32nd International Conference on Ground Control in Mining
Case Studies of Innovative Cable Bolt Technology
Ben Mirabile, Technical
Mirabile, B.
Sales and Service Engineer
Jennmar Corporation, Inc.
Pittsburgh, PA
ABSTRACT
Over the past three decades, the U.S. coal mining industry has
widely used cable supports to supplement traditional primary
bolting systems, especially in difficult ground conditions. However,
increased mining activity in adverse conditions has underscored
the limited effectiveness of the non-tensioned, partially grouted
cable supports used to supplement primary bolts. Roof failures in
conditions such as corrosive environments, highly laminated strata,
low overburden depth and water intrusion have demonstrated that
the need for cable technology has reached beyond the traditional
non-tensioned, partially-grouted cable tendon. Furthermore,
declining market conditions and increased competition for coal
customers has demanded that new cable bolt technology be cost-
effective and readily adaptable to the mining cycle.
Jennmar Corporation has developed several cable bolt
technologies that can be used as stand-alone solutions or in concert
with one another to mitigate adverse conditions. These technologies
include rapid tensioning of cable supports, structural surface
control and polyurethane injection. The case studies presented in
this paper use one or more of these technologies to address adverse
mining conditions or special ground control problems.
INTRODUCTION
Based on customer purchase decisions and successful
completion of special ground support projects, three recent
developments in cable bolting technology have proven especially
beneficial to the U.S. coal mining industry:
•  Rapid tensioning of cables has been successfully employed to
support highly laminated strata.
•  Structural surface control used in conjunction with cable
supports is regularly used to support weak or disturbed strata.
•  Also, polyurethane injectable cables have been used for
corrosion protection, mitigation of water intrusion and
consolidation of roof strata.
The Jennmar INSTáL CC cable bolt is a hybrid of a traditional
cable bolt and a conventional roof bolt (Figure 1). A bail-type
expansion shell is attached to a heavy-walled stiffener tube. This
expansion shell can be located from four to six feet above the roof
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line, depending on mining height. The cable tendon passes through
the heavy-wall stiffener tube, and extends from the barrel-and-
wedge assembly at the roof line to the maximum length of the
cable support. The expansion shell allows tensioning of the cable,
up to approximately 10,000lbf. Tensioning is completed as the
bolt is installed and does not require additional equipment or time
after initial installation. Traditional post-tensioned cables require
individual cables be tensioned with a hydraulic tensioner after
the resin grout has cured. This additional installation step limits
the installation rate and overall deployment of tensionable cables.
Operators often have difficulty maintaining a cable bolt installation
rate that is consistent with the mining rate. This situation often
results is un-tensioned cables or cuts that sit unsupported for an
extended length of time.
Figure 1. Jennmar Instal CC cable bolt.
The application of structural surface control is simply a marriage
of two existing ground support technologies. Truss systems have
been used to support mine roofs for a number of years. Angle bolts,
anchored into undisturbed strata above the mine ribs, support a
horizontal cross-member that is designed to support and confine the
immediate roof. In an ideal situation, mine roof can be supported
without having to suspend weak lower strata from more competent
strata higher in the mine roof. Traditionally, trusses have been
employed when it is impractical to drill vertical holes deep enough
to reach competent, undisturbed strata.
One of the major disadvantages of traditional roof trusses
is evident in uneven mine roof (Figure 2). Often there will be
large, unsupported gaps between the cross-member and the roof.
Additionally, traditional bar or cable cross-members are not
inherently strong against bending moments. These factors make a
traditional truss system very flexible when subject to roof loading.
As will be shown in the case studies, the Jennmar engineering
staff often specifies the use of cable bolts and roof channel in the
 32nd International Conference on Ground Control in Mining
B-Rigid truss configuration as a stiff, high capacity truss alternative
(Figure 3). A three- or four-hole roof channel is used to apply
structural surface control. The cross-section of the roof channel is
designed primarily to resist bending moments. Two cable bolts are
angled over the mine ribs to anchor into undisturbed strata, similar
to a traditional roof truss. One or two cable bolts are installed
vertically toward the center of the channel, and these vertical
cables provide additional stiffness to the center of the channel and
may or may not anchor into competent strata. The B-Rigid truss
utilizes off-the-shelf roof control products, and many mines already
have the assorted components in stock in the mine supply yard.
Additionally, no special tools are required to install the B-Rigid
truss. It can be used in conjunction with all cable bolt systems
including INSTáL CC cables, fully grouted cables, post-tensioned
cables and non-tensioned cables.
Figure 2. Channel forms to the roof line; truss cross-members
leave unsupported gaps.
Jennmar Corporation began development of the Fully-Grouted
Cable Bolt (FGCB) in 2010. It was developed in response to
coal operators’ concerns regarding cable corrosion in workings
