield pillar, as shown in figure 28. The floor began continuities may have been associated with a changing roof
to move upward when the face was approximately 30.5 lithology. The mine roof was heavily fractured in the areas
(100 ft) from the area. Measurements made with a rate- traversed by rock spars and dikes. This roof condition re-
closure meter indicated that when the face was 7.6 m sulted in some heavy loading almost immediately after
(25 ft) inby the measurement location, the floor moved up- panel 2 had mined past the site. In one specific area, ap-
ward, relative to the roof, at 0.43 cm/h (0.17 in/h), then proximately 3 m (9.9 ft) long and 5.5 m (18 ft) wide, the
leveled off. The heave never forced the entry to close cables were loaded to 142.3 kN (32,000 Ibl) and the roof
tighter than 1.8 m (6 ft) or interfered significantly with appeared broken and fractured. Unfortunately, the differ-
ventilation. The roof of entry 1 behind the face remained ential sag station installed in the area was lost because of
intact and open an estimated 30 to 45 m (100 to 150 ft) the broken roof. Calculating the roof separation height
and then caved gently. The roof behind the shields con- based on pressure pad loads, suggests that the loads meas-
tinued to cave, and no large overhangs were noted. ured on the cable supports could be the result of the roof
separating at a height of about 3.7 to 4.0 m (12 to 13 ft).
Stiff Support System Test Area However, the cables, combined with primary support,
Monster Mats,' and wire mesh, kept the immediate roofin
At the conclusion of panel 2 mining, the loads on the place. The average loads on the instrumented cables at
instrumentation in the stiff support system test area ranged the conclusion of panel 2 mining ranged from 18.2 to
from 3.4 to 37.3 kN (775 to 8,390 lbl), and the average for 151.2 kN (4,100 to 34,000 lbl) and averaged 50.7 kN
the 10 pieces of instrumentation (a combination of load (11,400 Ibl) for the .12 instrumented cables. The tension-
cells and pressure pads) was 20.6 kN (4,640 lbl). The able cable support area, when the panel 3 face is approxi-
average load on the instrumentation was 25.9 kN mately 152.4 m (500 ft) inby, is shown in figure 32.
(5,840 Ibl) when the face entered the test area. Cable load
measurements, recorded when the longwall face was 8Sce footnote 5.
22

Figure 26

Resin-grouted coble test area when panel 3 face was 243.8 m (800 ft) inby test area.

Figure 27
DISTANCE FROM FACE, ft

350 300 250 200 150 100 50 0

0.00 0.00
E
u .s
KEY

I
t-" t-"
z 0 64 em (25 in) z
w w
:::;; /'::, 130 em (51 in) :::;;
w -0.25 -0.10 w I
I

U
<{ o 168 em (66 in) u
<{
--' --'
a.. 0198 em (78 in) a..
(f)
0 o 259 em (102 in)
(f)
0
0284 em (112 in)

-0.50 -0.20
105 90 75 60 45 30 15 0
DISTANCE FROM FACE, m
Results from differential sag stoIion being located in rust intersection ofpassive test area.
 1
23

Figure 28

!
,

Floor heave in ]NlSsive support system test area.

Figure 29
DISTANCE FROM FACE, ft

500 400 300 200 100 0

0.00 0.00

-0.50
-0.25
E
u S
-1.00
,.: ,.:
z -0.50 z
w w
:::;; -1.50 KEY :::;;
w w
0 o 74 em (29 in) u
« -0.75 «
-'
0..
-2.00 t:,. 135 em (53 in) -'
0..
(f) (f)
0 o 178 em (70 in) 0
-2.50 0206 em (81 in) -1.00
o269 em (106 in)
-3.00 0292 em (115 in)
-1.25
-3.50
150 125 100 75 50 25 0
DISTANCE FROM FACE, m

Results from diJJerentiol sag station being located in [lTSt intersection of stif! support system test area.
24

Figure 30

Stiff support system /est anll condiJion during]NllU'l 3 mining.

