Thickness Design and Stability Analysis of Stage Pillar Under High and Large Backfill Loads

In underground mining, the stage pillar (SP) is essential for maintaining stope stability, acting as a load-bearing structure between stages. Determining the minimum safe SP thickness is critical to balancing mineral recovery and operational safety. This study investigates the design and mechanical stability of SP under substantial backfill loads, using a representative Iron ore mine as a case study. Based on the geometry of the overlying backfill and core sampling data, extreme loading conditions were identified, with the stope measuring 85 m in height, 72 m in length, and 18 m in width. A mathematical model incorporating the pressure arch effect and triangular pillar geometry was developed to estimate the backfill-induced load. Safety factors for various SP thicknesses were calculated using thin plate and elastic beam theories. Considering sequential excavation of the first- and second-step stopes, the minimum safe SP thickness was determined to be 6.0 m. This design was evaluated using FLAC3D numerical simulations. The results reveal that during the first step, stress concentrations occurred mainly at the pillar base, with a maximum displacement of approximately 2.0 cm and peak tensile stress of 0.36 MPa—both within acceptable limits. These findings support improved pillar design for safe, efficient ore recovery in underground metal mining.