STW Apr 2019

THE FIRST PRIORITY FOR AUSTRALIA’S MINING INDUSTRY

ISSUE 3 - APRIL-JUNE 2019

Risk management Safety around mining tyres Dust suppression

Training

Technology

Materials handling

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Comment Controlling the safety risks of mining SAFETY IS A PROGRESSIVE PART OF MINING BUT THE TAILINGS DAM INCIDENT IN BRAZIL EARLIER THIS YEAR SHOWS THE INDUSTRY IS BEHIND IN SOME AREAS.

BEN CREAGH

R

isk comes in many forms in mining, particularly from a safety perspective.

This edition of Safe To Work highlights a number of safety risks and what mining and METS companies are doing to keep them at bay.

For example, tyre management is an area of an operation that requires a series of considerations to mitigate and control the safety risks involved.

Tyre management teams must make sure they are aware of how to safely operate equipment to control the immense weight and air pressure of mining tyres, while also understanding how their physical health can be impacted.

This awareness involves ongoing training and education around these operations and the equipment, including how to use tools like jacks and stands, or when to wear personal protection equipment (PPE).

From a health perspective, the risks that mines pose to workers are becoming better understood through ongoing research and the

VANESSA ZHOU Tel: (03) 9690 8766 Email: vanessa.zhou@primecreative.com.au PUBLISHER CHRISTINE CLANCY EDITOR BEN CREAGH Tel: (03) 9690 8766 Email: ben.creagh@primecreative.com.au JOURNALISTS EWEN HOSIE Tel: (03) 9690 8766 Email: ewen.hosie@primecreative.com.au

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use of technology.

The potentially damaging dust at sites is an area of focus that is being better managed to help improve the health of workers later in life.

In Australia, dust is a constant concern, from the iron ore mines in the west to the coal mines in the east.

Fortunately, significant inroads have been made in developing initiatives that control this dust and lower the number of people suffering from the related diseases.

However, despite the improvement in controlling mining’s risks, the management of tailings dams remains a part of the industry where progress is still needed.

Vale’s tailings dam disaster in Brazil during January prompted one response in particular: How could this happen again?

Barely three years after the Samarco dam breach that devastated local communities, Vale’s Brumadinho tailings dam incident again shocked the global mining industry.

It also forced the hand of the world’s leading miners to

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SAFETOWORK.COM.AU 3 APR-JUN 2019

reinforce the safety and quality of their portfolio of tailings dams by publicly stating their commitment to the facilities.

While this response was welcomed, it did at the same time seem too little, too late being in the wake of Brumadinho.

As safety innovation continues to roll out across the sector, let’s pray that this extends to tailings dams in the coming years.

Ben Creagh Managing Editor

FRONT COVER Managing tyre management safety concerns.

Image: Kal Tire.

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In this issue Features 18

42 Against downward current

eeping hazardous K dust away

44

Australia’s top universities attract next-gen miners

The wonders of audits on machinery cabins

20 Natural light underground MineARC is getting more SiriUS about cap lamps

44 A revolutionary approach Managing risk during dangerous drilling activities

46 Safe commissioning of Amrun

62

Rio Tinto brings in game-changing innovations

57 Meeting lighting standards

48 Conveyor idler

change-outs get safety lift

Vayeron hails crucial innovation from Mackay

51 Competing for talent 22 Tailings safety a priority Industry responds to Brazil’s tailings disasters

26 Nivek Industries upgrades

Attracting skills in the face of automation

54 A helping hand in QLD The mining industry’s strong response to flooding

Mining technology continues to innovate

60 Making relationships a priority

Curiosity is the new empathy in the workplace

62 Safescape shows way out

Escaping underground mines safely

64 Level-up PPE defence

Resist abrasion with disposable gloves

quality of life

18

Fitters gets a lift from Tracked Elevating Device

28 Maintaining clear vision Bollé shares everyday pointers on eye care

30 Foundations of Industry 4.0 Technology to avoid conveyor system breakdowns

32 Kal Tire keeps a consistent safety focus

Training is at the centre of the company’s culture

36 Multi-layer protection

against welding fumes

Blackwoods shares an all-around strategy

40 Mobilising mining rookies Fitzroy Australia’s safe recruitment approach at Ironbark No. 1

REGULARS

6 NEWS

14 PRODUCTS

SAFETOWORK 4 APR-JUN 2019

66 EVENTS

News Work health and safety laws set for update following review

The MCA agrees that some law changes are needed.

Former Safe Work Australia director Marie Boland has produced 34 recommendations that could enhance workers’ safety after launching a review of the Work Health and Safety (WHS) laws 2018.

Among her recommendations as an independent reviewer are to make regulations that deal with psychological health, improve the quality of asbestos registers and provide for a new offence of industrial manslaughter that can make businesses liable for their workers’ gross negligence.

While the review found the laws largely operate as intended – as agreed by Minerals Council Australia (MCA) chief executive Tania Constable – some changes are needed to provide clarity and drive greater consistency in the enforcement of the laws across jurisdictions.

However, MCA does not support the introduction of a new industrial manslaughter clause as proposed in the review.

“These objectives should not be at the expense of an environment that encourages prompt learning and sharing of important health and safety

lessons,” Constable said.

“Law reforms should not impose oppressive and unnecessary criminal liability on some individuals that does not contribute to general or specific deterrence or improve health and safety outcomes at Australian workplaces.

“MCA has yet to see evidence that the current legislative framework is inefficient in dealing with serious offences.”

A response to the review will be issued this year.

SAFETOWORK 6 APR-JUN 2019

The recommendations are with WHS ministers for consideration before a response is issued in 2019.

According to Boland, the discussion paper is just a signal that the review is starting, before it’s being handed over to workers and business practitioners for their thoughts.

“This review is really important because it gives us the first opportunity since the laws were enacted some five to six years ago to step back and look at how they’re working practically in workplaces, and are they actually effective in making sure that workers across Australia are able to come home safely every day to their families,” Boland said.

“I’m looking forward to getting to each state and territory and also some regional centres. We really want to make sure that we have an opportunity to talk to everyone who might have an interest in how the Work Health and Safety laws are operating.

“The most important thing for this review to be successful is to hear from you.”

News Roy Hill and WesTrac support education with simulator Roy Hill has introduced a new CAT simulator to its ROC-Ed Learning Centre in Perth.

Caterpillar dealer WesTrac donated the simulator to Roy Hill’s ROC-Ed program, enabling students to immerse themselves in the experience of operating a large wheel loader.

Roy Hill’s learning centre has been running since 2017 and is designed to support classroom teaching and learning in maths, science, geography and business studies for Year 8 and 9 students.

The half-day program, which aligns with the Australian Curriculum, provides an opportunity for students to experience a busy mining operation centre and corporate headquarters in action.

WesTrac chief executive officer Jarvas Croome said the simulator aligned perfectly with the objectives of Roy Hill’s program, enabling students to experience what it’s like to drive the 994H, one of the company’s largest wheel loaders.

“Through this experience, students can explore how their studies relate to real-time operations on a mine site.

Julian Hill and Jarvis Croome with the simulator.

It’s programs such as this that will stimulate enthusiasm amongst the next generation to pursue a career in mining, which is something WesTrac is proud to support,” Croome said.

Roy Hill CEO Barry Fitzgerald said the simulator was an expensive piece of equipment that enabled the miner to immerse students visiting the centre in a life-like mine experience.

“As a knowledge-based organisation,

we are constantly leveraging technology to consider new and better ways of doing things – and the CAT simulator is a perfect example of how we support our staff to learn new skills in a safe environment,” Fitzgerald said.

The simulator joins a refreshed suite of activities for students as part of the ROC-Ed program, including practical tasks, online activities and interactive experiences.

Queensland forms mine safety partnership with India The Queensland Government and the Government of India have signed a three-year memorandum of understanding (MoU) to develop mine safety management plans.

The MoU was approved by a union cabinet chaired by Indian Prime Minister Narendra Modi. It establishes a partnership between India’s Directorate General of Mines Safety (DGMS) and Queensland’s Safety in Mines, Testing and Research Station (SIMTARS).

The two groups will implement riskbased safety management systems

incorporating training programs, seminars and technical meetings, a national mine disaster centre and occupational health and safety (OHS) academy.

In addition, the groups will work on modernising the DGMS research and development (R&D) laboratory.

SIMTARS, part of the Queensland Government’s Department of Natural Resources, Mines and Energy, specialises in health and safety training and environmental issues within the resources sector.

SAFETOWORK 8 APR-JUN 2019

“Mining accident rates in Australia [are] the lowest in the world,” the Indian Government stated.

“Australia has pioneered in conceptualising and implementing riskbased safety management plans for the mining sector using the technique of hazard identification and risk assessment.”

India recorded 377 official mine deaths between 2015 and 2017, with more than half that number killed in coal mines, according to figures from India’s Labour and Employment Ministry.

News Miners urged to manage exposure to diesel fumes

Diesel fumes are a safety concern in mining.

Exposure to high levels of diesel fumes could well be the next major occupational health threat since asbestos, according to hydraulic engineer Norm Mathers.

Testing at a Western Australian mine showed levels of up to a million nano diesel particulates per cubic centimetre.

This is about 100 times more than people would inhale walking down a busy city street.

Numerous medical studies over the past decade found that long term exposure to diesel fumes is likely linked to an array of serious health issues. These include cancer and dementia.

In line with this finding, the European Union (EU) Commission has increased its target of 30 per cent carbon dioxide reductions by 2030 from 20 per cent by 2025 and 35 per cent by 2030 on

class eight heavy trucks and buses. It has also banned older diesel cars from 2022 onwards.

“Australia needs to change our emission targets to mirror that of the EU Commission,” Mathers said.

“In order to achieve a 35 per cent reduction in emissions by 2030, it is impossible unless you can capture braking energy in trucks and buses.

