The movements of overburden induced by mining a thick coal seam with a hard roof extend widely. The effects of breakages in the hard strata on the strata behaviors might vary with the overlying strata layers. For this reason, we applied a test method that integrated a borehole TV tester, borehole-based monitoring of strata movement, and monitoring of support resistance for an in situ investigation of a super-thick, 14–20 m coal seam mining in the Datong mining area in China. The results showed that the range of the overburden movement was significantly high, which could reach to more than 300 m. The key strata (KS) in the lower layer main roof were broken into a ‘cantilever beam and voussoir beam’ structure. This structure accounted for the ‘long duration and short duration’ strata behaviors in the working face. On the other hand, the hard KS in the upper layer broke into a ‘high layer structure’. The structural instability induced intensive and wide-ranging strata behaviors that lasted for a long time (two to three days). Support in the working face were over-pressured by large dynamic factors and were widely crushed, while the roadways were violently deformed. Hence, the structure of a thick coal seam with a hard roof after mining will form a ‘cantilever beam and voussoir beam and high layer structure’, which is unique to a large space stope.

The key to the safe mining of thick coal seams under rivers is understanding the development patterns of fractured water-conducting zones (FWCZ) when various mining methods are used. To solve this problem, we employed numerical simulation to investigate FWCZ when slice mining and longwall caving mining are performed. When slice mining was carried out, the maximum height of the FWCZ in the higher slice was 88 m. When the lower slice was mined, the maximum height became 95 m, and the ratio of the fracture height to the coal seam thickness was 15.8. For longwall caving mining, the height of the FWCZ reached 126 m, which was 31 m more than that of slice mining, and the ratio of the fracture height to the coal seam thickness was 21. Through field measurements, the height of the FWCZ during longwall caving mining of thick coal seams was verified. The measured height was 108.87–112.57 m, and the measured ratio was 19.08–19.28. Under the same stratigraphic conditions, changes in the bulking factor and structural stability of key strata were the dominant factors that determined how mining methods affected the height of the FWCZ. These development patterns can provide significant theoretical insights for effectively preventing water hazards on mine roofs.

Aiming to reduce the high mining stress observed in large-space roof structures during mechanized mining of thick coal seams, a control technique based on protective-seam mining is proposed. This technique was used to investigate the 8108 working face of the No. 3–5 thick coal seam of the Tashan mine located in the Datong area of Shanxi, China, by means of simulations and field measurements. The numerical simulation revealed that the No. 3–5 coal seam undergoes expansion and deformation, accompanied by stress relief due to the mining of the overlying No. 4 coal seam. The physical simulation demonstrated that mining the protective seam changes the structural characteristics of the overlying strata in advance and reduces the integrity of the roof in the No. 3–5 coal seam. Field measurements showed that the support loads in the 8108 working face are significantly weaker than those in the adjacent 8107 working face, where protective-seam mining was not performed. In the absence of high resistance on the support and distinct periodic weighting characteristics, the rock masses around the 8108 working face and roadway could be easily supported.

China consumes more than 3.6 billion tons of coal every year. In the meanwhile, coal accounts for over 60% of the energy consumption sector. Therefore, the sustainable development of coal mines is a problem that needed to be solved by the Chinese government. During the coal resources recovery process, the protective coal pillars between the adjacent working faces lead to a vast waste of coal resources. In order to mitigate the resource-wasting issue, a new technology of roof cutting with chain arm retaining roadway was put forward in this paper. First, the procedures of retaining roadway, roof-cutting parameters and the damage ranges of roadway surrounding rock induced by roof cutting with chain arm were analysed. Then, the working resistance of the temporary support equipment is given when using the new technology to retain the roadway. Next, the roof-cutting height, the temporary support equipment selection, working resistance of portal support and support parameters of the bolt and anchor cables were optimized based on the numerical calculation. The industrial experiment of retaining roadway by roof cutting with chain arm was carried out in a working face. The surrounding rock damage was lowered and controlled with the application of chain arm roof-cutting technology. Also, it was found that the variation range of the uniaxial compressive strength was only 5%, resulting in the roof damage range of 82 mm. The new technology has proved a potentially wide application in the coal mining industry with prosperous economic and safety improvement.