AEIC 07, Cairo Egypt

FORENSICS AT COLLAPSED PHOSPHATE UNDERGROUND MINE:

NUMERICAL APPROACH

Salah A. Badr and Samir E. Sleem

Mining and Petroleum Engineering Department, Faculty of Engineering, Al Azhar University, Nasr
City, Cairo Egypt

ABSTRACT
A dry self-supported Room & Pillar phosphate mine at Zug ElBahr area - Egypt
flooded on winter of the 1994. Given that only random timber is in place, the Marly
immediate roof deteriorated and finally collapsed. A previous mineralogical SEM study
indicated that the Marly roof contains nearly 70% of the swelling Ca Montmorillonite. A
22% volume increase occurred at no-load point of Odometer experiment pointing to
swelling as possible cause of roof failure. Such scenario is highly possible as most of the
Eastern Egyptian UG phosphate mines are developed in equal fashion at similar
geological setting. The geotechnical responses of the mine roof to assess future roof
support requirements and action plans are numerically assessed. A FLAC2D mine model
is developed to replicate mining, swelling and act of gravity leading to roof collapse. The
model incorporates plastic behavioral regime for phosphate and its country rocks. The
model quantitively showed that the mine was initially self-support before flooding.
Model qualitatively was able to replicate roof swell and failure regime modes. The roof
reaction curves before and after flooding was developed to assess required support
capacities needed. A regional support system rather than random tempers is
recommended. Surface flood preventive measures are foreseen as prime solution while
proposed regional support system is sought at flood-vulnerable areas.

Key words: Mine collapse, Forensics, Swelling, Odometer and FLAC2D.

1. INTRODUCTION
The Zug ElBahr phosphate mine is located near the city of Al Quseir on the Red
sea coast of the Egyptian Eastern desert. Also well-know as arid “dry” area a sudden
rainfall and complete mine flood occurred through the valley-level entrance in the winter
of 1994. There was no attempt to pump the water out on time and let go for nature drying
to take place. Later when dried the mine immediate roof collapsed totally leading to
complete stoppage of mining operations. Zug ElBahr mine phosphate bed (≅2m) is part
of a longitudinal northeastern direction sedimentation basin. The basin has a length of 8
km and width of 1 km. The area stratigraphy is a typical Duwi phosphate formation lies
above Quiser variegated shale and below the Dakhla shale formation [1]. Figure 1 shows
a drilled borehole stratigraphy at the basin. As shown a Marl layer (Mrl) is the immediate
roof and has 1.75 m thick overlaid by a sequences of thin layers (3.75m) of Marl-
Phosphate-Marl and finally 4 m strong Oyster limestone. The mine floor is 2.25m sandy
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shale (S-S). The mineralogical and swelling characteristics of the Marl are listed at Table
(1). The Marl is made of mainly Ca Montmorillonite 69% and 25% of silt, clearly
identified as a high possible swelling stratum [2].

Type Thick Index

(m)
Ph 0.5 ..
Mrl 9.75 ..
O-L 5.5 Legend:
Mrl 1.75 “Ph” Phosphate
Ph 0.25 ..
O-L 4 “Mrl” Marl
Ph 0.5 “O-L” Oyster Limestone
Mrl 1.5 .. “S-S” Sandy Shale
Ph 0.5 .. “S-C” Sandy Clay
Mrl 1.75
Ph 2 Mining
level
S-S 2.25
S–C 1.75
Ph 0.25

Figure 1: The typical mine geological column

Table 1: Mineralogical (SEM) and physical characteristics of the Marl

Mineralogical Physical characteristics
composition %
Ca Montmorillonite 69 mo γd WL WP IP Activity Free swell
% KN/m2 % % % % %
Kaolin 10 9.05 19 120 35 85 1.1 22
Silt 25 IP% Plastic limit, γd dry unit weight, mo Natural water content
Others 6 WL% liquid limit, WP% plasticity limit