“By definition, it has to be applied to buses, waste trucks, delivery trucks, class eight trucks as well as underground and above ground mining machinery.”

In June 2012, the International Agency for Cancer Research (IARC) classified diesel emissions, including diesel particulate matter, as a known human carcinogen.

India has banned 10-year-old diesel trucks from its cities as an estimated 1.24 million people have been lost to early death due to its city pollution.

Companies have introduced chemical exhaust cleaning and improved engine efficiencies, however they had made no concentrated effort to meet the EU commission’s initial 30 percent carbon dioxide reduction targets, according to Mathers.

Soft tissue health a top priority for reducing LTIs A physical trainer, noted for helping FIFO workers with fitness and weight reduction plans, believes soft tissue health is the “key focus” to reducing total recorded injury frequency rates (TRIFR) among miners in Western Australia.

Cam Wild, director of FIFO-focused Fifo Fit, said poor soft tissue health and excessive weight were being overlooked in risk assessments.

Wild cited government statistics that found the Western Australian

resources sector lost $570 million in days to lost time injuries (LTI) in 2016–17, with 51.5 per cent of LTIs in the same time period being due to “traumatic joint/ligament and muscletendon injury”.

Wild said the government statistics were “very conservative” because they did not account for average costs per claim or productivity hits due to switching workers to light duties.

He pointed to an increase in focus on

SAFETOWORK 10 APR-JUN 2019

soft tissue health as a way to reduce TRIFR. “[These] statistics are not so surprising when you consider that the mining sector has the highest instance of overweight and obese employees, making up almost 80 per cent of the workforce,” Wild said.

“While an initial risk assessment is essential, its overall effectiveness is compromised by poor soft tissue health and excessive weight resulting in unforeseen or overlooked risks.”

Reversing the leading vehicle activity of WA incidents

The WA mines department has exposed the industry’s safety concerns.

A Western Australian Department of Mines, Industry Regulation and Safety (DMIRS) report has found that reversing is the primary vehicle activity that accounts for the largest number of collisions in the state’s mining industry.

Out of the 172 collisions and near collisions involving 292 vehicles from 2015 to 2016, 42 incidents were associated with reversing.

The primary vehicles involved in the accidents were surface loaders and dozers, with stockpiles and waste dumps as the main areas.

Two thirds of the collisions were caused by visibility and communication issues during reversing, such as communication breakdown, unchecked rear view and obscured visibility.

Meanwhile, the leading cause of the 172 collisions was parked-up or stationary secondary vehicles, resulting in 26 incidents.

Mines safety director Andrew Chaplyn urged the Western Australian mining industry to look at what the injury data was revealing, and use it as a guide to develop better systems and reduce harm.

“This report can help mining operations better identify problem areas and assist them in developing improved systems of traffic management,” Chaplyn said.

Among others, the report recommends mines to develop risk assessments for all vehicle types to include potential contacts and interaction with workplace and equipment.

Inspection processes should examine physical aspects of workplaces such as stockpiles, waste dumps, go lines and ramps to understand vehicle interactions.

Mines can also reduce the risk of vehicle collisions by separating or isolating light vehicles from interaction in areas such as run of mine pads and stockpiles, where large vehicles such as loaders and dozers work continuously.

The analysis follows two previous reports released by the DMIRS of Western Australia, which studied fatality data from 2000 to 2013.

NESS

News Weir Minerals improves safety with automated systems The wear rate of a slurry pump’s throatbush has a major impact in the overall efficiency and safety of slurry pumps.

However, these adjustments are often performed while the pump is operational to avoid impacting the plant’s production.

The task poses safety implications to workers, especially those working at the front of the pump unit.

Recognising that throatbush is the component that has the shortest life compared to the impeller and liners, Weir Minerals has created a solution by developing a rotating and axial adjustment technology.

The systems speed up the maintenance process, allowing for more frequent adjustments with minimal effort.

“Manually adjusting an alloy throatbush on a large pump requires several

people and is labour intensive,” Weir Minerals global product manager for centrifugal pumps Marcus Lane said.

“It requires mechanical tools to adjust the four pusher bolts, one at a time, in order to reduce the gap between the throatbush and impeller.

“We wanted to find a safer and quicker way to extend the wear life of the pump with regular adjustments, which led us to the development of this technology.”

With Weir Minerals’ automated adjustment systems, all four bolts can be adjusted at the same time. This ensures even adjustment and accurate positioning, improving the wear life of the throatbush.

And by mechanising the adjustment procedure, personnel are removed from the line of fire and the accuracy of axial movement is increased.

This technology is available for pumps Weir Minerals has made advances that improve safety with the innovation.

SAFETOWORK 12 APR-JUN 2019

fitted with either rubber or alloy throatbushes on Warman slurry pumps used in the most arduous applications.

For adjustments of rubber throatbush, Weir Minerals has developed an automated rotating solution, which maintains an optimum gap between the throatbush and impeller front shroud for the particles to flow through without catching and tearing the rubber.

“The localised surface wear is usually near the discharge position,” Weir Minerals application engineer Claudio Needham said. “But by slowly rotating the throatbush, we even out the material loss over the entire face.

“Field results have been very positive, showing an average of 40 per cent increase in wear life.”

For the smaller Warman slurry pumps used in medium to heavy duty applications, Weir Minerals offers a single point adjustment mechanism, providing both axial and rotational repositioning. This allows one individual to safely stand to the side of the pump while making the adjustment.

Weir Minerals has taken its adjustment technology one step further by also integrating it with its IIoT Synertrex platform to offer predictive maintenance feedback.

“This is made possible through machine learning,” Lane said. “Over time Synertrex learns from past adjustments, recording how many times the throatbush was adjusted and the magnitude of adjustment each time.

“This trending data is collected and analysed by Synertrex to communicate future adjustment requirements.

Through automating all adjustments, we can successfully communicate remaining useful life, and inform customers of optimum times to adjust the pump to increase efficiency and maximise wear life.”

BHP bolsters flexible work across operations BHP believes the race is on for a genderbalanced boardroom, and importantly, a gender balance of employees.

The mining major emphasises flexible work to achieve greater workforce diversity, with almost half (46 per cent) of its workforce, both operational and office based, claiming they work flexibly.

A further 8.6 per cent indicated they would embrace flexible work over the next 12 months.

Flexible work arrangements are being used by BHP’s long-distance commuters and residential employees at its operations through rosters and job share arrangements.

This has challenged the prevailing mindset that flexibility is only available to office-based employees, according to

the company.

Internal reporting revealed those who were formally working flexibly reported a significant increase in wellness compared to the overall group average.

Haul truck operators at Western Australia Iron Ore’s (WAIO) Mount Whaleback operations have also reported a 60 per cent reduction in fatigue related events after adopting an even time roster.

Whaleback operators have worked a two-day, two-night, four-day off roster – a short duration and rapid change from day to night shift – for the past 20 years.

BHP is also focused on creating a workforce that is diverse, with an even balance of genders and mix of cultures.

The company has set an ambitious target to achieve gender balance by 2025.

Mining companies are increasingly adding flexible work arrangements.

“Since 2016 when we announced our aspiration goal, overall female representation has increased from 17.6 per cent to 22.4 per cent and the number of women in the business globally has increased by over 2000,” the company said.

Products NESS+ ULTRA WRAP-AROUND FRAMES FOR PANORAMIC VISION This new model has been designed to offer wearers an excellent field of vision, thanks to its all-round coverage.

Thin linear temples can be easily slipped under a hard hat and worn comfortably with hearing protection. Ness+, with its lightweight temples and wrap-around design, provides effective protection without compromising safety.

Ness+ offers wearers additional comfort with its co-injected temples and even more performance, thanks to its platinum coating (double sided anti-scratch or anti-fog).

As Bolle’s vision has no limits, Ness+ can be customised to company colours. bollesafety.com.au

ABB EXPANDS MINING PORTFOLIO The ABB Ability MineOptimize portfolio offers open, digitally connected mining applications for unmatched operation, maintenance, process and production performance.

Its digital applications enable mine operators to maximise reliability, safety, productivity and energy efficiency while optimising planning and visibility across operations and the entire enterprise.

ABB Ability MineOptimize also enables IT/OT integration for some of the world’s most cost-effective mines.

The portfolio will enable sustainable mining by powering the all-electric mine, reinvent mining automation with the next generation of ABB Ability System 800xA for process and power control, and improve availability through enhanced collaborative services with new predictive cloudbased analytics for grinding, hoists and conveyors. abb.com

MICROMINE GIVES OPERATORS BETTER DATA CONTROL Fleet management and mine production solution Pitram provides an intuitive, quick and highly reliable real-time data capture and analysis.

Pitram assists mine operators to track results in real-time, analyse data, better manage start and end of shift control, pinpoint weaknesses in the production pipeline and even track lone workers to enhance safety management.

The voice capture software is also capable of extracting information received via two-way radio and plot that against schedules, targets and surveys.

Pitram’s data acquisition can integrate multiple information technology systems that are already in place to aid information sharing between systems, saving time and improving the value and accuracy of all the data collected.

The mining software could be used to bolster operational safety and efficiency, and support a mine’s low-cost production and exploration strategy, such as that of Kirkland Lake Gold’s Fosterville gold mine in Victoria. micromine.com SAFETOWORK 14 APR-JUN 2019

MAPTEK RELEASES COLD CLIMATE MODEL OF SENTRY SYSTEM Maptek Sentry is a mobile remote monitoring system that uses laser scanning to continuously measure ground movement with extremely fine spatial resolution and accuracy.

Maptek redesigned each of the major components in the standard temperature Sentry mobile system, with significant changes to achieve the required cold climate specifications.

The Sentry system can operate continuously from -20° Celsius to +50° Celsius, with operation for a limited time in temperatures below -20° Celsius. It requires an XR3 cold climate laser scanner, which has been redesigned and tested to operate at these low temperatures.

