20" International Conference on Ground Control in Mining Tensioned Cable Bolts as Primary Support: Update John C. Stankus, President Keystone Mining Services, LLC Pittsburgh PA Terry Suder, Superintendent CONSOL Energy - Buchanan Mine ‘Oakwood, VA Doug Williams, Superintendent ‘CONSOL Energy - Oakwood, ABSTRACT tthe 19th International Conference on Ground Contral in Mining, a paper was presented detailing new types of Jennmar INSTAL ensionable cable bolts (Stankus and Taylor, 2000). Since that time, significant testing and trials of the various types of tensionabi cable bolts have been conducted. Several MSHA districts and state regulatory agencies have now approved these systems as, primary support. This paper will detail the use of tensionable cable bolts as primary support at two longwall mines in Virginia (MSHA District 5). INTRODUCTION Consol Energy's Buchanan and VP 8 mines operate inthe Pocahontas #3 seam in the Oakwood, Va. area. Each mine operates ‘one Jongyall with 1000 ft wide faces and average length of 7500 f Seam height and overburden range from 60-76 in. and 1.400-2,700 ft respectively. Both mines utilize a four entry gateroad system, (Over the years, ground control has been fairly successful at both mines. The immediate roof consists of laminated shale, sandy shale, and sandstone. Stratscope analysis also has indicated fccasional thin layers of elaystone and carbonaceous material at various roof horizon. typical stratagraphic columa i shown in Fig |. Primary support has consisted of fully grouted, non-tensioned rebar, tensioned threaded rebar, and fully tensioned INSTAL type, point anchor bolts. Various lengths, diameters, and grades of stel hhave been used in the systems. Prior tothe advent of cable bots, supplemental bolting when needed, consisted of multiple coupled, | in, diameter Combination bots in lengths ranging from 8-16 R. These bolts were effective. However, many times duc to lateral stata movement, bolt shear failure occurred at the coupler arca, ‘Subsequently cable bolts replaced the Combination bolt as the main supplemental support system. Grade 270,06 in. diameter eable bolts in lengths ranging from 8-16 ft. were utilized. The systems were non- 252 VP 8 Mine. VA tensioned and utilized a minimum of four equivalent fet of resin for anchorage, DEVELOPMENT AND IMPLEMENTATION ‘OF SUPPORT PLAN Shown in Fig. 2 isa typical plan utilized at both mines showing the non-tensioned cable bolts used as supplemental support in conjunction with the primary bols. Tis support plan as proven to be very effective. However, this plan could not be implemented in cycle without causing significant development delays. Much ofthe supplemental bolting had to be completed off cycle, A cable bolt system was needed that could be installed quicker and as par of the Primary support plan. In early 2000, the first tensionable, INSTAL «able bolts were made available in the epoxy coated, CableOx systems shown in Fig 3. Testing of these systems was conducted at both mines, From the testing, and based on consistency ofthe lower strata, the INSTAL CC cable bolt was determined to be best suitable forthe conditions at both mines. Refer to Fig. 4 fora plot ofthe pul test data. Four equivalent ft. of resin encapsulation in a 1-3/8 inch diameter borehole produced anchorage capacity compatible to the grade 270, 0.6 in. cable. To determine installed bolt tension and lension/torque relationship, load cell tests were conducted and are shou in Table I. Further, due tothe fact that these bolts would be used in short term, gateroad entries, corrosion and longevity were not concerns. The epoxyccoated CableOx was not necessary. Shown in Fig 5 isthe INSTAL CC system in regular, non-coated cable that was determined to be the appropriate system for use as primary suppor. Support plans were generated utilizing the INSTil. CC tensionable «able bolt used as primary support installed in conjunction wth other normal type approved bolts. Shown in Figs. 6 and ? are the respective Support plans for 20 and 22 f wide entries, MSHA approval for use of the tensionable cable bolt as part of the primary support plan was granted in December 2000. Shortly thereafc, implementation of the plan commenced,20 International Conference on Ground Control in Mining Fine cbemceur ada wae oes Med. Sly ited ale Fig. Typical strata column . . o"o ofa . . 