2. MARL SWELLING CHARACTERISTICS

Tri-axial testing is getting ground in expense of Odometer test to characterize
swelling responses. It is typically account for confinement stresses, thus replicating real
state of stress paths at UG opening boundaries [3]. Odometer test is still in extensive use
when complemented by numerical modeling to added missing behavior of boundary
conditions. The Huder - Amberg Odometer test procedure was carried out on the believed
to be undisturbed roof Marl sample [4]. Loading-unloading-reloading cycle was carried
out to eliminate possible sample disturbance if any and develop virgin state of stresses at
the nearly 32 m mining depth. Fig (2) shows the result of the Odometer test. Sample is
loaded at the stress path “A” to state at point “D1” equals to expected virgin stress at the
mining level. The sample then unloaded at path “B”, reloaded on path “C” to reach at
Point “D2”. Water then allowed to flow-in and loads are removed sequentially till
completely removed at the end of the free-swell path “S”. On Path “S” the no-swell state
was reached at ≅0.8 MPa and the free swell percentage reached 22%. Fig (4) shows the
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developed phosphate rock strength parameter derived from a triaxial testing as an

example. The free ware program RocLab® [5] was used to establish the failure envelops
thus the strength parameters for country rock as summarized at table (2).

25

20

15

10
Axial strain %

5 S

0
A
-5
C
-10
B D1
-15 D2

-20
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2
Axial stress (MPa)

Figure 2: The load-unload-free swell experiment result

M-C fit
Failure
Envelop

Figure 3: In-situ phosphate bed strength parameters development using RocLab

program.

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Table 2: Summary of the modeled materials mechanical properties (* assumed)

Young’s Poisson’s Cohesion Friction Dilation Density
Rock type Modulus Ratio* (Mpa) Angle (o) Angle* (o) (Kg/m3)
(GPa)
Roof 6.800 0.25 2.556 25.27 10 2500
Phosphate 14.173 0.25 2.987 30.38 10 2700
Floor 8.366 0.25 2.97 26.1 10 2500

3. MINE MODELING

The mine is modeled utilizing the well-known FLAC2D® program [6]. FLAC2D
is a two-dimensional explicit finite-difference program for engineering mechanics
computation. It can model non-linear systems as they evolve in non-physical time.
FLAC2D models are much complex compared to conventional modeling that produce “a
solution” at the end of its calculation phase. The FLAC2D include a built-in
programming language called FISH® that is utilized for developing special modeling
algorithms. An extensive use of the FISH programming language is utilized at both
mining and swelling modeling phases.

3.1. Modeling Practice

The modeling practice adopted to simulate the mine collapse is illustrated at Fig
(4). Modeling exercise includes two phases: Mining and swelling phase. Typical
stereography is modeled within the 22m-width model Fig (5). The model is consisting of
64000 zones. Zone physical size is 0.125 m in length and 0.125 m in width with regular
mesh scheme. The initial state of stresses was assumed to be isotropic. During Plastic
regime the Phosphate and immediate roof / floor are assigned plastic behavior while the
result of model is kept elastic. During each modeling phase a developed FISH algorithm
records data that will be used to establish the ground reaction curves (GRC) thus asses
support load requirements.

Model built Ground reaction Support

Plasticity + Mining
curve (1) - dry requirement

Elastic run Swelling algorithm Ground reaction Support

curve (2) - wet requirement

Figure 4: Modeling phases of the mine (Phase 1:Mining and Phase 2: Swelling)

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AEIC 07, Cairo Egypt

g=9.81 m/s2

36 m
31.75 m

2m

2m

22 m

Figure 5: Model geometry and boundary conditions.

3.2. Phase 1: Mining

The FLAC2D model is developed of horizontal layers with typical physical

thickness. No support timbers are modeled expecting absence of a significant marginal
effect. The model runs elastically for equilibrium to generate virgin state of stresses.
Then Mohr-Coulomb plasticity model is initiated with required material plastic
properties. The squared opening (2m by 2m) is mined with tractions relaxing algorithm.