What hasn’t changed is the proven capability to monitor multiple areas, with the data displayed intuitively and ready for immediate application in risk management programs.

The 3D point cloud data that has been collected while monitoring can be used for geotechnical analysis and other applications. The Maptek laser scanner can also be redeployed from the monitoring for routine survey tasks. maptek.com

TML ROLLS OUT MINING MACHINE UNIDACHS 740 SCALER TML adapts the Unidachs 740 Scaler to the extreme conditions underground, in addition to the unique kinematics of the telescopic boom. The package offers comprehensive protection for machine operators.

The operators cabin has a falling objects protection system (FOPS) installed on the roof and on the front screen, which is made of armoured safety glass. The cabin can be tilted so that the operator has an optimal upward view.

The machine itself is protected for the typical underground mining and tunnelling environment: TML hides the hydraulic hoses away in a guide system inside the telescopic boom.

This ensures that the hoses are protected against any damage in the case of loose rocks or debris falling onto the boom while in operation. This not only increases the availability of the machine, but also reduces the risk of hydraulic oil leakages to almost zero. tml-technik.com

RHOSONICS INTRODUCES MEASURING INSTRUMENT The Slurry Density Meter WT (SDM WT) is an ultrasonic measuring instrument that shows the density value in percentage by weight (wt%) solids with an accuracy up to 0.005 wt%.

The SDM can measure the density of challenging water-based slurries, from light to very dense slurries. For the mining industry, typical applications are a thickener underflow and a cyclone feedline.

The device is an ultrasonic technology which, rather than the nuclear devices traditionally used in measuring density, will significantly reduce operational costs and eliminate the associated health and safety risks on-site.

The Rhosonics SDM WT integrates a sensor, analyser, cable and software in one system. The density meter is compact and lightweight. The sensor is made of durable and abrasion resistant materials for a long service life and low maintenance needs. rhosonics.nl SAFETOWORK.COM.AU 15 APR-JUN 2019

Products EXAIR SOFT GRIP SAFETY AIR GUN The back blow air gun uses the smallest back blow nozzle available to deliver a blast of air to effectively blow debris and liquids from inside small pipe or hose diameters, channels, bores, holes, internal threads and other internal part features.

An array of holes on the model 1004SS M4 back blow air nozzle provides a forceful back-facing 360-degree airflow to clear out coolant, chips and light oils from machining processes.

This nozzle prevents blowing chips further into a part, tube or pipe and eliminates hazards created by blowing debris out the far end of a pipe.

Air consumption is only 4.5 SCFM at 80 PSIG with a low sound level of 75 A-weighted decibels. The nozzle is manufactured to clean inside openings as small as six millimetres and up to 25 millimetres. It is constructed of type 316 stainless steel to provide durability and superior resistance to corrosion. caasafety.com.au

SANDVIK TO DEVELOP INTEROPERABLE PLATFORM FOR AUTOMINE Sandvik Mining and Rock Technology is set to unlock automation’s full potential for all equipment regardless of manufacturer – by equipping companies with mixed fleets with AutoMine behind them.

To enable interoperability, Sandvik will introduce the AutoMine Access API (Application Programming Interface), which will provide standard, pre-defined interfaces for connecting third-party loaders and trucks for control by Sandvik’s AutoMine system.

An API consists of functions and procedures that can access the features or data of an operating system, application or another service.

In addition to APIs, third-party equipment designs must conform to the functional safety requirements specified for AutoMine to be compatible with it. rocktechnology.sandvik

BRIDGESTONE DEVELOPS FIRESTONE VERSABUILT LINE Bridgestone has expanded its popular Firestone VersaBuilt All Traction (AT) radial tyre line with AT 14.00R24 tyre.

The tyre is designed primarily for loaders and graders, and is engineered to provide improved traction, versatility and dependable performance in a variety of environments with increased tyre life.

The addition of the 14.00R24 tyre rounds out the existing Firestone VersaBuilt All Traction offering and complements the total portfolio of radial off-the-road products with the durability expected from the Firestone brand.

All sizes feature a heavy-duty all-steel casing and a SideArmor sidewall that deflects stones and debris to help protect against cuts and punctures.

Additionally, a self-cleaning tread pattern allows for more traction in soft and muddy surfaces. bridgestoneamericas.com SAFETOWORK 16 APR-JUN 2019

PROXIMITY WARNING SYSTEM LOWERS RISK The BodyGuard i-Tag proximity warning system reduces the risk of accidents by helping stop vehicle operators and pedestrian staff from colliding into each other.

The system is made of three components which interact with each other: a personal tag worn by pedestrians, a sensor unit attached to the vehicle and a cab alert unit which speaks to the driver.

When a pedestrian wearing a personal tag gets too close to a vehicle, it is picked up by the vehicle’s sensor unit and informs the driver via the cab alert unit, even through solid objects.

The cab alert unit warns the driver in a human voice to ensure the driver hears it and hits the brakes to avoid an accident.

The technology avoids vehicle and plant repairs, equipment and personnel downtime, workplace accident investigations, and most importantly, accidents that may result in a worker’s injury or death. bodyguardsafety.com.au

FENNER DUNLOP ARAMID-REINFORCED CONVEYOR BELT KordFlex uses a high-tensile, extremely low-stretch aramid carcass, which has the highest strength-to-weight ratio of all the conveyor belt reinforcements used. It has a 10:1 safety factor, more than twice that of synthetic fibres like polyester and nylon, and five times that of steel.

The carcass is especially useful in weight sensitive, high abrasion, high tension applications. Kordflex, when used in place of existing steel cord belting, can result in a 70 per cent carcass weight reduction.

The transition from a steel cord belt to a KordFlex belt also offers economic benefits by having greater ‘available cover’ life. This is due to the fact that the covers can be worn down much closer to the carcass without significantly compromising its impact, tear or tensile strength, providing a minimum additional two millimetres of usable cover. fennerdunlop.com.au

ESS ENGINEERING EZI-GUARD SYSTEM ESS Engineering’s Ezi-Guard system comprises a range of versatile and easy to install brackets, lightweight panels and standard structural tubing to form an off-the-shelf system that can be adapted to almost any application.

Ezi-Guard, available in a range of materials such as aluminium, 304 stainless steel and galvanised mild steel, suits most applications including corrosive environments.

It is available in customisable colours, is easy to install and can be tailored to fit site needs.

Ezi-Guard provides high-quality guarding systems for bulk handling requirements in Australia, meeting the guard design requirements of AS 4024.3610:2015 Safety of Machinery – Conveyors and ISO 14120-2015 Safety of Machinery. esseng.com.au SAFETOWORK.COM.AU 17 APR-JUN 2019

Dust suppression

Protecting workers from respirable dust in machinery cabins and control rooms DUST PARTICLES MAY BE SMALL, BUT THEY CAN CAUSE BIG PROBLEMS FOR THE HEALTH AND SAFETY OF WORKERS AT MINES, QUARRIES, LANDFILLS, PORTS, AND IN CONSTRUCTION AND DEMOLITION. ENGINEERING CONTROLS AND EDUCATION ARE NEEDED TO MAKE SURE WORKERS STAY SAFE.

E

xposure to dust at mineral processing and industrial work sites is a cause for concern, leading to potentially serious respiratory problems and diseases if not kept in check.

The current workplace exposure standards set out by Safe Work Australia state that exposure to respirable crystalline silica (RCS) should not exceed 0.1 milligram per cubic metre over an eight-hour time-weighted average.

A 2016 study by Oxford Academic found that 6.6 per cent of Australian workers faced exposure to RCS, with earthmoving works or excavation works, and construction workers the most likely to be affected.

RCS, or silica dust, is extremely small (around 100 times smaller than the average grain of sand), so it is generally imperceptible when inhaled. It is often the product of natural rocks and quartz, as well as construction materials such as bricks, cement, tiles and some plastics.

The everyday minerals processing works common to materials processing causes hazardous dust to rise into the air in significant quantities, so it is important that protection is in place to ensure workers stay safe.

Respirable dust is a common sight at the nation’s mine.

Coal workers’ pneumoconiosis (CWP), a disease caused by respirable coal dust and colloquially known as black lung, has also received increased public awareness in Australia due to a spate of recent cases in Queensland.

In the United States too, black lung is a problem — a study by the American Journal of Public Health revealed last year that in the coal-rich Appalachian states of Kentucky, Virginia and West Virginia, a shocking one in five coal miners with over 25 years’ experience had contracted the disease.

Respirable dust exposure is usually broken down into three stages. Inhalable dust (or the inhalable fraction) is the airborne particle that is breathed through the mouth or nostrils.

SAFETOWORK 18 APR-JUN 2019

This then becomes a thoracic fraction when it penetrates the airways of the lung. Following this is the respirable fraction, which represents the particulates that can breach the gas exchange tissue of the lungs. These are usually between four and 10 microns in diameter, and represent the biggest threat for industrial site workers over an extended period of time.

This dust is so small that it can be easily overlooked. Australian company BreatheSafe has adopted the European Standard EN15695-3 as the baseline for rules regarding exposure limits for cabin operators in the absence of sufficiently detailed Australian regulations.

This standard is actually designed to protect operators in tractor cabins using

The control cabin of a D10 dozer.

“This standard is actually designed to protect operators in tractor cabins using hazardous materials such as pesticides.” hazardous materials such as pesticides, but according to BreatheSafe sales and operations manager, Javier Riveros, they are equally applicable to mining cabins.

“The cabin has to be very well-sealed so that there’s no chance for particles to ingress into the cab, and there is a stipulation that the filter has to be highly efficient at levels above 99 per cent,” he tells Safe to Work.

Safe Work Queensland guidance materials released in December 2018 recommend that cabin doors and windows be closed at all times to maintain an effective seal and to maintain pressure. High efficiency particulate air (HEPA) filters should also be fitted to further isolate the operator and protect expensive components in the cabin from becoming damaged.

BreatheSafe offers audits on machinery cabins to make sure operators are effectively protected.