1 ose anevion ok comaonstion Fig. 2 Previous supplemental support plan 25320" International Conference on Ground Control in Mining 118" Square Head ifn shor: Flat Spherical Housing ‘andlor ‘Stifener Tube Resin Mixing! Anchorage Buttor ae (Grit Surface Cable Fig. 3. INSTAL Cableox system 3 Shel ns «Plug Assembly Zee Epory-Coated Threaded Tube \ Support Nut l “JENNIVAR CORPORATION PULL TEST HEAD DEFLECTION VP #8 MINE 08 beta! 00x10" Oy atest a _ 08 208 q o4 gos oz ot o 0 10 20 30 40 50 Applied Load, x 1000 Ib Fig. 4 Poll test Table 1 Load Cell Test Bolt | Installed Load Torque Tension / Torque Number _| (ibs) (ft-lbs) Ratio #1 9,850 270 36 #2 | _9,550 270 35 #3 | 9,850 270 36 #4 9,250 270 34 HS 14,175 270 53 #6 8,625 270 32 Average 10,217 270 38 254 420" International Conference on Ground Control in Mining STIFFENER ‘TUBE W/THREAD SQUARE HEAD BIRD CAGE EXPANSION SHELL noe! ‘COMPACTOR ys SPHERICAL WASHER WEDGE Fig. 5. INSTAL CC cable bolt (regular, non-coated cable) oso soo eo 20" MAX, 0 romraxcion ox connination INSTAL CE TENSIONABLECADLE BOLT (GFT MN LENGTN (© srearascore nous Fig. 6 Current primary support plan ~20 ft wide entry and erosscut 25520" International Conference on Ground Control in Mining ao ao Fig. 7 Current primary support plan ~ 22 ft, wide entry and 20 ft wide erosscut EVALUATION OF SUPPORT PLANS To evaluate the effectiveness of the new support plan (Fig) in a 20 8. wide entry and the previous plan (Fig. 2), & ‘monitoring program was implemented. Stratascope and convergence Stations were installed in three intersections bolted with each plan in the same section and conditions. Each intersection was bolted with the following bolts: Previous Plan (Fig. 2) No. Bolts 6 Ft. Tensioned Rebar 60 10 Ft, Non-Fensioned Cable 28 Total Bots 88 New Plan (Fig. 6) 6 Ft, Tensioned Rebar 30 10 Ft Tensioned Cable 30 Total Bolts 256 Since the new support plan utilized 32% less total roof bolts, the criteria for evaluating the new plan would be if bed separation and/or fracture patterns and entry convergence were the same or better than with the previous plan, then the new plan would bbe considered effective. General conditions in both areas were also ‘evaluated. Stratascope boreholes and convergence stations were installed during entry development with initil data recorded. Subsequent stratascope and convergence readings were taken on & periodic basis. Shown in Figs. § and 9 are generalized stratigraphic ‘columns for both support plans. The stratascope daa in terms of bed Separation and fracture patterns are nearly identical. A slight decreas in the numberof fractures is detected withthe new plan, summary ofthe averaged convergence data for both plans is shown in Fig. 10. The convergence data for both plan is similar. However, slight reduction in convergence with the new plan s detected. Overall, conditions in both areas were similar. It appears that due tothe 10 f. cable bolts being tensioned on installation, th total beaming effet hhas ben enhanced, thereby affecting the stratscope and convergence data. Based upon this data it ean be conclided that the new support, plan (Fig. 6) is effective 420" International Conference on Ground Control in Mining Sandstone, solid Fine carbonaceous atria with mine » Sandton, slid Sandstone with areaks Laminated santone wise se ior aces" haion Med. ry lami sake Mat. ray finely amit she wih minor ctr at 2 and 2 6 hain Top of cos sean Fig. 8 Stratascoping results in previous plan Sandee sd Med ay ind sae ‘nc ci tharos Fig. 9 Stratascoping results in new phan 25720" International Conference on Ground Control in Mining [a= New plan —4— Previous plan Convergence (in) 0 200 400 600 800 Distance outby face (ft) 1000 1200 1400 1600 1800 2000 Fig. 10 Comparison of roof convergence between previous and new plans CONCLUSIONS ‘The INSTAL CC tensionable cable system, when used as part ofthe primary support plan, has been effective at both Buchanan and VP § mines. Previous production delays associated with installing supplemental, non-tensioned cable bolis have been eliminated. Material and related labor cosis have been reduced, Strictly from a ground control perspective, implementation of cable bolts as part of the primary mining cyle, closer tothe freshly mined 258 face, has enhanced the beaming effect and enables the cablesystemto interact sooner with the ground conditions providing beter contol REFERENCES Stankus, JC. and K.L. Taylor, 2000, “INSTAL CableOx: A [New Tensionable & Corrosion Resistant Cable Bolt.” Proc. 19th International Conference on Ground Conivol in Mining, edited by SS. Peng, West Virginia University, pp. 261-268.