,

Figure 31
~~~------------------------------~--------.

Roof condition inby ]NIIU'1 3 longwall face.

 25

Tensionab1e support system test area condition during panel 3 mining.

The differential sag station results, shown in figure 33, to high loading. These areas were usually associated with
are from the sag station located in the second intersection the geological features as described earlier. The face and
of the tensionable support system test area. The results the integrity of the immediate roof:lfe shown in figure 35.
indicate four distinct separations between the instrumented This type of roof condition, encountered throughout the
levels, with a major separation forming between the 160- entire test area, provided a safe and accessible travelway
and 188-cm (63- and 74-in) anchors in the roof. The roof and maintained the ventilation airway.
below this level separated approximately 2.54 cm (1 in)
when the face was approximately 9.4 m (31 ft) from the Pillar Peifonnance
station. The separations occurred between geological in-
terfaces, with the largest at the expected level. However, The performance of the pillars and panels were eval-
the cables maintained the immediate roof, which permitted uated to examine the support, if any, that the yield pillar
reading the sag station when the face was 2.1 m (7 ft) past
or panel edge would provide for the immediate and main
the station. The major separation had a displacement of
roof. This factor, which affects overall entry width, can
approximately 1.3 cm (0.5 in), and two minor separations
dramatically change the cable support system design. The
occurred between the 221- and 282-cm (87- and 111-in)
anchors. gate road pillar layout consisted of a three-entry system.
Floor heave also occurred in the tension able support The stiff pillar was adjacent to panel 2 and between entries
system test section with rates similar to the previous two 2 and 3. The yield pillar was adjacent to panel 3 and be-
areas. Closure instrumentation and the general condition tween entries 1 and 2.
of the test area when the face was approximately 45.7 m BPC's were installed in the pillars and adjacent panels
(150 ft) inby are shown in figure 34. As shown, if the ca- to measure the vertical ground pressure changes as the
bles failed or appeared to have taken considerable load, a face advanced. The BPC analysis included forward abut-
timber post was placed adjacent to the cable. Additionally, ment pressures, pillar-panclload transfer, and the general
some cable nuts appeared to be slipping under heavy load, yield behavior of the instrumented pillars. BPC's do not
preventing all seven strands from actively resisting move- provide absolute pressures, but simply an understanding of
ment. The area was mined through without incident, and the relative pressure increases and decreases, which may
a total of nine timber posts were set in the areas subjected be an indication of strcss change and coal failure.
26

Figure 33
DISTANCE FROM FACE, ft

-0.50
500 400 300 200 100 a

- 1.00 -0.50
E -1.50
0
.!;
>-'" -0.75 >-'"
z -2.00 z
w w
:::;: KEY
w :::;:
u 097 em (3B in) w
« -2.50 u
-1.00 «
-' t:. 160 em (63 in)
a. -'
a.
Ul
0 -3.00 o 1BB em (74 in) Ul
0
o 221 em (B7 in)
-1.25
-3.50
o 2B2 em (111 in)

-4.00 -1.50
150 125 100 75 50 25 a -25
DISTANCE FROM FACE, m

Resu/Is from difJerenliIII sag sfIltion being located in second intersection of /tlnSionQb1e supjJOlt system 1m
IlTI!IL

Figure 34

1
I

Closure-Tale instrumenlolion and condition of tensionable suppott system test IlTI!IL

 27

Figure 35

Roof integrity and stDbi/ity of tensionoble support system test area.

The forward abutment pressures during panel 2 mining extracted panel 2, as expected. The average increase
were characterized by monitoring vertical pressure in the across the yield pillar was 11.2 MPa (1,620 Ibf/in'), with
longwall panel 2 headgate, as shown in figure 36. For the the major loads being observed on the entry 2 side of the
purposes of discussion, the BPe pressure changes from yield pillar. The cells in the panel 3 edge were begin-
equilibrium pressure are presented. All pressure cell data ning to load slightly, increasing approximately 2.9 MPa
are plotted versus distance from the cell location to the (425 Ibf/in').
active mining face. The onset of the forward stress abut- The analysis of the data started again after panel 2 was
ment was first observed when the panel 2 face was approx- completed and the panel 3 face had mined to a position