800000

600000
Normal stresses (Pa)

400000

Plasticity
indicators
200000

0
0 0.0001 0.0002 0.0003 0.0004 0.0005
Net Displacment (m)

(a) (b)

Figure 6: The failure modes around the opening (a), the resulting ground
reaction curve GRC at mining regime (b)

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The model runs for equilibrium to show developed induced mining stresses. A FISH
algorithm is called to collect normal stresses at the roof / side walls versus corresponding
displacements to establish the ground reaction curve. Figure (6a) shows the failure
modes and extends around the opening after FLAC2D equilibrium is reached. Figure (6b)
is the developed ground reaction curve “GRC” of the mine. As can be seen the mine
reacts elastically (graph straight segment) therefore the mine is considered self-supported
unless widening in crossing is present then it must be rechecked.

3.3. Phase 2: Swelling

The swelling behavior of Marl is a mixture of two phenomenons: mechanical

swelling (presence of negative bore pressure due to mining relaxation) and chemical
swelling (Montomorlenite/water reaction). Both types of swelling would contribute in
developing Path “S” at Figure (2) although chemical swelling is expected to be the major
contributor. To model-replicate this behavior we adopted the following technique: as
swelling volumetric strain occurs a corresponding increase in effective stress at FLAC2D
mesh is generated. A FISH algorithm is implemented utilizing Path “S” stress values as
inputs to force the mesh to generate volumetric stresses at the Marl roof domain. This
algorithm when implemented at the Marl domain will force areas distant from the
opening to generated volumetric stress, which is not physically true due to presence of
confinement pressure of the overburden. To overcome this obstacle an IF control
statement is introduced to prevent application of the path “S” stresses at areas of current
stresses ≥ virgin stresses of Marl domain. Fig (7a) shows modes of failure around the
mine opening. The roof suffers from extensive shear yielding that produces a wedge
shape while surrounded by tension failures caused by migration of the wedge towards the
opening. The swelling GRC showed a horizontal straight line i.e., the roof is in merge of
collapsing (Fig 7b)

800000

600000
Yield in
Normal stresses (Pa)

tension
Yield in 400000
Shear

Roof 200000
Wet
Line

0
0 0.001 0.002 0.003 0.004 0.005
Net Displacment (m)

(a) (b)
Figure 7: The failure modes around the opening (a), the complete GRC at
both mining (dry) and swelling (wet) regimes (b)

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4. RESULTS AND RECOMMENDATIONS

The Model was able to replicate the dry mining stage efficiently. The dry mine
GRC indicates a stable roof condition. Which is the known state of the mine before the
flooding? Although the model was able to replicate the marl swelling deformations it was
smaller than Odometer test expectations. This is due to the absence of modeling the
Marl/phosphate interface that would encourage additional swelling strains to develop thus
cause slipping of the Marl. The wet GRC showed a horizontal straight line i.e., the roof is
in merge of collapsing unless additional support elements are introduced to stop
deformation. In general terms the mine roof collapsed due the deterioration and act of
gravity on the Marl roof. Recommendations regarding future practice would include
implementing a regional yieldable support system capable to resisting extensive swelling
deformation while permitting safe and feasible access to the mine workings. The load
exerted in such support would theoretically reach a percentage of the virgin stress
depending on stage of swelling when supporting is implemented. A separate future
modeling exercise is sought to examine such scenario.

REFERENCES:

[1] B. Issawi, M Francis, M El-Hinnawi and a. Mehanna “ contribution to the

structure and phosphate deposits of Quser area”, Egyptian geological survey
paper No.50 – (1968)
[2] Samir m E Sleem “Effect of Shale Swelling phenomena on Tunneling”. PhD
thesis submitted to Mining engineering Department, Faculty of Engineering Al-
Azhar university-Egypt (1922).
[3] M. Barla, S. Ferrero, G. Barla “A new approach for predicting the swelling
behavior of expansive clays in tunneling”. An interim report at the Politecnico di
Torino, Department of Structural and Geotechnical Engineering, Italy, (2003)
[4] Rolf Selmer-Olsen. “ Tunnel collapses in swelling clay zones – Part 2”. Tunnels
& tunneling magazine, January (1990)
[5] “RocLab® - Rock mass strength analysis using the Hoek-Brown failure criterion”
Program user’s Guide. Rocscience Inc. (http://rocscience.com/) (2002)
[6] Itasca Consulting Group Inc. “FLAC2D – Fast Lagrange Analysis of Continuum”.
User manual. Minneapolis, MN, USA, (2003)

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