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A new cable truss support system for coal roadways affected by dynamic pressure
Hong Yan a,⇑, Fulian He a,b
a
College of Resources & Safety Engineering, China University of Mining & Technology, Beijing 100083, China
b
State Key Laboratory of Coal Resources and Safe Mining, Beijing 100083, China
a r t i c l e i n f o a b s t r a c t
Article history: The support of coal roadways is seriously affected by intense dynamic pressures. This can lead to prob-
Received 14 December 2011 lems with large deformation of the roof and the two side walls of coal roadways. Rapid convergence of
Received in revised form 26 January 2012 the walls and roof, a high damage rate to the bolts and cables, or even abrupt roof collapse or rib spalling
Accepted 28 February 2012
can occur during the service period of these coal roadways. Analyzing the main support measures used in
Available online 13 September 2012
China leads to a proposed new cable truss supporting system. Thorough study of the entire structure
shows the superiority of this design for roadways suffering under dynamic pressure. A corresponding
Keywords:
mechanical model of the rock surrounding the cable truss system is described in this paper and formulas
Dynamic pressure
Roof collapse
for calculating pre-tightening forces of the truss cable, and the minimum anchoring forces, were deduced.
Cable truss The new support system was applied to a typical roadway affected by intensive dynamic pressure that is
Pre-tightening force located in the Xinyuan Coal Mine. The results show that the largest subsidence of the roof was 97 mm, the
convergence of the two sides was less than 248 mm, and the average depth of the loose, fractured layer
was only 6.12 mm. This proves that the new support system is feasible and effective.
Ó 2012 Published by Elsevier B.V. on behalf of China University of Mining & Technology.
1. Introduction decreases the excavation speed and then changes the balance of ef-
fort between actual mining and ancillary excavation.
The total coal production in 2010 was 3.25 billion tons in China. Intensive dynamic pressure on the roadway when the second
This is 2.35 times as much as that in 2001 and 1.09 times that pro- method is used leads to results that are far from universally suc-
duced in 2009. Although this increasing production ensures the cessful. For instance, many roadways are affected by dynamic pres-
growth of the national economy it is difficult for many coal mines sure in the Xinyuan Coal Mine and suffer large deformation and
to balance between mining and excavation activity. This is espe- damage. This includes some steel bands breaking up, serious roof
cially true for supporting roadways affected by dynamic pressure subsidence, bolts pulling out, and supporting plates dropping down,
two or more times [1–4]. The common characteristics of deforma- among other things. Despite all these deformations the roadways
tion in these roadways include rapid breaking, large roof subsi- are still brought to a passive situation by immediate repairing after
dence, convergence of both side walls, and frequent damage of excavation. Occasionally a cycle of excavation and repair results.
conventional bolt and cable supports. As time passes, the roadway Comprehensive consideration of these support measures sug-
is prone to abrupt caving or rib spalling accidents [5,6], as illus- gests the last has the best effect on roadways affected by dynamic
trated in Fig. 1a. This directly threatens the safety of the workers pressure, especially for many intensive coal roadways.
and renders subsequent repair of the roof collapse difficult and un- From the viewpoint of support economics, however, the costs
safe because of the large area involved, see Fig. 1b. are significantly increased and this method is difficult to put into
The support measures applied to mining gateways repeatedly practice in a wide range of situations.
affected by dynamic pressure consist of: (1) Combining supports A new cable truss support system is proposed and analyzed
with bolts, cables, and U-shaped steel; (2) Lengthened resin an- herein that will safeguard the security of a roadway affected by
chors and supports together with high strength bolts and cables; intensive dynamic pressure and will reduce the cost of support.
(3) Excavation of unconventional roadway sections and grouting These facts will make it widely applicable.
for reinforcement of the cables; (4) And, highly pre-stressing the
entire short cable support around the cross-section [7–12].
Although these support methods have been used in the coal 2. A new cable truss support system
fields, the first and third methods are so trivial in their results that
adopting U-shape steel supports or additional grouting just 2.1. Key structure and supports
⇑ Corresponding author. Tel.: +86 13426073906. Fig. 2 shows the supporting structures including the cable truss
E-mail address: cumtbyh@foxmail.com (Y. Hong). system, bolt truss system, and a simple form of cable truss system
2095-2686/$ - see front matter Ó 2012 Published by Elsevier B.V. on behalf of China University of Mining & Technology.
http://dx.doi.org/10.1016/j.ijmst.2012.08.003
614 Y. Hong, H. Fulian / International Journal of Mining Science and Technology 22 (2012) 613–617
with joint steel [13–18]. Pre-tightening forces have been increased strength for the whole system. Hence, the cable truss system pro-
from no pre-tightening force to a low pre-tightening force, then to vides greater supporting to complex roadways than can the con-
a high pre-tightening force. The new cable truss support system in- ventional cable and bolt truss.
cludes highly pre-stressed cables of a relatively small diameter, re-
sin anchors, connectors, and lock sets. The cables in this system go 2.2. A mechanical model of the rock surrounding a cable truss support
through the roof obliquely and are then anchored with a suitable
resin bonding agent. About one and a half hour later the outside The friction forces between the outer section of the cable and
cable should be immediately locked with an arc connector after the shallow surrounding rock of the roof, and between the inner
applying the high pre-tightening force. section of the cable and deep surrounding rock, are small after
The superiority of the new cable truss support system can be applying pre-tightening force in the cable truss support system.
