<p>Fault-crossing roadways often experience severe stress perturbation and large deformation, posing critical challenges to surrounding rock control. Taking the Duanwang Coal Mine as a case study, this study investigates the evolutionary characteristics of the plastic zone and stress redistribution mechanisms induced by fault structures. The results show that the presence of a fault substantially alters the in-situ stress field, producing a pronounced stress concentration near the fault interface. An increased lateral pressure coefficient promoted the extension of plastic zones in both the roof and floor, whereas reductions in the Geological Strength Index and uniaxial compressive strength accelerated the nonlinear expansion of plastic failure. Numerical simulations further revealed that the fault dip angle plays a decisive role in stress distribution: low-angle faults induce greater stress asymmetry and result in more significant shear deformation on the roof–floor system. Based on the spatial pattern of rock deformation, a zonal support strategy was proposed. Within the fault-influenced zone, a composite support system consisting of bolts, cables, and a steel-frame canopy was adopted, while a full-length anchorage scheme was applied in high-stress concentration areas. Field monitoring indicated that the optimized support system effectively restrained roof subsidence and rib convergence, with bolt and cable load levels stabilizing within safe bearing limits. The deformation rate of the surrounding rock was significantly reduced. This study provides a theoretical foundation and practical guidance for the design and optimization of support systems in fault-affected roadways.</p>