The company’s goal is to work towards implementing zero harm at industrial sites, including protection from exposure to silica dust (particularly in the mining

and construction industries), asbestos, sulphuric acid, hydrogen fluoride, diesel particulate matter and other inhalable and respirable substances.

BreatheSafe’s cabin audits follow similar guidance principles to Safe Work Queensland’s for managing hazardous substances recommendations, ensuring a tight seal to isolate the cabin’s air conditioning system.

The company also implements software that uses cameras that can be placed in the cabin or worn by the operator (on their helmet for example)

to help identify sources of exposure to respirable dust.

“This software can be used as a real-time dust monitor to correlate visual data so you can actually pinpoint when you’ve had high exposure and what the operator was doing at the time,” explains Riveros.

“In the case of a cabin, if the operator keeps opening and closing a window for example, it can show that there are high spikes and that the operator is doing something unsafe.”

Riveros says that while it is unfeasible to keep the cabin sealed at all times — such as instances where a driver has to exit the cab to check on something — it is also quite common for workers in cabins to have their windows open in spite of the risks.

By introducing such engineering controls, it is possible to significantly reduce respirable dust, he continues.

“The whole idea is that if you’re in a pressurised cabin with high-efficiency filters you maintain the closure of doors and windows at all times, but it just depends,” he says. “Some operators may have to go out and clear tracks or debris that has threatened their view or impeded their movement and in such situations they will have to open the door to do something.

“The main thing is that when we have this audit we can actually show them that by doing that they’ve introduced dust into the cabin.”

It is important that operators keep cabins sealed and windows closed to avoid contamination.

SAFETOWORK 19 APR-JUN 2019

PPE

Redefining cap lamps in underground environments MINEARC SYSTEMS HAS LAUNCHED THE CAP LAMP THAT HAS IT ALL – RELIABLE DUAL BEAMS, SUPERIOR COLOUR RENDERING AND A ROBUST DESIGN. SAFE TO WORK EXPLORES THE CAP LAMP THAT BREAKS INDUSTRY NORMS.

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hen working underground, the need for a cap lamp is undisputed; eyes alone can’t ensure clear visibility and safe operations below ground.

At the same time, this essential element in personal protective equipment (PPE) hasn’t gone through any major changes in almost a decade.

According to engineering manager of MineARC Systems, Daragh Quinn, the cap lamp industry has been stagnant

for the past eight years – the last major development in the market was the transition from an incandescent light bulb to LED lighting.

Since then, all the cap lamps that have been available for the industry have been geared towards the same design philosophy: to provide a narrow beam of intense lighting.

“All cap lamps focus on a very specific type of light. They all have a strong focused beam. However, what we were finding was there

SiriUS operates two lenses and LED lights.

SAFETOWORK 20 APR-JUN 2019

wasn’t a lamp that could give us a nice, wide illumination of your surroundings,” Quinn says.

These cap lamps project only a narrow, strong pencil beam that helps visibility into the far distance, but not comfortably as users look down at their feet.

“You’re trying to find a tool in your tool bag, but the light on your cap lamp is very intense. It reflects a lot of light back at you and when you look up, your eyes need to take a little while to refocus,” Quinn says.

As intense lighting isn’t necessarily useful, the team at MineARC created the SiriUS cap lamp on the premise of improving the eye comfort of underground workers.

SiriUS activates two different lenses and LED lights at the same time. This ensures the projection of a more natural light. A narrow beam delivers focus, while a wide beam provides a more dispersed, farther-reaching flood light.

The lamp also features an automatic light adjustment that allows for automatic dimming when in contact with ambient light intensity, aimed to mimic natural daylight as closely as possible.

It ensures eye comfort when looking directly at a co-worker during group situations and reduces any safety concerns associated with the startling glare of high beam in the eyes, including that of other lamps.

KEEP YOUR DUST DOWN Dust emissions constitute a significant operating, environmental and occupational health hazard that is unacceptable to the modern Bulk Materials Handling Industry.

ESS Dust Suppression systems generate a spray of fine water droplets to encapsulate dust particles to prevent the material from becoming airborne outside chute areas.

The cap lamp is made up of quality lighting and practicality.

The ESS Dust Suppression system is suitable for use with most dust producing materials where the process will allow for small amounts of added moisture.

Workers can also switch to a turbo mode to activate high intensity LED light, which can last for a short period of time without completely draining the battery.

While consistent lighting in a wide beam or high spot mode can last for 18 hours, a low power mode makes sure the cap lamp keeps going for another two hours – more than enough time for a worker to swap over to a fully charged battery.

Other battery packs can also be kept on hand, with one connected to the cap lamp through coils that hug close to the body, preventing them from getting snagged while a worker is on the move.

“Additionally, tracking is becoming something that’s required in a lot of cap lamps, so we’ve made that functionality available, depending on the requirement of mine sites,” Quinn says.

The global leader in safety technology incorporates RFID tagging and its own GuardIAN Tracking software in the SiriUS cap lamp. The GuardIAN software allows wearers to be tracked remotely from the site’s control room, providing vital information for search and rescue teams in an emergency situation.

“The cap lamp isn’t tracking you, but it has the ability to be tracked,” Quinn says. “When you’re going to a dangerous area, someone can alert you and tell you that you’re stepping into a dangerous zone.

“The cap lamp is quite a simplistic product, but its computing power absolutely makes it unique.”

The ESS Dust Suppression system is: - Simple, Safe and Easy to Maintain as all maintenance is performed from the outside of the chute.

- When the Quickfit Nozzle is combined with an appropriate filter, decreasing blockages and maintenance.

- A Low Water Consumption Unit, using only 2 liters of water a minute over a range of pressures. Making it suitable for drier environments.

- Supplied in Kit Form, comprising 2, 4 or 6 Quickfit nozzles, a manifold, push fit hoses and fitting.

Proudly Manufactured in Australia

SAFETOWORK 21 APR-JUN 2019

Tailings management Pollution to a reservoir caused by the Samarco tailings breach in 2016. Image: Flickr - Felipe Werneck/Ibama.

Brazil disaster throws spotlight on tailings management THE MINING INDUSTRY SUFFERED A SHOCK WHEN THE BRUMADINHO TAILINGS DISASTER OCCURRED IN BRAZIL IN JANUARY. SAFE TO WORK EXAMINES THE RESPONSE SO FAR.

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razil experienced its worst ever environmental disaster with the collapse of Dam 1 at Vale’s Córrego de Feijão iron ore mine in Brumadinho, Minas Gerais in January.

The collapse of the upstream-style dam led to the deaths of an estimated 300 people, causing widespread condemnation.

It was also the Brazilian iron ore major’s second tailings failure in just over three years, following the Bento Rodrigues dam breach that killed 19 people in the same region in November 2015.

The Brumadinho incident has caused a ripple effect across the global mining industry, prompting responses from various Tier 1 mining companies, particularly to reinforce the safety of

their upstream dams.

Tailings dams are generally constructed in one of three ways: upstream, downstream and centreline.

Upstream tailings dams, which are generally cheaper to build than their counterparts, begin construction with a dyke that continually expands upwards with the construction of raising lifts built in a trapezoidal pattern to accommodate waste as the tailings level rises.

These lifts are constructed on a bed of spigots (or a tailings beach) at the pond’s perimeter, a construction technique that introduces liquefaction to the sand or soil used to construct the lifts.

This contrasts with downstream dams, which build on the dam wall successively away (downstream) from the tailings pond, and centreline dams,

SAFETOWORK 22 APR-JUN 2019

where dykes are built vertically on top of each other.

In light of January’s Feijão incident, the Brazilian Government has decided to ban upstream tailings dams altogether by 2021.

The International Council of Mining and Metals (ICMM) has, meanwhile, elected to use an independent panel to develop new international tailings standards for its 27 members, a laundry list of the world’s leading mining companies that includes Vale, Glencore and Anglo American.

BHP chief executive officer Andrew Mackenzie praised the ICMM, saying the mining industry needs to act with greater urgency to make sure such incidents don’t happen again.

“While we don’t yet know the cause of the dam failure, we will review all

lessons as they emerge and apply them to further upgrade the construction and operation of our dams,” he comments at a mining conference.

BHP was involved in the 2015 Bento Rodrigues tailings disaster through its Samarco joint venture with Vale, though the company settled a class action in August last year for $US50 million ($70 million) with no admission of liability.

BHP spin-off South32 was among the first mining companies to highlight its dam management standards in response to the incident with comments it placed near the start of its 2019 first half report. The company is also active in Brazil through a share in the Brazil Alumina bauxite operation.

The company highlighted its operational tailings dam inventory, which included 18 active dams and 15 inactive dams, capital expenditure on

Minas Gerais firefighters search for survivors after the Brumadinho disaster in January. Image: Flickr/Romerito Pontes

tailings dams over the past two years, and other tailings-related history dating back to May 2015.

This was in stark contrast with the company’s half-year reports for 2017 and 2018, which did not mention tailings management or tailings dams at all.

Rio Tinto followed by posting what was perhaps the most dramatic response to the disaster, announcing that it would review the tailings and water storage facility management standards it launched in August 2015 and last updated in 2017.

What price is a life?

You can’t put a price on the ongoing devastation that workplace injuries and fatalities have on the individuals and their loved ones. If your site Regardless of doesn’t have a TED yet, ask why not? @Nivek Industries #Liftyoursafetygame

www.nivekindustries.com.au “TED is a great safety innovation...

Sadly fatal injuries have occurred from belly plates..

Every site needs a TED!”

Albert Scheepers, GM, Wambo Coal Mine, Peabody

SAFETOWORK 23 APR-JUN 2019

how you calculate the cost of a life or limb, TED will be cheaper every time.

Tailings management

The Doce River in the aftermath of the November 2015 Samarco tailings breach in Brazil.

The company has 51 tailings facilities in Australia, nine of which are built using the upstream method.

