The stability of underground openings is pivotal to sustainable safe mining in underground coal mines. To determine the stability and tunneling safety issues in 800-m-deep underground openings through large fault zones in argillaceous rocks in the Guqiao Coal Mine in East China, the pilot industrial test, laboratory experimentation, and field measurements were used to analyze the large deformations and failure characteristics of the surrounding rock, the influence factors of safe excavation and stability of underground openings, and to study the stability control countermeasures. The main factors influencing the stability and tunneling safety include large fault zones, high in situ stress, poor mechanical properties and engineering performance of the argillaceous rock mass, groundwater inrush and gas outburst. According to the field study, the anchor-ability of cables and the groutability of cement-matrix materials in the argillaceous rock in the large fault zones were extremely poor, and deformations and failure of the surrounding rock were characterized by dramatic initial deformation, high long-term creep rate, obviously asymmetric deformations and failure, rebound of roof displacements, overall loosened deformations of deep surrounding rock on a large scale, and high sensitivity to engineering disturbance and water immersion. Various geo-hazards occurred during the pilot excavation, including roof collapse, groundwater inrush, and debris flow. Control techniques are proposed and should be adopted to ensure tunneling safety and to control the stability of deep underground openings through large fault zones, including regional strata reinforcement technique such as ground surface pre-grouting, primary enhanced control measures, floor grouting reinforcement technique, and secondary enclosed support measures for long-term stability, which are critical for ensuring the sustainable development of the coal mine.

The longevity of grouting has a significant effect on the safe and sustainable operation of many engineering projects. A 500-day experiment was carried out to study the long-term mechanical behavior of nano silica sol grouting. The nano silica sol was activated with different proportions of a NaCl catalyst and cured under fluctuating temperature and humidity conditions. The mechanical parameters of the grout samples were tested using an electrohydraulic uniaxial compression tester and an improved Vicat instrument. Scanning electron microscope, X-ray diffraction, and ultrasonic velocity tests were carried out to analyze the strength change micro-mechanism. Tests showed that as the catalyst dosage in the grout mix is decreased, the curves on the graphs showing changes in the weight and geometric parameters of the samples over time could be divided into three stages, a shrinkage stage, a stable stage, and a second shrinkage stage. The catalyst improved the stability of the samples and reduced moisture loss. Temperature rise was also a driving force for moisture loss. Uniaxial compressive stress-strain curves for all of the samples were elastoplastic. The curves for uniaxial compression strength and secant modulus plotted against time could be divided into three stages. Sample brittleness increased with time and the brittleness index increased with higher catalyst dosages in the latter part of the curing time. Plastic strength-time curves exhibit allometric scaling. Curing conditions mainly affect the compactness, and then affect the strength.

A new experimental method for characterizing the porosity of loose media subjected to overburden pressure is proposed based on the functional relationships between porosity, true density, and bulk density. This method is used to test the total porosity of loose coal particles from the Guobei coal mine in Huaibei mining area, China, in terms of the influence of pressure and particle size on total porosity. The results indicate that the total porosity of loose coal under 20 MPa in situ stress is about 10.22%. The total porosity and pressure obey an attenuated exponential function, while the total porosity and particle size obey a power function. The total porosity of the loose coal is greatly reduced and the sensitivity is high with increased pressure when stress levels are low (shallow burial conditions). However, total porosity is less sensitive to pressure at higher stress when burial conditions are deep. The effect of particle size on the total porosity reduction rate in loose coal is not significant, regardless of low- or high-pressure conditions; i.e., the sensitivity is low. The total porosity remains virtually unchanged as particle size changes when pressure exceeds 20 MPa. Overall, the sensitivity of total porosity to pressure is found to be significantly higher than sensitivity to particle size.