Roof fall is a frequent and destructive disaster in the working face of extra-thick coal seams. The important technology for disaster elimination is roof grouting, and the key to its success is to accurately predict the distance of the advanced fractures based on a reasonable rock constitutive relationship. In this paper, the constitutive relationship reflecting the progressive failure process of rock was established, including the elastic–plastic constitutive relation of intact rock, the fracture constitutive relation of non-penetrating fracture, and the shear friction constitutive relation of penetrating fracture. On this basis, the finite–discrete element method (FDEM) numerical calculation method was developed. Taking Yushupo Coal mine with a 16-m-thick coal seam as an example, the numerical results showed that the fractures in the roof appear 15~35 m ahead of the working face, and the maximum value of advance bearing pressure is between 16 and 30 MPa. Meanwhile the laboratory test results showed that the compressive strength of the grouted coal is 14.91 MPa after solidification for 7d. The above data mean that the grouting slurry can solidify the broken roof into a whole without roof fall disaster. At the same time, the rock pressure of the extra-thick coal seam can effectively crush the top coal, which is conducive to the top-coal caving operation. The in situ test shows that when the pre-grouting is carried out in the range of 20~30 m in front of the working face, the roof fall disaster can be effectively avoided, which is consistent with the numerical simulation results. It shows the rationality of the FDEM numerical method and the constitutive model of rock deformation–fragmentation failure process.

A reliable numerical simulation method and large-scale in-situ test method for super-thick coal seams are very important to determine the failure range of mining floors, which is often the basis to protect Ordovician limestone water, an important drinking water source for people in North China. This paper takes Yushupo Coal Mine as an example; the explicit–implicit coupling simulation method and the corresponding double scalar elastic–plastic constitutive model were established to predict the failure depth of the floor numerically, and verified by the full section borehole stress–strain in-situ testing method. The results show that the explicit–implicit coupling numerical program and the double scalar elastoplastic constitutive model are suitable for predicting the floor failure depth under the condition of extra-thick coal seams. In this condition, the overburden moves violently, resulting in a loading–unloading–reloading process with large stress variation amplitude in the mining floor, which leads to serious rock failure compared with that of medium-thick coal seam conditions. In Yushupo 5105 working face, the floor failure starts to develop from 9.3–24.2 m ahead of the coal wall of working face, and the failure depth no longer increases after 35 m behind the coal wall, with the maximum failure depth of 28 m; the envelope line of the floor failure depth presents an inverted saddle distribution. The above research results lay a foundation for further protecting the Ordovician limestone water, and realizing green coal mining.