Fracture expansion in rock masses can be observed by monitoring the break of contacts between the bounding particles via the discrete element method. The latter’s realization in this study via the PFC^2D program tracked the evolution process of the zonal disintegration in an exemplary roadway-surrounding rock affected by mining. Besides, the damage evolution pattern in a high-stress soft rock roadway was simulated by the FLAC^2D program using a strain-softening plastic model, revealing the effects of rock mass strength, stress state, and anchor support on the zonal disintegration of the roadway. Numerical simulation results show that in a roadway with high-level stress, the obvious fractures spread from the roadway surface to the depth of the surrounding rock along a series of geometric planes and cut the surrounding rock into rock mass blocks. Under high crustal stress, conjugate shear fractures occur near the roadway surfaces and form a closed-loop fractured zone after intersecting the conjugate fracture faces. The closed fractured zone becomes a free face, from which conjugate shear fractures develop, forming new closed fractured zones in the deep surrounding rock. By repeatedly generating the closed fracture zones, a fracture network appears in the roadway-surrounding rock. The development of zonal disintegration of roadway-surrounding rock mainly depends on the rock mass strength and its stress state. Zonal disintegration only occurs when the crustal stress of the roadway-surrounding rock exceeds its strength. When the horizontal stress is low and the vertical stress exceeds the rock mass strength, zonal disintegration only occurs on two sides of the roadway. When the vertical stress is low and the horizontal stress exceeds the rock’s mass strength, it only appears on the roof and floor. When the values of cohesion, internal friction angle, and tensile strength are reduced in the same proportion, cohesion has the greatest impact on the expansion of the zonal disintegration zone, followed by the internal friction angle, while the tensile strength effect is the least. In anchor-supported roadways undergoing zonal disintegration processes, the intact zone blocks slide relatively along the fracture surface during the process of loosening and deformation of the surrounding rock, making the anchor rods susceptible to tensile, shear, and bending actions.

Strong mine pressure has a great impact upon the safety production of coal mines. Microseismic information provides a more advanced technical means for overburden fracture dynamic identification and mine pressure mechanism research, since it contains rich information on rock fracture sources. In this study, the isolated LW8102 working face in Tongxin Mine was investigated in order to propose a spatio-temporal microseismic event data analysis method based on the k-means clustering algorithm. This algorithm can handle dynamic identification of overburden fractures constrained by spatiotemporally discrete distributions of microseismic events. This provided the dynamic extension process and the fracture distribution pattern of the overburden: eight fracture extensions were formed in the overburden. In each extension, vertical fractures connected the low and high rock layers in the LW8102 and LW8103 goafs, and through fractures connected the LW8102 and LW8103 goafs in their high, middle, and low levels. Some extensions had fractures that were connected to form a closed loop structure. In the vertical fracture, there was a tendency for one or two layers of the stratum to fail first, and then extend to one or both sides. The process of through and vertical fracture propagation followed a certain temporal sequence, reflected primarily in two forms: firstly, as the vertical fracture extended to a certain layer, it provided the initial rupture space for through fracture spreading; secondly, the through fracture first broke, and then extended to the vertical fracture until it intersected with the vertical fracture or provided the initial rupture space for the expansion of the vertical fracture. By matching the overburden fracture to the mine pressure that responded to the support resistance, we analyzed the mechanism of mine pressure at the working face. Through fracture at the high level was found to be the primary cause of the occurrence of mining pressure. It was precisely placed that the formation of multiple adjacent high through fractures 110 m from the floor, triggering simultaneous instability motion of the lower multi-layer level rock; this was the main reason for the phenomenon of strong mine pressure at the working face. Meanwhile, high through fracture at 80 m from the floor was the main reason for the phenomenon of large mine pressure at the working face.