“Rio Tinto is committed to play its part in any industry response, including an independent expert review,” Rio Tinto chief executive Jean-Sébastien Jacques says.

Anglo American, meanwhile, made a point of noting in its 2018 full year report that the dam at its Minas-Rio mine in Brazil is not constructed using the upstream methods favoured by Vale due to risks associated with the country’s high rainfall.

University of Queensland professor David Williams, director of the Geotechnical Engineering Centre at UQ’s School of Civil Engineering, tells Safe to Work that this is not necessarily the case, however.

“Water must be kept well away from

the embankment, which may still be possible in a wet climate, provided that water is well-managed,” he explains.

“There are upstream tailings dams in Canada, which is considered a wet climate.

“Tailings deposition towards a water-retaining embankment, resulting in a decant pond (water) against the embankment, relies on a well-designed, constructed and operated downstream embankment with appropriate measures to maintain a low phreatic surface (water table) within the embankment, well inside the downstream face.”

Williams says there are several factors that contribute to safe upstream tailings dam construction, including desiccation of the tailings beach to provide a foundation of sufficient strength for raising, low seismicity, a limited rate of rise in tailings, and good

SAFETOWORK 24 APR-JUN 2019

tailings deposition management with drying periods between lifts.

Technology is a key factor improving tailings safety monitoring and management. New South Wales-based tech company Otus Intelligence Group has developed a system it says can provide a ‘first line of defence’ by using satellite imaging to identify potential issues arising at tailings dams (as well as other infrastructure projects such as road and rail networks) that couldn’t be seen otherwise.

This includes miniscule surface movements that can’t be picked up by other means, including drones and ground workers. While the satellite technology itself is not brand new, Otus hopes that its technology helps mining companies delineate the information in a way that can be more easily digested by the top brass.

“Our approach is to deliver something for less technical users that have to make the decisions at corporate level,” Otus managing director Marc Beaudry explains.

“When managing tailings, for example, decision typically comes from a corporate level, because it involves a huge financial risk for the companies.

The novelty of our approach is how we deliver the data to be used by a less technical audience.”

The system scans large areas for signs of activity and if something is found that warrants further analysis, recommendations are implemented to improve surface-level monitoring.

This also has other safety benefits as it removes the necessity of having workers enter often remote and dangerous tailings areas, allowing

for more efficient deployment on the ground.

“We turn the lens of multiple satellites on to one site to try to find the answer to why it is moving. In most cases, it was an excess of water in the tailings that was putting excess weight on the dam itself,” Beaudry explains.

The Brumadinho disaster is a wakeup call that has forced the industry to tighten its management of tailings dams.

While the full ramifications of the incident won’t be felt for some time, recent trends such as real-time monitoring of embankment pore pressures and deformations, satellite imaging, co-disposal of dewatered tailings and waste rock, and overall structural improvements will help to mitigate future risks.

As Williams says, “Any major

The dry bed of the historic Brukunga pyrite mine tailings dam in South Australia, which has been undergoing remediation since 1980.

tailings dam failure impacts the entire mining industry, not just the particular company involved, and stakeholders expect an increased focus from major mining companies on tailings dams in response.”

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Mining equipment

TED lifts more than safety standards THE QUESTION OF HOW MUCH SAFETY IS WORTH IS A POPULAR TRAJECTORY IN MINE SITES. RACHEL FRASER FROM NIVEK INDUSTRIES GOES IN TO THE FIELD TO FIND OUT MORE.

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ivek Industries sales and marketing manager Rachel Fraser has found that the Tracked Elevating Device, or TED, is lifting morale, efficiency and quality of life for fitters in mines all over the country.

Fraser spoke to a contract worker who highlighted TED’s value in these areas during a site visit in the Hunter Valley in New South Wales.

The contract employee, who regularly works on dozer, haul truck and grader maintenance and repairs across five pits in the region, describes TED as an extraordinary safety innovation.

In addition to saving lives, TED adds to the quality of life by making jobs easier and preventing workers from feeling sore and exhausted at day’s end.

“I don’t do steer cylinders without TED. With TED, you don’t have to put your hands in so many dangerous places, and it saves your back a lot more as well.”

TED is an Australian-made remotecontrolled, all-terrain, battery powered, hydraulic belly plate jack that has developed into a lifesaving multipurpose tool since its inception in 2011. It removes the need for workers to place themselves under suspended loads. This has been achieved through

The Cat24M GET tool is suited to assist in the removal and refit of grader blades.

SAFETOWORK 26 APR-JUN 2019

the continual development of new smart attachments.

The technology is used to take the weight out of a myriad of heavy, dangerous maintenance jobs via a wireless remote control. This way, fitters are removed from the line of fire during the dangerous lift and lower phase of component removal and replacement.

Prior to having TED, the Hunter Valley fitter removed belly plates using cummalongs. He also used a component handling trolley to accomplish the task, but points to his lack of control over them. In fact, he says removing belly plates at a mine site never felt “right” or “safe”.

“I don’t do steer cylinders without TED. With TED, you don’t have to put your hands in so many dangerous places, and it saves your back a lot more as well,” the fitter says.

“When I came in today, I wasn’t sure if we had a hire TED turning up.

If I didn’t have TED for this dozer today, I just wouldn’t be motivated. And you see that on the sites that don’t have a TED. A dozer comes in and people don’t want to get into it.

“And that’s when they start cutting corners. When you’re in a pit that doesn’t have one, you think that TED’s such a reward – I’m stoked when I’m back at a pit that has one.”

Removing belly plates with TED can save up to three hours. Fitters don’t need to find air lines and set up, and neither do they need to push, pull or carry heavy loads in and around the workshop and the field.

The total lifting capacity of TED is engineered at a safe working load (SWL) of 800 kilograms, and is complemented with a maximum lifting height of 1170 millimetres.

TED has several built-in safety features, including a deadman switch, forcing the operator to physically engage before every operation to avoid any accidental operational signals; load lock valves to prevent unplanned movements; and strobe and alarm to

TED is improving the work lives of fitters in more ways than one.

give effective visual and auditory alerts when TED is operating.

It also boasts 14 attachments that increase the versatility of the device, such as a track roller carrier, recently upgraded cutting edge tool, steer cylinder cradle, stand locating tool and TED slope jig.

“The best thing with TED, regardless of where I’m working in the Valley, is

you know where it is,” the fitter says.

“It’s in its home on all the sites – they’re all the same. Once you’re passed out, you’re ready to go.”

With nearly 200 TEDs at work and six distributors internationally, Nivek Industries is committed to constant product development on the TED system and will release other safety tooling in the near future.

TED, when fitted with its attachment steer cylinder cradle, aids in the replacement of steer cylinders, tie rods and other similar components.

SAFETOWORK 27 APR-JUN 2019

Eye safety

Keeping vision protected from hazards MINING IS AN INDUSTRY SECTOR WHERE WORKERS ARE AT RISK OF EYE INJURIES. BOLLÉ SAFETY SPEAKS TO SAFE TO WORK ABOUT THE PRACTICAL WAYS THAT WORKERS AND EMPLOYERS CAN STAY IN CONSTANT VIGILANCE. Copyrights: Bollé Safety – F. Bourcier

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hen a drill bit snapped and hit a worker with a shard, he and his colleagues wouldn’t have expected a near-miss. But the shard was sticking out of the worker’s left lens without him even realising it — ­ until a colleague pointed it out.

Following the accident, the worker involved only had his safety glasses manufacturer to thank for saving his eyes.

This eye hazard is no foreigner to mine sites. Furthermore, flying or falling objects (or sparks striking the eye) account for nearly 70 per cent of the analysed accidents, according to the Bureau of Labor Statistics in the United States. The particles are reported to be travelling faster than a hand-thrown object at the time of accidents.

Unfortunately, the mining industry, along with construction, manufacturing and agriculture, is a sector where employees most often suffer eye injuries during work.

Both underground and open-cut miners are vulnerable to eye injuries, and each group of workers faces different factors that increase the risk of eye injury. Common hazards include dust and flying particles, various fumes, UV exposure and chemical hazards.

CHEMICAL EXPOSURE Wearing the right eye protection for the job is crucial to maintaining eye safety.

the mine sites creates additional danger, while surface mines are also subject to wind and dust conditions.

These particles can cause abrasions, punctures and contusions of the cornea.

In fact, corneal abrasion is one of the most common types of eye injury, especially in dusty environments.

Eye injuries vary from something minor, such as scratches that can heal in a couple of days to more severe abrasion, which could cause permanent damage.

LIGHT AND HEAT DUST Regular blasting and the use of mining machinery creates airborne objects such as sand and dust. Active ventilation of

heat. The eye is even more sensitive to radiation than the skin, which is protected by the skin’s outer layer and protective pigment.

Apart from flash burn, which can present itself immediately, adverse effects can occur cumulatively when the eyes are exposed to bright light or high temperatures. These injuries come from a number of sources, including fires, furnaces, welding torches, molten metal, sparks and direct sunlight.

The sensitivity of eyes to light is fundamental to sight, but it also makes them vulnerable to ultraviolet (UV) radiation in the form of light and

SAFETOWORK 28 APR-JUN 2019

The fragile moisture and pH balance of the eyes could make common chemicals found in the workplace cause serious harm to the eyes.

A short exposure to vapours, mists or fumes of many industrial chemicals may also be strong enough to cause irreversible eye damage. The escape of air and water under high pressure is another possible cause of eye injury.

KEEPING EYES SAFE WITH SUITABLE PROTECTION Not wearing eye protection at work is considered a major factor contributing to eye injuries, according to Bollé Safety. Wearing the wrong protection for the job may also lead to many accidents.

Evidence suggests that glasses and goggles designed for specific workplaces are the best way to protect eyes from the wide range of hazards.

In dusty environments, safety

glasses with SBR “positive seal” gasket and strap kit maximise eye protection.

To fight dusty and humid environments, choose models with scratch and for resistant coating.