designed to remain open long term. The FGCB consists of standard
seven-wire cable with the addition of a bottom-hole plug and
modified head. The FGCB is installed in exactly the same manner
as a non-tensioned, partially grouted cable bolt with a 48 in resin
cartridge for bolt anchorage. The bolt head is modified to allow
the attachment of polyurethane injection equipment. Because
the FGCB is installed with the same method as a non-tensioned
partially grouted cable bolt, there is little to no disruption of the
mining cycle on miner sections where cable bolts are normally
installed. Polyurethane can be injected into the bolt annulus at
any time after the resin grout has cured. This feature allows mine
operators to install the FGCB in areas where adverse conditions are
anticipated, then inject the bolts on an as-needed basis.
CASE STUDY 1
Case study 1 is a longwall headgate in the Eagle seam, in
southern West Virginia. Supplemental support in the headgate was
installed approximately 9 months after the headgate was developed.
The roof in this area consisted of highly laminated sandstone
with mica streaks (Figure 4). During installation of supplemental
support, mining-induced roof fractures were discovered up to 11 ft
above the roof line, using test drilling with a roof bolter. Fracture
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Figure 3. Jennmar B-Rigid Truss.
location and density were confirmed with a video borescope.
Fracture density was very high in the first four feet above the roof
line, with some test holes showing 6 fractures per foot of test hole.
Polyurethane resin was specified to consolidate the highly fractured
immediate roof, and 0.7 in × 120 in grade 270 FGCB cables were
used to inject polyurethane. This bolt length produced an injection
zone to 6 feet above the roof line when used with a standard 1 ¼
x 48 in resin cartridge for anchorage. A single cable was installed
approximately every 8 feet near the center of the entry. In this
case, polyurethane was used in conjunction with previously
installed supplemental support. After all supplemental support
was installed; polyurethane was injected into the FGCB cables,
and allowed to migrate into the roof (Figure 5). Migration of the
polyurethane was evaluated with a video scope and by day lighting
of the polyurethane in adjacent bolt holes. With these methods,
the polyurethane was found to migrate in an approximately 10ft
radius around the bolt (Figures 6 and 7). In this case, the FGCB
was used as a cost-effective and efficient method for consolidation
of the immediate roof. The installed cost of the FGCB was
approximately 75% of a traditional inflatable packer polyurethane
injection system.
CASE STUDY 2
Case study 2 is a long-term belt corridor in the Eagle seam,
central West Virginia. Constraints on the mining reserve required
that the corridor be developed underneath a valley where
the original overburden depth was less than 50ft (Figure 8).
Compounding the difficulty was the fact that the valley had been
filled in the 1950s and the fill depths reached approximately 150ft
in the belt corridor area.
 32nd International Conference on Ground Control in Mining
Figure 4. Roof Geology -- Case Study 1.
Figure 5. Polyurethane injection for strata consolidation.
Two coreholes were drilled near the location of the lowest
overburden areas of the mining projections. In addition, a
borescope was used to examine the roof in developed areas
of the mine adjacent to the belt corridor. Both the coreholes
and borescope observations indicated the mine roof consisted
predominantly of massive sandstone. Some indications of
weathering, such as high angle fractures and water staining, were
found in the upper portion of cores retrieved from the coreholes.
Due to the low overburden depth, it was considered very likely
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Figure 6. Polyurethane found in adjacent test holes.
Figure 7. Polyurethane migration at roof line.
that significant weathering and unconsolidated strata would be
encountered during development of the belt corridor.
In cooperation with mine engineers, Jennmar Corporation
engineers specified a bolting system that would resist long-term
corrosion, and have the ability to consolidate highly weathered
and broken strata. Primary support consisted of (3) ¾ in x 72 in
grade 60 fully grouted rebar bolts per row with four-foot spacing
between rows of bolts. Supplemental support consisted of (4) 0.7
in x 144 in grade 270 FGCB bolts used in conjunction with T5 x
192 in roof channel in a B-Rigid Truss configuration. The final
spacing between B-Rigid trusses was 4ft. The B-Rigid Truss
system with FGCB bolts provided confinement to the immediate
roof, and allowed polyurethane to be injected into the roof for strata
consolidation and water control.
Development of the belt corridor began in late 2012. As the
corridor approached the 100ft overburden line, polyurethane
pumping equipment was installed in preparation for adverse
conditions. A borescope was used to evaluate weathering in the
roof on an ongoing basis. As the #3 entry approached the minimum
overburden area, weathering was found in the underground
borescope holes (Figures 9 and 10). This weathering was
consistent with weathering observed in coreholes prior to mining.
Indications of weathering included: water staining, presence of
high angle fractures, and clay infilling of fractures. As the section
advanced, polyurethane was injected into the roof thru the Fully-
Grouted Cable Bolts to consolidate weathered areas and mitigate
water intrusion. In general, bolts were injected no more than 100ft
 32nd International Conference on Ground Control in Mining