In order to determine appropriate anchoring parameters after enlarging the cross-section of the mining roadway, a comprehensive study was conducted to investigate the development of deformation and failure characteristics in the surrounding rock. The mechanical behavior of rock failure under high-stress conditions and the progressive evolution of deformation and failure from shallow to deep zones were thoroughly analyzed. It was proposed that the primary function of bolt support in mining roadways is to guide the surrounding rock to form a stable compressive arch or ring structure. The mechanical mechanism underlying the formation of such an arch under bolt guidance, along with the stability characteristics during this process, was investigated. The principles for determining bolt support parameters were established as follows: (a) ensuring the formation of a closed compressive ring within the anchorage zone around the roadway; (b) preventing shear failure at the roadway corners; and (c) controlling the extent of roof subsidence under gravitational loading. Design methodologies for determining rock bolt and anchor cable length and spacing were formulated and implemented in the support design of large-section mining roadways within million-ton fully mechanized mining faces. The cross-sectional dimensions of the supported roadway are 5.8 × 4.0 m. Field monitoring results indicate that, after stabilization of the surrounding rock deformation, the maximum convergence between both sides does not exceed 140 mm, the maximum roof subsidence remains below 40 mm, and the maximum roof separation is limited to within 4 mm. These findings provide strong evidence that the selected design parameters fully meet the engineering requirements for roadway support.

Extremely loose and soft coal seams, with a Platts coefficient of less than 0.3, are easy to break in the process of integrated mechanized roof coal mining and are prone to spilling and piling up between the hydraulic supports, which is a safety hazard for the movement of equipment. The coal particles must be cleaned up manually, resulting in reduced resource recovery rates and lower mining face efficiency. To effectively mitigate and control the problem of coal spillage accumulation amidst hydraulic supports, this study utilizes discrete element numerical simulation to examine the characteristics of block size distribution and the spilling process during the crushing of highly loose and soft top coal. By taking into account various parameters associated with shelf spacing, this research identifies key factors for controlling arching and self-stopping phenomena in top coal particles. The study findings suggest that the uppermost coal layer undergoes significant fragmentation during the integrated mining process of loosely packed and soft coal seams, resulting in a higher probability of coal leakage issues observed near the rack’s coal wall side and at the end of the roof control area. The key factors contributing to the self-arresting of spilled coal particles include inherent characteristics of the coal body, particle diameter, and stand spacing. In this specific mine under investigation, an arch formation naturally occurs to prevent further leakage when the distance between stands is less than eight times the diameter of particles, and after process correction, the average time saving for a single shift of manual floating coal cleaning at the working face is about 2 h, and the proportion of time saving is more than 50~75%.

To address the challenging issues of large deformation, control difficulties, and susceptibility to failure in the support structure of soft coal roadways, this study utilizes the CVISC block creep model in UDEC software. The model incorporates Coulomb slip without cohesive contact to simulate the characteristics of soft coal, such as its loose, fragile, and small-block nature. Additionally, a soft coal nonlinear discrete element creep model is developed to investigate the creep characteristics of soft coal under triaxial compression, with the aim of revealing the underlying creep destabilization mechanism in soft coal tunnels. Based on the research findings, a primary, strong active support technology is proposed. This approach involves the use of high-preload, high-strength anchor rods and anchor cables, as well as the implementation of steel mesh and plastic woven mesh to enhance surface protection. The study highlights that: (1) The shear cracks inside the coal body of the soft coal specimen transform into tensile cracks under external force, leading to an increase in the number of tensile cracks. This is an important symbol of accelerated creep in soft coal. Improvement in peripheral pressure helps inhibit the generation of tensile cracks inside the specimen. (2) The rapid development of creep and inter-particle tensile fissures within the coal body particles themselves, along with the change in stress state after the excavation of the roadway, are the main reasons for the overall creep damage of the roadway. (3) The support force in the early stage of shed cable support is small, which cannot inhibit the accelerated development of tensile fissures. This leads to continuous deformation of the roadway, resulting in the failure of the support structure in the later stage and aggravated roadway damage. (4) The new support technology helps control surface deformation by enhancing the strength of the roadway protection surface. This suppresses the development speed and number of tensile fissures during roadway deformation, improves the starting strength of the roadway for accelerated creep, and enables effective control of the overall deformation of the soft coal roadway. Thus, the effectiveness of roadway support is remarkable.

Rock mechanics serves as the fundamental theoretical pillar supporting the safe, efficient and sustainable implementation of geotechnical engineering in construction, transportation, water conservancy, mining and urban underground space development