imately 30.5 m (100 ft) inby the BPe locations. A minus approximately 121.9 m (400 ft) inby the instrumentation,
sign H indicates the panel face was inby the cells. An as shown in figure 37. At this point, the abutment pillar
increased rate of cell pressure rise on the panel was edge adjacent to entry 2 had yielded to the cell established
observed when the face was 2.4 m (8 ft) inby the pres- 19.2 m (63 ft) inside the pillar from entry 2. The abut-
sure cells, resulting in an average increase of 6.5 MPa ment pillar had also yielded about 3.0 m (10 ft) from entry
(940 Ibf/in'). At this time, the abutment pillar, adjacent 3 next to previously mined panel 2. The yield pillar re-
to the panel, experienced an average increase of 3.0 MPa mained intact with the exception of the outer 3.6 m (12 ft)
(435 Ibf/in'). The yield pillar, adjacent to panel 3, real- of the pillar on the entry 2 side. This area, heavily loaded
ized an increased average cell pressure of 6.6 MPa during panel 2 extraction, had yielded by the time the pan-
(965 Ibf/in'), with the major stress concentration occurring el 3 face approached the site. When the panel 3 face was
adjacent to entry 1 on the panel 3 side. Panel 3 cells 61.0 m (200 ft) inby the instrumentation, the yield pillar
experienced a minor loading change of about 1.2 MPa core lost pressure. Even though the yield pillar appeared
(170 Ibf/in') as panel 2 was mined through the instru- to be intact with only minor sloughage, the instrumentation
mentation site. indicated that the yield pillar loading had decreased. Load
When the panel 2 face was 91.4 m (300 ft) outby the in- from the yield pillar was transferring to panel 3 and the
strumented pillars and panel, the pressure increases av- core of the abutment pillar. The abutment pillar and
eraged 11.4 MPa (1,650 Ibf/in') on the abutment pillar, panel 3 experienced increased load.
with the major concentrations of load indicated next to the
28

Figure 36

KEY
• BPC location

...... 28 (4,000)
NC
S
e 21 (3,000) ,.
:.::s
~ 14 (2,000) FACE
w LOCATION
a:
:) ~~~=128m(420ft)

~ 7 (1,000) 08881~~ '91 m (300 tI)

-I:ZS83~- 61 m (200 til
~ ~mrn~~~lit~ m (100 tI)
Q.
~ m (-6ft)
o (0)~~~~~~~~~~~;:::~-30 m (-100 til
I· ••• I I···· ·11 • • • • • ••• II· •• ~
Panel 3 Yield Abutment Panel 2
pillar pillar
Pillar and panel loading during panel 2 extraction.

Figure 37

KEY
• BPC location
69 (10,000)

:. 41
::s
u.i A
a:
:)
28 !
U)
U) FACE
~
Q.
14

~~E~i~i~~~III~~i~'
1·····1
.~'~~'~"~-6
mm
1····1
. LOCATION
-30 m (-100 tt)
-61 (-15tt)tt)
(-200
-122 m (-400 tI)

Panel 3 Yield Abutment

Panel 2
pillar pillar
Pillar and pane/loading during panel 3 extraction.
 29

When the panel 3 face was 30.5 m (100 ft) from the Discussion
site, the yield pillar core appeared to be intact, but no load
increases were noted in the BPC's; the load-carrying ca- Resin-grouted cable support systems were extremely
pacity of the pillar had diminished. The abutment pillar successful at this test site in maintaining a longwall gate
cells had pressure increases in excess of 60.7 MPa (8,800 road during first and second panel mining. Data were re-
Ibf/in'), and the average on the remaining core cells was corded from 120 instruments and evaluated 30 times dur-
39.0 MPa (5,650Ibf/in'). The instruments in the panel 3 ing this lS-month investigation. The data provide an
edge loaded to an average stress increase of 9.0 MPa adequate understanding of the successful application of
(1,300 Ibf/in,). The final data were recorded when the resin-grouted cable supports in a longwall tailgate. Three
panel 3 face was 4.6 m (15 ft) inby the installed instru- different cable concepts were evaluated-passive, stiff, and
mentation. The BPC in panel 3, 12.2 m (40 ft) from entry tensionable-to examine any differences ill roof and subse-
1, was loaded to about 51.7 MPa (7,500 Ibf/in'). The BPC quent pillar response. The data were inconclusive in de-
9.1 m (30 ft) from the entry had dropped pressure, in- termining if anyone cable design was better in preventing
roof separation. Differential sag-station measurements in-
dicating the panel edge was yielding. Several bounces I
dicate that all three systems allowed some separation in
were recorded in the area of the abutment pillar, and the
loads on the remaining abutment pillar core cells averaged
the immediate roof at geological interfaces. However, the ii
significant point is that the cables, in conjunction with