Figure 10. Roof weathering observed in test hole.

Figure 8. Mining projections for belt corridor under very

low cover.
from the active face. Polyurethane migration was observed in test
holes and vertical fractures in the roof (Figures 11 and 12). To date,
the belt corridor has advanced beyond the minimum overburden
depth and has experienced no roof control issues. Figure 11. Polyurethane migration at roof line.

Figure 12. Polyurethane migration at roof line.

Figure 9. Roof weathering observed in test hole.

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CASE STUDY 3

Case study 3 is a longwall setup face in the same mine as

Case Study 1. The roof in this area consists of highly laminated
sandstone with mica streaks. Equipment size required that the
setup face be developed to a final width of 26 ft, but it was initially
developed to a width of 18 ft.

Three stages of roof support were installed in the setup face;

the first stage consisted of (4) ¾ in x 72 in grade 60 fully grouted
torque tension rebar bolts installed on a T5 x 192 in roof channel.
Spacing between rows of primary roof bolts was 4 ft. Additionally,
(4) 0.7 in x 144 in grade 270 non-tensioned cable bolts were
installed on T5 x 192in roof channel between every row of bolts.
After the first stage of roof support was installed, the setup face
was advanced again at an 18ft width. Before the slabbing cut was
taken, the second stage of roof support was installed.

The second stage of roof support consisted of (4) 0.7 in x 192

in grade 270 post-tensioned cables installed adjacent to each non-
tensioned cable bolt. The slow installation procedure for post-
tensioned cables prompted the mine to install them outside of the
primary bolting cycle. According to mine management, the second
stage of roof support was installed in large batches sometime after
the setup face had advanced. Typically, the second stage of roof
support was installed in crosscut-to-crosscut batches. A 6 foot
slabbing cut was then taken to widen the setup face to the final 26ft
width. For the final stage of roof support (2) additional ¾ in x 72
in grade 60 fully grouted SuperTwist bolts were installed in the
roof above the slabbing cut with (1) 0.7 in x 192 in grade 270 post-
tensioned cable for supplemental support. The slabbing cut was
then cribbed off until longwall equipment was installed (Figure 13).
Figure 14. Signs of roof movement.
The roof in the setup face was examined with a borescope.
The immediate roof consisted of approximately one to two feet of
silty shale, and a roof of laminated sandstone with mica streaks
above that. Mining-induced horizontal fractures were found up to
approximately 10ft above the roof line (Figure 15). Timing of the
roof movement and appearance of cutters indicated that applying
tension to the supplemental roof support in a more timely fashion
would improve roof conditions.

Figure 13. Initial support plan for case study 3. Figure 15. Fractured roof observed in initial support plan area.

As the setup face was developed, vertical fractures, cutters and
other signs of roof movement developed outby the active face
(Figure 14). Based on interviews with face personnel, most of the
roof movement developed between installation of the first and
second stages of roof support. After the second stage of support
was installed, further indications of roof movement ceased.
Because stability of the longwall setup face was critical, post-
tensioned cables were not eliminated from the roof support
plan. Instead, the (4) 0.7 in x 144 in grade 270 non-tensioned
cables with T5 x 192 in roof channel were replaced with (4) 0.6
in x 144 in grade 270 INSTáL CC cables. These cables allowed
application of tension to the supplemental support during the first
stage of roof support. In addition, installation time was reduced by
approximately 20 seconds per cable.

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After adoption of the new support system, signs of roof
movement were greatly reduced (Figure 16). Scope data indicated
similar geology, with a reduction in fracture density of about 63%.
Additionally, the maximum fracture height was reduced from
approximately 10 ft to approximately 3 ft (Figure 17).
Figure 16. Revised support plan.
Figure 17. Revised support plan showed 65% reduction in
roof fracturing.
CONCLUSION
Recent innovations in cable bolting technologies from Jennmar
Corporation have assisted mine operators with supporting mine
roof in a safe and efficient manner. The B-Rigid Truss system
effectively applies structural surface control to weak, fractured
strata. The INSTáL CC cable bolt provides a means to rapidly
apply tension to the cable support. This rapid deployment of
cable tension has proven effective in controlling roof movement
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and mining-induced fractures. Where polyurethane injection
is necessary, the Fully-Grouted Cable Bolt can be used as both
a supplemental support and an injection point. In addition, the
Fully-Grouted Cable Bolt is approximately 75% of the cost of
an inflatable packer injection system. All of these technologies
have been designed to dovetail into the mining cycle, and present
minimal interruptions in mining activity.
REFERENCES
Suder, T, Stankus, J. C., Williams, D. (2001). “Tensioned Cable
Bolts as Primary Support: Update.” Proceedings of the 20th
International Conference on Ground Control in Mining,
pp. 252-258.
Mirabile, B., Poland, R., Campoli, A. (2010). “Application
of Tensioned Cable Bolts for Supplemental Support.”
Proceedings of the 29th International Conference on Ground
Control in Mining. pp. 128-133
Faulkner, D. (2012). “The Development and Application of
Polyurethane Injectable Cable Bolts.” Proceedings of the
31st International Conference on Ground Control in Mining.
pp. 1-5.