generalized as follows. The force is applied in two directions, pro- These forces can be omitted during calculations and analysis. How-
viding a long and relatively soft linear shearing force along with ever, the intersection between the cable and the intermediate roof
firm bolting points locked along with roof deformation. Salient bears a considerable force. The locally effective stress on the roof is
points are: included in the mechanical model of the surrounding rock and
cable truss support as shown in Fig. 3. The calculations of anchor-
The support system reinforces both in the vertical and horizon- ing and pre-tightening forces in the support designed for field
tal directions, which switches the stress from two directions applications are given by Eq. (1).
into a balanced stress state;
P p
The cable is much longer than a conventional bolt so the sup- 6 F 1 cos b ð1Þ
2 2
ported region is also larger. Meanwhile, the superior extension
provides a powerful shearing assistance; P1 ¼ P2 ¼ P=2 ¼ q0 a=2 ð2Þ
The linear contact between the outer section of the cable and
the roof provides a uniform force on the shallow surrounding where P is a vertical force, N; F1 the friction force inside the inclined
rock; cable, N; b the obtuse angle between the horizontal and the inclined
The bolt points are located in regions deep in the roof and coal cable; and q0 the uniform stress, N/m2.
sides so spalling can be prevented and the roof is stabilized; Furthermore, following Fig. 4, the relationship between the pre-
As the support system deforms it will gradually lock and, thus, tightening force, F, and the friction force, F1, is obtained from:
can control larger roof displacements. b
F 1 ¼ F j 2F cos ð3Þ
2
The main support styles using bolts or cables in the coal fields in
China are listed, compared, and analyzed in detail in Table 1. where j is the friction coefficient.
In conclusion, the cable truss is superior compared to the con- Then, substituting F1 from Eq. (3) gives:
ventional cable and the bolt truss. The conventional cable has a lar-
ger support range, which could harmonize the shallow and deep P
FP ð4Þ
stratum during excavation and service periods. Bolt trusses tie 2 1 2j cos 2b cos b p2
the roof to the support structure in a horizontal direction as roof
subsidence occurs, which can control roof deformation to a degree. Now suppose the rock inside the cable truss is under a uniform
The cable truss system replaces the bolt and bar with the cable and load. Then the pre-tightening force should exceed the horizontal
the connector respectively. This allows larger pre-stress to be force that arises from the combed effects of the ground stress
applied than in the bolt and truss method and results in a higher and the vertical load:
(a) Bolt truss (b) Simple cable truss with joist steel (c) Conventional type of cable truss
Table 1
A comparison of support methods using bolts or cables.
Support style comparison Cable truss support Bolt truss support Single cable support Simple cable truss support
index
Adaptive production and Intensive dynamic pressure General dynamic pressure effect, General dynamic pressure General dynamic pressure
geological condition effect, large cross-section, relatively large cross-section, effect, small cross-section, effect, large cross-section,
complex surrounding rock simple surrounding rock simple surrounding rock complex surrounding rock
Position of bolting points Above coal sides in deep and Nearby the coal sides in shallow Above the roadway, easily Above coal sides in deep and
compressive rock strata rock strata affected compressive rock strata
Connection pattern Flexible connection Rigid connection Connect without the Flexible connection
horizontal direction
Fastener to connect two Arc connection and locking Horizontal threadbar, truss Large support plate, lock set Support plate, lock set
cables device bracket, tightening nut
Pre-tightening force and Large, horizontal and vertical Small, horizontal and vertical Large, vertical upward Small, horizontal and vertical
corresponding direction upward directions upward directions direction upward directions
Contact style between Linear contact, continuous Nonlinear contact, discontinuous Point to point contact Linear contact, discontinuous
support system and transmission transmission transmission
anchoring surrounding
rock
Structural property Equal strength, locking, large Unequal strength, small structure No structure Unequal strength, small
structure structure
Control region and roof Long, wide, high, strong Long, narrow, low, weak Short, wide, high, without Long, wide, low, weak
anti-shear deformation effect
Stress state of surrounding Significantly improves stress Improves stress state of the roof in Unable to improve stress state Improves stress state of the
rock in the region of state of the roof in horizontal horizontal and vertical direction of the roof in the horizontal roof in horizontal and vertical
anchoring and vertical direction direction direction
q0
and 3.0 m high and the roof rock stratum is composed of multiple
mudstone layers. A section of the immediate roof of the extracting
roadway contains 2# coal in a thickness from 0 to 0.1 m.
In addition, each roof layer has a great deal of developed cracks.
The layer thickness is from 0.1 to 0.5 m and the crack spacing is
F1
from 0.1 to 0.5 m. Hence splitting of the roof rock can occur and
this might extend to final caving once the support system for the
A B
roadway is weakened and unable to adapt to the local deformation.
P1 F P2
These results from the intensive dynamic pressure developed after
installing supports.
Fig. 3. Mechanical model for calculations.
Conventional cable costs of the roadway; (3) a reduction in accident treatment costs;
Cable truss (4) A speed up of the fully mechanized coal face. The social benefits
consist of three parts: (1) An improvement in the support velocity
and the relationship between excavation and mining; (2) A reduc-
tion in the working intensity of the miners; (3) A strengthening of
the ability of the support system to ensure safe work.
10° 20°
250 250 4. Conclusions
1000 1000 1000 1000
300
(1) The main support methods for coal roadways affected by
10° 1200 2100 1200 intensive dynamic pressures have been studied and ana-
800
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