Abstract This paper examines the intrinsic mechanisms of cutter roof failures by combining field investigations, laboratory testing, underground instrumentation, and numerical modelling. Cutter roof occurred during the development of a set of longwall panel entries in a West Virginia coal mine, and is presented as a case study. Mining alternatives applicable to the mine are recommended. Cutter roof occurrences in two other West Virginia coal mines were also investigated. Detailed comparisons were made between the three cases to derive useful information regarding the intrinsic cutter roof mechanisms. Three-dimensional finite element analyses were employed to validate the cutter roof mechanisms. As a result of the extensive investigation, intrinsic mechanisms of cutter roof failures under various conditions are presented from the practical and theoretical points of view. Mining alternatives for controlling cutter roof formed under various mechanisms are recommended.