53.1 MPa (7,700 Ibf/in'). primary support, mesh, and mats, provided enough II
The yield pillar did not quit taking load until panel 3 resistance to prevent the roof from progressively failing be-
was approximately 61.0 m (200 ft) inby the site. The pillar yond these initial separations. The largest separation re-
provided an element of roof support, but the load-carrying I
corded in the entire test area was less than 3.8 cm (1.5 in).
capacity had diminished before the stress levels hecame This is minimal for the types of loading occurring in a coal
large or dangerous. mine gate road.
Even though entry 1 experienced floor heave 30.5 m The loads generated by roof separation and movement
(100 ft) outby the face that was caused by the apparent could not account for the loads measured on the cribs im-
strength of the panel, which did not yield at the panel edge mediately inby the test area. The additional loads were
until the face was within 4.6 m (15 ft) from the instrumen- the result of the floor heave that occurred along the length
tation, the roof structure remained intact, and the cable of the entire gate road.
supports held the immediate roof in place; very little roof- The BPC's indicated that the yield and abutment pillar
bed separation was recorded. The cable system between behavior was adequate for maintaining the integrity of the
the yield pillar and panel at the BPC instrumentation site roof while minimizing coal mine bounces or bumps. The
were the "stiff' cables with the longest column of resin yield pillar width of 9.7 m (32 ft) was sufficient to maintain
grout. Whether or not this assisted in the stress transfer an active core, which aided in roof performance, until the
to panel 3 and protected the integrity of yield pillar cannot panel 3 face was approximately 30.5 m (100 ft) away. This
be determined. There were no visible differences in pillar was noted in the individual cable loads and reflected in the
performance in other portions of the tailgate test areas. differential sag-station data.

FUTURE RESEARCH

The underground success of resin-grouted cables at the available in early 1995, at current mining rates. Addi-
West Elk Mine has prompted the mine operator to sup- tionally, cable supports are being evaluated as primary
port the entire next gate road (tailgate entry 1 between support, secondary support in difficult intersections where
panels 4 and 5) with resin-grouted cables. The final se- trusses were traditionally required, longwall setup rooms,
lection, based on test site performance and ease of instal- and recovery chutes.
lation, was similar to the design used in the passive test Resin-grouted cable support technology has proven to
area. Cables 4.S m (16 ft) long, anchored with a 1.7-m be a practical and economic alternative for timber sup-
(5·ft-S-in) resin column, are being used in conjunction with ports in certain ground conditions and may be the next
Monster Mats' and high-capacity, dome-bearing plates. major shift in roof support and ground control technology.
The test results from this gate road should be USBM personnel, with the continued support of industry,
are continuing to examine the effectiveness of cable
supports under a wide range of difficult geological and
9See footnote 5. mining conditions.
•

30

SUMMARY AND CONCLUSIONS

Cable supports have been successfully installed with from several ongoing investigations are completed. USBM
both cement- and resin-grouted anchorage systems. Ca- personnel, with the assistance of industry, are continuing
bles have shown their ability to stabilize ground conditions to examine the effectiveness of cable supports under a
in adverse situations, such as gate roads and bleeder en- wide range of geological and mining conditions. The im-
tries. Design principles have been presented to permit ini- provements to ventilation and entry passage, although not
tial simplistic cable configurations and spacings. These specifically studied in this investigation, only add to the
design schemes will be modified and npdated as the results benefits to be received from cable supports.

ACKNOWLEDGMENTS

The authors wonld like to thank Mountain Coal Co., enthusiasm, and assistance during the cable support in-
West Elk Mine, Somerset, CO, in particular Robert Koch, stallation and subsequent test site investigations.
senior mining engineer, for their continued support,

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INT.BU.OF MINES,PGH.,PA 30054