MINING MINING MINING MINING MINING 
COMPUTERIZED ROOF BOLT DESIGN SYSTEM 
BENEFITS 
Project Fact Sheet 
• Increases safety in an 
underground mine 
• Decreases energy requirements 
of clean up efforts of a roof fall 
• Decreases cost of clean up of a 
roof fall 
• Reduces waste disposal 
generated from roof falls 
• Improves productivity 
APPLICATION 
Computerized roof bolt system will 
reduce the occurrence of roof falls 
in any underground mine. This will 
increase mine worker safety and 
reduce the cost and energy 
associated with a roof fall clean-up. 
ROOF BOLT SYSTEM WILL ENABLE REAL TIME EVALUATION OF 
ROOF GEOLOGY AND IMPROVE MINE SAFETY 
In this project a computerized method to evaluate the roof geology and stability in 
real-time during roof bolting operations will be developed. In addition, roof bolt 
system design requirements will be developed. U.S. underground coal mine entries 
are required by law to be roof bolted. Roof bolting is also the most popular roof 
supporting method for underground openings in the mining industry, especially in 
bedded deposits. Hardrock mines commonly implement roof bolting using split 
set, swellex or cable bolts. However, roof falls still occur frequently in roof bolted 
entries. Two possible reasons are the lack of knowledge and technology to 
accurately assess the roof’s geological conditions and insufficient roof bolting 
design to accommodate change in local geology. The development of real time 
evaluation of roof geology and stability conditions as well as design requirements 
for roof bolting systems will reduce roof falls. 
For the evaluation of roof geology and stability condition in real time, drilling 
parameters such as feed force, feed rate, rotation torque, rotation speed, drill 
position, and vacuum condition will be studied. Also, rock cores will be obtained 
for determining rock strata, mechanical properties and structure within the bolting 
horizon. For the development of roof bolting requirements, parameters such as 
bolt size/strength, bolt length, bolt spacing, grout annulus and length, and roof 
geology will be studied in laboratory and field tests. 
The results will be used to develop a computer program that will work with the roof 
bolter for real-time production of the mechanical properties and structures of roof 
strata, and design requirements for the roof bolting systems. 
ROOF BOLTER 
The system will help improve roof bolting operations such as this one 
shown above. 
OFFICE OF INDUSTRIAL TECHNOLOGIES 
ENERGY EFFICIENCY AND RENEWABLE ENERGY U.S. DEPARTMENT OF ENERGY
Project Description 
Objective: To improve roof-bolting techniques, the most popular method for 
supporting roofs in underground mines. A computerized roof-bolting control 
system that can evaluate the geologic conditions of a roof in real-time will be 
developed to determine suitable roof bolt system design requirements. 
Improvements in roof-bolting systems will lead to increased worker protection and 
mining production. 
Progress and Milestones 
This project includes the following activities: 
• Development of operator control technology for monitoring roof bolter drill 
operation parameters. 
• Laboratory and underground testing of operator control technology. 
• Drilling parameter data analyses and correlation with roof stability 
conditions. 
• Software development for mapping of roof geological conditions. 
• Computer modeling to investigate the mechanisms of roof bolting. 
• Development of computerized roof bolting design system for use in the 
primary roof bolting cycle. 
Commercialization Plan 
The results of this project will be aggressively transferred to the mining and 
scientific communities. The results will be published in various media including 
peer-reviewed journals and conference proceedings. The research will be 
presented before professional gatherings including the Society of Mining 
Engineers, the American Rock Mechanics Association and the International 
Ground Control Conference. A series of technical workshops will be held 
throughout the United States where the technology will be demonstrated. The 
technology transfer program will be focused on obtaining a significant industry 
penetration within five years. 
PROJECT PARTNERS 
West Virginia University 
Morgantown, WV 
CONSOL Inc. 
Library, PA 
Commercial Stone Co. Inc. 
Connellsville, PA 
The Ohio Valley Coal Co. 
Alledonia, OH 
J.H. Fletcher & Co. 
Huntington, WV 
Newmont Mining Co. 
Denver, CO 
Riverton Coal Production Inc. 
Charleston, WV 
FOR ADDITIONAL INFORMATION, 
PLEASE CONTACT: 
Office of Industrial Technologies 
Clearinghouse 
Phone: (800) 862-2086 
Fax: (360) 586-8303 
clearinghouse@ee.doe.gov 
Visit our home page at 
www.oit.doe.gov/mining 
Office of Industrial Technologies 
Energy Efficiency 
and Renewable Energy 
U.S. Department of Energy 
Washington, D.C. 20585 
January 2001