When working in an outdoor environment, polycarbonate lenses in safety glasses block 99.9 per cent of UV rays regardless of the lens colour. However, polarised models are excellent in removing the reflection and glare.

While alternating exposure to bright and low light, comfort sensitivity perception (CSP) lens technology is recommended. This type of lens is also suitable for extreme temperature environments.

Bollé suggests wearers choose the product that fits their face and ensure the equipment is adapted to each wearer’s face.

If wearing prescription lenses, users should consider prescription safety glasses or comfortable over the glasses (OTG) or goggles (in dusty environment) that would fit over prescription eyewear.

ALL-AROUND PROTECTION Reducing hazards in the workplace is essential and there are many other things companies can do to ensure workers are safe from potential hazards.

These include making sure to reduce and avoid falling and flying debris, as well as smaller particles like chips and dust. Lighting should be adapted to better suit the health and wellbeing of workers. First-aid kits should be readily available, and eye wash stations should be carefully positioned around the facility. Eye safety policy, training and drills will help educate and reinforce best practices in eye care.

DOs •R inse the glasses under cold water to remove any dust •C lean the lenses softly with cleansing solutions or pre-moistened wipes •U se a clean microfibre soft cloth to dry the lenses •A lways carry and store your spectacles in a protective case or pouch •E yewear that are scratched or which frame is damaged must be replaced.

DON’Ts •N ever use hot water which can alter and damage the coatings of the lens (anti-reflective, anti-fog, etc) •N ever use clothes, fingers or generalpurpose tissues to clean lenses •D o not clean with any solvent or alcohol-based cleaning product •D o not place your glasses with the lenses facing down.

A NEW UNIQUE COMPACT-SIZED GAS MASK IN THE INDUSTRY KIMAX is designed to provide its users with short-term respiratory protection in incidents involving high concentrations of chemical agents, such as industrial chemical spills.

The KIMAX protects against organic gases with a boiling point higher than 650C; several inorganic gases; sulfuric gases and other acidic gases, ammonia and ammonia derivatives. It also protects against such chemicals in particle form. The KIMAX approved standards EN 14387: 2004 A2B2E2K2 gas filters with electrostatic particle filtration P2.

The KIMAX’s design is tailored to meet the rigorous demands of the following industries: Mining, oil and gas

Transportation

Chemical and petrochemical

Defense

SAFETOWORK 29 APRIL-JUNE 2019

Technology

Laying the foundations of Industry 4.0 with IO-Link materials handling solution POINT-TO-POINT COMMUNICATION ALONG THE LENGTH OF A CONVEYOR SYSTEM IS NO LONGER A TECHNOLOGY OF THE FUTURE. IFM EFECTOR’S PRODUCT MANAGER FREDDIE COERTZE TELLS SAFE TO WORK WHAT WAS ONCE IMAGINED IS NOW BROUGHT TO TANGIBLE REALITY.

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ll mining companies will agree on one major problem: the breakdown of a conveying system.

German sensor specialist Ifm Efector has completed extensive market research in the mining sector, and particularly in partnership with some mining companies in Western Australia.

According to product manager of industrial communications Freddie Coertze, a lot of these large companies have a similar need when it comes to their assets, especially conveyor belts.

When a conveyor breaks down, a lot of implications may appear in the form of unplanned downtime and a loss of valuable production.

Additionally, repair jobs need to be done in as little time as possible to minimise the cost of missed opportunities.

But depending on the cause of its failure, a conveyor’s breakdown not only hurts a company’s productivity – it may also harm its workers, depending on the cause of failure.

“We first identified this problem.

And rather than selling a product, we thought it was best to sell a solution,” Coertze tells Safe To Work.

In addressing the lack of control faced by many companies in managing conveyor breakdown, Ifm gives

Aerial view of ore and conveyor belt.

operators the ability to identify problem ahead of time. After all, “being able to predict your maintenance over the life of the conveyor will be better than running to a failure.”

The company’s IO-Link module is a small unit with enough power to gather data in respect to any movement, instrument or safety switches on a conveyor system with the use of

SAFETOWORK 30 APR-JUN 2019

sensors. This gives mining companies the power to instantly identify the point of failure in a conveyor.

“We mainly want to gather data from the conveyor. And IO-Link is the one that connects to all the different sensors and devices attached to a conveyor system and unlocks their data before loading it to the server or Cloud,” Coertze says.

“It’s a plug and play solution – really straightforward.”

“So we can take the data out, and that data is really available. That’s why we see this device as being really great in that environment.”

The data is also updated every 2.3 milliseconds to the network, providing real-time feedback to operators.

Based on the information gathered, operators can locate the source of the error and have it fixed more quickly, as opposed to having a repairer check every single device that may have tripped in the conveying system.

Users also apply this data to identify a conveyor’s health condition, which enables mining operators to predict when maintenance is next required for the system.

The IO-Link module, combined with a small vibration sensor on all critical moving assets, also collects vibration data – this will be sent to a remote location where operators will identify an issue upon detecting increased vibration levels.

The practicality of the IO-Link module doesn’t stop there. “Our little

field module – if we can call it that – can be stuck on the conveyor, connected on to your network and you’ll get everything you need from it,” Coertze says.

“It’s a plug and play solution – really straightforward.”

The unit provides point-to-point connections to mining operations without complex installation.

Operators can stick as many as 10 modules down the length of a conveyor system and collect all the information, thanks to the module’s rugged quality and adaptability to harsh outdoor environments.

“If you look at Ifm’s history, you can see that we’re also strong in the food industry – from your breweries to your dairies. Because of that we have the capacity to manufacture sensors and devices that can handle really harsh environments including chemical washdowns, high temperatures and temperature fluctuations,” Coertze says.

“With our expertise in that arena, we can design this block-like module for use in a harsh environment such as mining.”

The IO-Link module is installed close to the instruments.

IO-link, with rope pull switches, provides security protection.

This is the winning characteristic of Ifm’s IO-Link module. Though there are more than 240 manufacturers of IO-Link, not all of them have an IP-rated block that can be put out in the field.

“You normally have to put the module in a cabinet to protect it from extreme temperatures. Not ours,” Coertze says.

“When a safety rope switch is pulled and your conveyor is in a safe state, we can indicate which one is tripped.”

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Tyre management Stands are a must to secure the massive weight that tyres carry.

Controlling the safety risks of tyre management MINE SITE TYRE MANAGEMENT PRESENTS A SERIES OF SAFETY CONCERNS THAT MUST BE MITIGATED TO AVOID INJURY. BEN CREAGH EXPLORES HOW KAL TIRE APPROACHES THIS PRIORITY.

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safe mine site starts and ends with its culture. Tyre management operations at mines make up a critical part of this ethos.

From the energy that is stored within a haul truck’s tyres to their sheer weight, tyre management teams need to be aware of the risks that come with their daily activities.

Kal Tire takes a leadership role with the mining companies it provides tyre management and services to as part of a relentless commitment to safety.

The Canadian company has introduced a consistent focus on maintaining high safety standards across its global operations, including at the

group’s sites around North America to its operations in Australia.

No risk is overlooked at Kal Tire. The company follows a thorough training and awareness regime that helps its teams stay on top of these risks on a daily basis.

Kal Tire Australia managing director Darren Wilson says the key objective is to help mining companies control and mitigate the risks associated with the operation and management of their tyres and wheels.

“In order to do this our team need to be armed with the right knowledge, processes and procedures,” Wilson says.

“At all of our sites our team undertakes specialised training to ensure that they are aware of the risks and

SAFETOWORK 32 APR-JUN 2019

are aware of the correct processes to manage these risks.”

Kal Tire uses an internally-developed learning management system (LMS) to provide training and skills knowledge to its workers.

Wilson says the LMS provides Kal Tire with an efficient way to deliver a constant safety message across its operations.

“Our internal service technical and training group also provides support to our front line team by offering specialised safety training and on the job advice to help them ensure that we continually improve our practices and processes,” Wilson says.

Kal Tire’s approach to managing the risks also allows it to demonstrate a focus

on innovation to deliver improvements.

The company’s Gravity Assist System, a mechanical tool developed to safely and weightlessly manoeuvre 36-kilogram torque guns used to fasten lug nuts on earthmover tyres, is a leading example of this innovation.

Gravity Assist mitigates some of the burden handlers face when dealing with the immense weight of tyres and wheel components.

Here, Safe To Work looks at the Kal Tire approach to safety and the key risks faced by the company at mining operations.

SAFETY LEADERSHIP Controlling and mitigating the individual risks of tyre management always circles back to the safety culture of the team and the leadership that drives it.

Kal Tire focuses on the development of its leaders and front line workers to instil this culture, according to Kal Tire area manager eastern region Brendan Schneider.

“There is a big focus on not just following a set of rules but understanding what the rules are and where they have come from,” Schneider says.

“It is about understanding why an incident can happen and then looking to proactively manage the risk that leads to the incident.”

Kal Tire maintains its strong safety performance and standards through a series of internal checks that the tyre management teams regularly undertake.

Wilson says this includes frequent safety audits and communication, operational audits and a process called the ‘6 Observables’.

“The management and supervisor team engage with team members doing tasks on the floor and talk to them about the top six risk areas and what thought process they are undertaking as they perform the assign tasks,” Wilson says.

The risks cover a number of areas that Kal Tire’s teams manage every

Brad Greenwood and Owen Cherry discuss Kal Tire’s upcoming activities.

“At all of our sites our team undertakes specialised training to ensure that they are aware of the risks and are aware of the correct processes to manage these risks.” day, including machine isolation, safe operation of equipment, correct use of jacks and stands, line of fire and correct use of PPE. TYRE PRESSURE The air pressure in ultra-class earthmoving tyres at mine sites can reach as high as 110 psi. With this amount of pressure, comes an incredible level of energy that needs to be controlled.

