Mechanisms and control of stress corrosion failure in coal mine bolt rods
HE Zhe1, 2, CUI Feng1, 2, 3*, ZHANG Nong4, 5, XIE Zhengzheng4, WANG Peng4, JIA Chong1, 2, CAO Chuang4, ZONG Cheng1, 2
(1. College of Energy Engineering, Xi?an University of Science and Technology, Xi?an, Shaanxi 710054, China; 2. Key Laboratory of Western Mine Exploitation and Hazard Prevention Ministry of Education, Xi?an, Shaanxi 710054, China;
3. Key Laboratory of the Ministry of Education for Green Mining of Xinjiang Coal Resources, Xinjiang Institute of
Engineering, Urumqi, Xinjiang 830023 China; 4. School of Mines, China University of Mining and Technology,
Xuzhou, Jiangsu 221116, China; 5. School of Civil Engineering, Xuzhou University of Technology,
Xuzhou, Jiangsu 221110, China)
Abstract：The stress corrosion failure of rock bolts is one of the key factors inducing the instability of coal and rock in coal mine roadways. To reveal its failure mechanism and improve the durability and reliability of rock bolt support, this study combines laboratory experiments, numerical simulations, and field tests to investigate the stress corrosion failure mechanism and control methods for rock bolts. The results show that the fracture cracks of the failed rock bolts underground exhibit a branched pattern, with oxides and Cl elements accumulating in the cracks. Additionally, the bolt body exhibits transgranular fracture characteristics, consistent with the typical stress corrosion failure mode. Laboratory stress corrosion tests further indicate that the stress level is a critical factor promoting the decay of the load-bearing performance of rock bolts in highly corrosive environments. The tests also found that the thread chamfer at the bottom of the bolt is prone to stress concentration due to external loads, with the degree of concentration being influenced by thread parameters. This reveals a fracture failure mechanism caused by the interaction between stress concentration and stress corrosion cracking (SCC) resulting from the bolt shape. Based on this mechanism, a new type of rock bolt was developed to effectively alleviate surface stress concentration. Under compound loading, the plastic zone range of the new bolt was reduced by 23.35%, significantly reducing the risk of stress corrosion failure. Hydrogen content analysis and the examination of typical hydrogen embrittlement features, such as white spots, revealed that the hydrogen content in galvanized rock bolts increased by 304.48% after underground service, indicating that galvanization significantly increases the risk of hydrogen embrittlement failure. To address the limitations of galvanized rock bolts in deep, highly corrosive environments, a surface anti-corrosion and full anchorage protection method was selected, utilizing flexible alloy coatings, single-component cement-based grouts, and thixotropic anchoring agents. A corrosion prevention and grading design method for rock bolts in coal mine roadways was established, and engineering application verification was successfully conducted, achieving safe and efficient control in deep, highly corrosive roadways.
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2026, Vol. 45 
