In longwall mining, particularly on long panels, it is common practice to install a “pusher” drive approximately halfway along the panel. To accommodate the pusher belt transfer point, additional height is required at the installation location. At our Buchanan mine, this can require up to 12 feet of material per 150 feet to be removed to ensure all transfer components fit correctly and that mined material flows efficiently.
As the longwall retreats, the shields extend to approximately 10 feet, leaving a two-foot gap between the shield tops and the mine roof in the pusher drive cavity. Historically, before mining could continue past this area, a temporary “false top” had to be constructed to allow the shields to anchor and enable continued retreat of the longwall.
Previously, this false top was built by hanging five-by-five timbers from the roof using chains, laying boards perpendicular to create a deck, and filling the void between the deck and the mine roof with cribs. This method required significant manual labor and introduced increased risk due to heavy lifting, ladder work, and extended exposure in the area.
During the most recent longwall operation approaching the pusher drive, employee Eddie Shawver developed an innovative solution. Eddie designed a pre-fabricated box system that could be installed in advance, with chains hung from the roof. This allowed the longwall shields to safely mine underneath, then anchor directly to the shield canopies while continuing through the remaining high cavity area, enabling the stage loader to push without interruption.
Eddie’s design has since been tested and has performed flawlessly, reducing manual handling and eliminating many of the risks traditionally associated with building a false top.