Kal Tire puts each tyre and all wheel components through an extensive inspection process to ensure they have the integrity to contain this level of air pressure, Kal Tire operations support specialist Ian Campbell explains.

SAFETOWORK 33 APR-JUN 2019

“We need a good inspection regime to make sure we pick up on any tyres that have been damaged and could, at worst, potentially burst,” Campbell says.

“A bursting tyre is not the hazard so much. It is more where the tyre might burst and who it is near if it does bursts – that is something we can control in terms of the pressure risk.”

Kal Tire has developed an ‘inflation station’ to protect tyre technicians from the force of energy that earthmover tyres hold.

The ‘inflation station’ establishes a barricade of at least six metres between the wheel and technician to mitigate the risk of injury to personnel in the event of a burst or rapid release of air.

Tyre management Kal Tire has equipped the ‘inflation station’ with the tools and devices the handler requires for this activity, such as pressure gauges.

“We park the tyre handler in front of the tyre and then usually inflate the tyre from zero to 10 psi, stop inflation, then inspect the tyre wheel assembly and make sure the lock ring and bands are installed and correctly seated,” Schneider explains.

WEIGHT The weight of tyres and the tools used on them can potentially cause a number of injuries to mine workers and tyre handlers.

Tyres and wheel components carry such a heavy weight that they put workers in danger in multiple ways.

A tyre service person must be aware of the long-term muscle injuries that can stem from the manual handling of these

weights, with backs especially at risk.

The components also contain a number of sharp objects and pinch points that put hands, in particular, in danger of being injured.

Kal Tire focuses on these risks in its training regime, which includes regular reminders of how workers should properly handle tyres or the location of pinch points.

“There are a lot of risks associated with the multi-piece rims and pinch points as we are working with big parts and torque multipliers,” Campbell says.

“The main guidance is to simply keep your fingers away from the pinch points, which means you have to add long extensions to torque multipliers – it is like a massive torque wrench.”

These tools increase the weight of the activity significantly, which is where the Gravity Assist System comes into play.

Gravity Assist acts like a mechanical

The Gravity Assist System makes a task previously demanding on the body much safer.

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arm to hold and swivel the torque gun like a weightless extension of the technician’s body, removing the need to fasten almost 70 lug nuts holding an enormous torque gun.

Despite the number of lug nuts contained in an average mining tyre, the Gravity Assist System renders a torque gun ‘weightless’, making the process much safer, more efficient and precise.

MINING ENVIRONMENT The principles of surface and underground operations have their notable differences, something that extends to tyre management.

Underground mines, in particular, pose unique risks that tyre management teams consider, especially in the event of a break down at the face of operations.

While scheduled maintenance is commonly scheduled to take place on the surface at underground sites,

break downs don’t afford this luxury to the teams.

“While there are some similarities to what tyre servicepersons do in a wide open area, the reality is that our underground teams aren’t able create a workspace like that,” Kal Tire general manager Miles Rigney says.

“There is no change in the emphasis we place on safety, but we have to get to the activity differently because we don’t have the benefit of the barriers and segregation as we do in the open cut environment.”

The safety risks primarily stem from the tyre management team having to complete tasks in situ with the location of the machine.

Underground activities can then be affected by a series of environmental factors that require specific preparation, including the gradient, lighting or noise.

Rigney says Kal Tire tailors its training, awareness, tooling and safe work programs to reflect the characteristics of each underground operation.

“We do job hazard analysis (JHA) to look for any deviation that may exist between the conditions described in the safe work procedure and the actual conditions, be it a gradient, noise or lighting,” Rigney says.

“The JHA allows us to identify and map any areas of deficiency and come up with control to effectively deal with that risk.”

LIGHT VEHICLE TYRES With so much focus on earthmover tyres, it can be easy to overlook the risks involved with light vehicle or ancillary tyres on mine sites, warns Rigney.

Earthmover tyres are one of the most expensive costs for companies, falling behind labour and fuel as the biggest at an operation. They also drive a large portion of the productivity at an operation for their role in hauling ore around sites.

Smaller tyres, however, share many

Brad Greenwood with the Gravity Assist System.

of the same safety risks as their larger counterparts, albeit at their own scale.

Rigney reinforces that light vehicle and ancillary tyres should be recognised by management teams in a similar way as they also contain high air pressures that are potentially dangerous.

“We work with the relevant mine to make sure that there is clear definition around how those ancillary and light vehicle tyres are being managed,” Rigney says.

“There is usually a couple of layers of support that goes over the top of that.

It is general practice for all mine site vehicles to have a prestart check either at the start of every shift or every 24 hours depending on what the equipment is.”

The check involves site personnel monitoring the condition of every tyre, including components such as wheel fasteners, and assessing the potential for future issues.

TYRE SELECTION Selecting suitable tyres for each mining activity works hand-in-hand with ensuring a high level of productivity and safety at sites.

Kal Tire continues to strengthen its service for monitoring and analysing the

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performance of mining tyres in operation to drive accurate tyre selection.

The company generates data on the performance of tyres in different mining conditions to provide a guide for this process.

“It’s important that we are involved with making sure mining companies have the right tyre for the application, and that the tyre is working within its capabilities,” Campbell says.

“We do studies on the tyres – we look at speeds and the loads the trucks can carry on the mines. We evaluate the machines to see if they meet the specifications of the tyres.”

These studies allow Kal Tire to analyse what causes tyre failures, whether it is because of incorrect tyre selection or how the operator is driving the machine.

Kal Tire is introducing its tyre operations management system (TOMS) across the company’s global operations to deliver a new standard in performance.

While these studies and systems drive productivity and efficiency, they also support the mitigation of the safety risks drivers face when operating machines.

Respiratory protection The powered air purifying respirator reduces welding fume exposure to as low a level as reasonably practicable.

Why protection against welding fumes is indispensable BLACKWOODS NATIONAL CATEGORY MANAGER FOR WELDING AND GAS FRED O’CONNOR INFORMS SAFE TO WORK THAT THE RECLASSIFICATION OF WELDING FUMES AS CARCINOGEN BY THE INTERNATIONAL AGENCY FOR RESEARCH ON CANCER (IARC) CALLS FOR MINING INDUSTRY ACTION BEFORE IT’S TOO LATE.

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n 2017, the International Agency for the Research on Cancer (IARC) reclassified welding fumes from “possibly carcinogenic to humans” to “carcinogenic to humans”.

The reclassification includes the risk of ultraviolet radiation from welding processes in causing skin and eye cancer.

While the reclassification has forced many welders and workplaces to rethink their current approach to respiratory protection, it seems

that much of Australia’s mining industry has been slow to implement significant changes.

The NSW Resources Regulator found during its recent planned inspections last year that mine operators had not identified or acted upon this reclassification, and were not consistently applying the principles of the hierarchy of controls to manage welding fumes.

The impact of exposure to welding fumes varies, from a worker falling ill

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immediately to exposure damaging the lungs gradually over a long period of time. What is most concerning however, is prolonged exposure to welding fumes. According to Safe Work Australia, the greater the exposure to the carcinogen, the higher the risk of developing cancer.

While short-term illness such as welding fume fever is considered the primary consequence of welding fume exposure, metal fumes such as nickel, chromium and cadmium (known

carcinogens) and molybdenum trioxide and indium tin oxide (classified as “possibly carcinogenic to humans”) can pose long-term health risks.

According to the WA Department of Mines, Industry Regulation and Safety, inhaled welding fumes may also cause chronic inflammation and weakened immune function, possibly increasing the body’s susceptibility to infections or tumours.

“Although isolated exposure to welding fumes may not be of significant concern, there needs to be more done to protect against the potential long-term effects,” Blackwoods national category manager for welding and gas Fred O’Connor tells Safe to Work.

“That’s why we’re focused on educating the market, and our customers, on preventative strategies that provide the necessary protection in their respective applications. The right respiratory equipment combined with having appropriate controls in place, are a fundamental step in the defence against welding fumes.”

This first layer of protection is a basic P2 respirator, O’Connor says.

This protection can be enhanced with a powered air purifying respirator (PAPR), which helps reduce welding fume exposure to as low a level as reasonably practicable.

“The immediate benefit of wearing a PAPR is improved overall health and reduced fatigue at the end of a shift,” O’Connor adds.

While PAPR welding helmets were traditionally quite expensive, Blackwoods is now able to offer a competitive and versatile range that meets our customers’ requirements from both a cost and performance perspective.

Other protective strategies available to welders include the use of downdraft tables that suck the welding fumes away from the

The use of the right respiratory equipment should be complemented with having appropriate controls in place.

“We’re focused on educating the market, and our customers, on preventative strategies that provide the necessary protection in their respective applications.” operator. An additional layer of protection in the form of portable welding fume extractors can also be used, which not only further protects the individual welder, but also surrounding personnel.

Finally, company measurement control that regulates welding fumes, including the optimisation of welding process consumables and equipment is critical in protecting their people.

“It’s important you look at the consumable that you’re using.

Adopting the use of copper-free wires is a good place to start,” O’Connor says.

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“Combining the above strategies will help deliver the right protection.

We not only recommend the appropriate safety equipment for work sites, but also engage our technical welding and safety experts who can provide complete solutions to support companies in managing their concerns.

“Our expertise is further complemented by our industry-leading suppliers including 3M (Speedglas), ESAB and Lincoln Electric, which allows us to offer the best protection available for mining workers exposed to welding fumes.”

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Training

Bringing ‘cleanskins’ into a safe mining environment INTEGRATING INEXPERIENCED MINE WORKERS INTO OPERATIONS CAN POSE CHALLENGES. FITZROY AUSTRALIA’S CEO EXPLAINS HOW THE COMPANY WILL DO THIS AT IRONBARK NO. 1. BEN CREAGH WRITES.

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itzroy Australia Resources plans to fill half of the jobs it is creating at the Ironbark No. 1 coal project in Queensland with workers who are new to the mining industry.

