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This paper presented a case study of the failure mechanisms and support design for deep composite soft rock roadway in the Yangcheng Coal Mine of China. Many experiments and field tests were performed to reveal the failure mechanisms of the roadway. It was found that the surrounding rock of the roadway was HJS complex soft rock that was characterized by poor rock quality, widespread development of joint fissures, and an unstable creep property. The major horizontal stress, which was almost perpendicular to the roadway, was 1.59 times larger than the vertical stress. The weak surrounding rock and high tectonic stress were the main internal causes of roadway instabilities, and the inadequate support was the external cause. Based on the failure mechanism, a new support design was proposed that consisted of bolting, cable, metal mesh, shotcrete, and grouting. A field experiment using the new design was performed in a roadway section approximately 100 m long. Detailed deformation monitoring was conducted in the experimental roadway sections and sections of the previous roadway. The monitoring results showed that deformations of the roadway with the new support design were reduced by 85–90% compared with those of the old design. This successful case provides an important reference for similar soft rock roadway projects.

This study focused on large-scale roof-fall accidents occurred in large-section coal seam roadways of Bayangaole Coal Mine, Inner Mongolia, China, and investigated the occurrence mechanism of roof-fall and the related supporting control method in detail. Firstly, the fracture characteristics of the surrounding rocks on the roadway roof were measured using a stratum detector. The results showed that the roadway roof underwent the most severe failure with a maximum deformation of 3.53 m; the bedding separation and fracture zones were distributed at irregular intervals. Accordingly, the entire stratum was separated into several thin sublayers, significantly reducing the stability of roof. In addition, the roof medium grained sandstone of roadway is water-rich strata, and water aggravates the damage of roof. Next, the mechanism of the occurrence of roof-fall accidents in the roadway was elucidated in detail. The following three reasons are mainly attributed to the occurrence of roof-fall accidents: (i) effects of mining-induced stress and tectonic stress, (ii) existence of equipment cavern on the side of roadway, and (iii) unreasonable support parameters. On that basis, a new supporting design is proposed, including a more reasonable arrangement of anchor cables and bolts, bolts with full-length anchorage which are applicable in cracked and water-rich roadway, high-strength anchor cables, and crisscrossed steel bands. Moreover, high pretightening force was applied. Finally, a field test was performed, and the mining-induced roof displacement and stress on anchor cable (bolt) were monitored in the test section. The maximum roof displacements at the two monitoring sections were 143 mm and 204 mm, respectively, far smaller than the roadway’s allowable deformation. Moreover, the stress on roof anchor cables (bolts) was normal, and no anchorage-dragging and tensile failure phenomena were observed. The monitoring data indicated that the new supporting design was remarkable on the control of large-section coal seam roadway roof deformation.