Key Technologies for Safe Mining Under Thin Bedrock with Water-Rich Unconsolidated Layers: A Case Study of Ground Pre-Grouting Application

Significant risk of water and sand inrushes is commonly encountered during coal seam mining when thin bedrock is directly overlain by thick, water-bearing, unconsolidated layers. Achieving effective strata control and establishing reliable water-isolating mechanisms under these conditions represent critical scientific and technological challenges for safe mining operations. Furthermore, this is a vital research direction for advancing the extraction limit (or recovery height) in coal seams. Initially, drawing on key stratum theory, ground pressure behavior patterns, and mining operation characteristics, the weathered zone was identified as the critical grouting horizon. During the initial mining stage, the first two periodic weighting intervals (approximately 60 m) were identified as the key area. Subsequently, a strategy of high-pressure grouting was proposed to modify the weathered stratum. Numerical simulation methods were employed to optimize the grouting parameters, with the core specifications determined as follows: grouting pressure ≥30 MPa, water–cement ratio of 0.7:1, and grouting hole spacing ≤30 m. Ultimately, a grouting system was designed that used directional drilling from the surface to access the weathered zone, followed by branched horizontal boreholes for staged high-pressure grouting. The borehole trajectory was predominantly L-shaped. Field implementation demonstrated that the grouting intervention increased the first weighting span by an average of 17.3%. Critically, no water inflow was observed throughout the initial caving period, and significant roof falls or rib spalling were effectively mitigated. This confirmed a substantial improvement in key stratum stability, ensuring the safe and efficient advancement of the mining face. This study provides essential technical support and a practical model for safely and efficiently extracting coal seams under thin bedrock under similar complex hydrogeological conditions.