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Abstract High-strength bolts have become indispensable support materials in geotechnical engineering, but the incidence of safety accidents caused by bolt fractures under complex geological conditions is increasing. To address this challenge, this study focuses on a typical roadway in the Xinjulong coal mine, employing a combination of mechanical performance testing, microscopic and macroscopic analyses to investigate the failure mechanism of bolt breakage. The research indicates that the cracks in the failed bolts underground exhibit subcritical patterns, with the presence of oxides and Cl elements, and multiple intergranular fractures internally, consistent with the characteristics of stress corrosion failure. Additionally, inherent defects in the bolts are also a primary cause of failure. For instance, for type A bolts, the levels of P and S elements significantly exceed the normative requirements, forming inclusions, while the low content of elements like Si and V leads to reduced plasticity, toughness, and corrosion resistance. Furthermore, the excessive pitch in type A bolts leads to stress concentration and cracking under complex loads. The study concludes that the synergistic effect of stress corrosion cracking and inherent flaws in bolts are the main causes of failure. Therefore, it is recommended to enhance the reliability and safety of bolt support by optimizing the bolt shape and developing anti-corrosion bolts, thereby achieving long-term stability in underground engineering.