Flexural Failure Characteristics and Fracture Evolution Law of Layered Composite Rock Mass

To address the engineering challenges of frequent flexural deformation and instability of composite roadway roofs and the difficulty in accurately controlling the support strength range during deep coal mining, this study takes the soft–hard interbedded composite roof of the working face in the West No. 1 Mining Area of Shuangyang Coal Mine in Shuangyashan as the engineering background. Typical fine sandstone (hard rock) and tuff (soft rock) from the on-site roof were selected to prepare layered composite specimens, and indoor four-point bending tests were conducted. Combined with theoretical calculations, strain monitoring, and acoustic emission (AE) real-time localization technology, the regulatory mechanisms of three key factors—lithological combination, loading rate, and span—on the flexural mechanical properties, deformation and failure modes, and fracture evolution laws of layered composite rock masses were systematically investigated. The research results show the following: (1) The flexural performance of layered composite rock masses is dominated by the interlayer interface effect. Their flexural strength is 46.7% and 41.1% lower than that of single hard rock and soft rock specimens, respectively, and the competitive mechanism between interface slip and delamination fracture is the core inducement of strength deterioration. (2) The strength and deformation characteristics of layered composite rock masses exhibit a significant loading rate effect. When the loading rate increases from 0.002 mm/s to 0.02 mm/s, the flexural strength decreases by 51.8% and the mid-span deformation deflection reduces by 50.1%. High loading rates will exacerbate the deformation mismatch between soft and hard rock layers, trigger premature failure of interface bonding, and inhibit the full development of structural plastic deformation. (3) Increasing the span significantly optimizes the flexural bearing performance of layered composite rock masses. When the span increases from 170 mm to 190 mm, the flexural strength increases by 65.7% and the mid-span deformation deflection synchronously increases by 65.7%. A large span can extend the flexural deformation path, promote the coordinated deformation of rock layers, and suppress local stress concentration. (4) The flexural failure of layered composite rock masses is dominated by Mode II shear cracks, while single-lithology specimens are mainly dominated by Mode I tensile cracks. Loading rate and span significantly change the crack propagation mode and energy release law. This study establishes a calculation method for the equivalent flexural stiffness of layered composite rock masses and reveals the mesoscopic mechanism of flexural failure of heterogeneous layered rock masses. The research results can provide a theoretical basis and experimental support for the optimization of support schemes and the prevention and control of roof collapse hazards for composite roofs of deep coal mine roadways.