The coal miner will require more than 350 workers at the coking coal operation near Moranbah and has flagged 50 per cent of the roles for mining rookies.

Fitzroy, which acquired a group of metallurgical coal assets from Brazilian miner Vale in 2016, has established a presence over the past three years at the Carborough Downs mine, employing 340 employees and contractors.

It is building off this start at its next coal project, Ironbark No.1, where it will require 350 underground workers for a

mine expected to produce six million tonnes of coking coal a year.

Ironbark No. 1, scheduled to reach production in first quarter 2020, will be an underground longwall, and bord and pillar site operated by Fitzroy. The project is designed to share major infrastructure with Carborough Downs.

Fitzroy has formed a partnership with SES Labour Services to provide the training, development and recruitment solutions to the workers it sources.

SES will help Fitzroy overcome one of the key risks faced at the Ironbark No. 1 development – the recruitment of so many workers that are new to the mining industry.

Fitzroy Australia chief executive officer Grant Polwarth says there will

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be a focus on mentoring at Ironbark No. 1, incorporating the experienced workers that Fitzroy and SES identify as suitable candidates.

The experienced miners will be required to work closely with the new workers to help them become comfortable in an underground environment.

“We will be developing with SES a unique cultural assessment program and training package to ensure the workforce are ready for the rigours of underground coal mining,” Polwarth says.

“We are currently investing in virtual reality platforms for principle hazard awareness training to synthesise the work environment and take training outcomes and preparedness to the next level.

The Carborough Downs mine site.

“We will be working to further our culture where we embrace accountability and celebrate our successes. We are proud and hungry to cut coal, and believe strongly in a mature safety culture where we are all one team.”

Fitzroy has prioritised that SES help it establish a culture that will become consistent at not only Ironbark No. 1, but all of its operations.

SES executive general manager Nathan Sharpe says the recruitment and training company has worked closely with Fitzroy to understand the mining company’s values and culture since forming the partnership.

“We are putting a series of assessment tools together – if the candidates score well in the areas that are aligned to the Fitzroy way then they will be the type of candidates that Fitzroy wants to bring into Ironbark No 1, both green skins and experienced operators,” Sharpe, a former Australian Wallabies

rugby union player, says.

“It is going to be a long process; the initial screening process is going to take a couple of months to get the right people lined up.

“Fitzroy is taking a truly unique approach. They are very proud of what their culture is (at Carborough Downs) and they want to extend that into another mine site.”

Fitzroy and SES will officially start recruitment for the underground roles in in the fourth quarter of 2019, but the partners have already received a significant amount of interest in the opportunity.

Polwarth says the company factored in the skills shortages facing mining and how it can overcome the challenge when coming up with the recruitment plan.

“Skills shortages in the underground coal mining industry are very real – from statutory officials, to trades, to operators,” Polwarth says.

“We must innovate and bring new people into the industry who share our values. This is the only way we will attract a uniquely talented team to help us build our business.”

The partnership approach with mining services has been an important part of this innovation.

Fitzroy workers at the Carborough Downs mine.

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Fitzroy has formed partnerships in other parts of Ironbark No. 1’s development, including with Nepean Mining, which will design and deliver key equipment and infrastructure.

Sharpe, who played 116 matches for the Wallabies over more than a decade, draws parallels with his experience as a professional sportsman to what Fitzroy Australia wants to achieve at Ironbark No.1.

“I just think it’s the importance of how teams interact; I have been in some good teams and some ordinary teams,” Sharpe says.

“That translates into mining, in the business and all other facets of team work as well. Getting the right people on the bus to start with is always a key.”

Beyond Carboroough Downs, Ironbark No. 1 and the Broadlea project, Fitzroy has more than 98,000 hectares of tenements in the Bowen Basin.

The company is determined to introduce the same culture it is establishing at Ironbark No. 1 across every operation it develops in the future to reach its ultimate goal.

“We aspire to build the next great Australian mining house. We set ourselves high standards in terms of safety, productivity and cost,” Polwarth concludes.

Education

The University of Western Australia is constructing a learning space for engineering and mathematical science students.

The favourable fight for talent AUSTRALIA’S BEST UNIVERSITIES HAVE JOINED THE REST OF THE INDUSTRY TO NURTURE THE FUTURE MINING WORKFORCE. VANESSA ZHOU SPEAKS WITH THE COUNTRY’S TOP THREE SCHOOLS FOR MINING AND ENGINEERING TO DISCUSS THEIR PART IN THE FIGHT.

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mid mining’s skills shortage, digital advances in mine sites require mining engineering graduates that are competent in understanding and using emerging technologies.

Fleets of tremendously large autonomous trucks are being mobilised at open pit mine sites in Australia, transporting enormous volumes of rock to processing plants.

In the future, such advanced technologies will be incorporated into underground mining activities that are currently potentially hazardous to human workers.

In the sphere of education, mining

engineering is one branch of the profession that feels the impact of technology advances as much, if not more, than any other, according to professor of civil, environmental and mining engineering at the University of Western Australia (UWA) Andy Fourie.

“We recognise that there is a reluctance by some students to study mining engineering because of the cyclic nature of the industry,” Fourie tells Safe to Work.

“Although extremely attractive salaries are on offer during boom times, employment security during downturns is understandably a key concern for many young people.”

SAFETOWORK 42 APR-JUN 2019

While enrolments in mining-focused courses are slumping to their lowest levels, Australia’s mining engineering courses are still considered amongst the best in the world.

Curtin University (second), the University of Western Australia (fourth) and the University of Queensland (fifth) were all named in the top five of the 2019 QS World University Rankings for their mineral and mining engineering courses, contending only with the Colorado School of Mines in the United States (first) and McGill University (third) in Canada.

“Given the crucial importance of mining to the Australian economy, it is

imperative that we continue to graduate mining engineers that have the skills to fully understand and appreciate the opportunities offered by digital advances, while also retaining traditional engineering skills built on sound fundamentals,” Fourie says.

To address these issues, students at UWA will continue to study all of the units currently required for a mining engineering degree, with an option to include up to six units in the field of data science.

These subjects include robotics, automation, cyber security and data mining – all of which will develop skills that are required by the mining industry of the future, according to Fourie.

“We believe that students who graduate with a mining engineering degree, supplemented with rigorous training in data science, will be highly employable as well as having the flexibility to adapt to new job opportunities that are currently not even imagined,” Fourie says.

Curtin University, meanwhile, continues to promote the mining industry’s profile in a bid to increase students’ enrolments in miningrelated courses.

The university has worked with relevant stakeholders, such as Western Australian School of Mines (WASM)

Barminco apprentice induction taking place in February this year.

alumnus and Saracen Mineral Holdings managing director Raleigh Finlayson, to undertake several initiatives to specifically improve the number of female students who pursue a mining course.

It is also revising the curriculum, which will be progressively rolled out from 2020 to attract more students.

Additionally, hands-on work experience is being used to attract more interest to mining-related courses. For example, the University of Queensland (UQ) has collaborated with the Queensland Resources Council’s (QRC) member companies to secure vacation work opportunities during the

Glencore’s McArthur River Mine is joined by Darwin local Tannah Gould as she begins her metallurgy apprenticeship this year.

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first year of engineering studies.

“By enabling students to observe and experience mining and metallurgical engineers on-site as they work, we’re able to show them what a career in this sector really looks like,” UQ School of Mechanical and Mining Engineering professor Peter Knights says.

“We’ve found this has had a positive impact on the number of students who elect to study mining engineering and pursue it as a career.”

A range of mining players in the industry also persist in their efforts to cultivate and retain talent in the industry by providing real work experience to young people, if not rising their apprenticeship programs intake.

These programs are offered by companies such as BHP Billiton Mitsubishi Alliance (BMA), Glencore, Anglo American and Barminco, among many others around the country.

“We are heavily invested in and very proud of [our] program,” Barminco safety and people general manager Patrick Bourke says.

“Participation in the Barminco apprenticeship program outlines a career pathway for each apprentice in their chosen trade, and provides longer term exposure to broader career pathways from entry-level through to supervisory or senior leadership roles.”

Drill and blast

A revolutionary approach to drilling DRILLING ACTIVITIES WILL ALWAYS DEMAND DUE CARE AND ATTENTION BUT TECHNOLOGY IS HELPING TO MAKE THINGS SAFER FOR OPERATORS IN NUMEROUS WAYS. SAFE TO WORK REPORTS.

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rilling is a hazardous operation that presents several risks for mining operators. There are several methods available to miners — such as reverse circulation (RC), sonic, diamond core, air core and augers — all presenting dangers if risk is not managed correctly.

Moving or rotating parts present a serious hazard, and hand injuries are

the leading cause of drilling-related injuries. Clothes, hair and limbs pose the biggest catch risks in particular, leading to the potential for serious injuries, including scalping, amputation or even death.

Ensuring appropriate work wear and personal protective equipment (PPE) are worn, including safety hats, as well as removing jewellery, helps to prevent catching when in the vicinity of rotating

A remotely operated Epiroc drill pictured at BHP’s Yandi mine in the Pilbara. Image: Epiroc.

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and moving drill parts such as heads, masts, rods, drive shafts and several other components.

Compressed air and hydraulic systems are also a cause for concern. If an inadequate type of hose or coupling is used, a sudden expulsion of air can cause hoses and couplings to become untethered from their fittings, risking serious damage to nearby staff. This risk also extends to hydraulics as well,

with the added risk of flammability.

Modern technologies such as automation, robotics and the Industrial Internet of Things (IIoT) are helping to reduce the risks associated with drilling, however.

Remote drill rigs are becoming an increasingly popular option, with original equipment manufacturers (OEMs) such as Epiroc, Sandvik, Komatsu and Caterpillar among the notable equipment companies proving their mettle in this area.

In March 2019, for example, Sandvik introduced an operatortraining simulator for its line of remote underground drill rigs to provide operators with a quicker way to gain familiarity with the systems.

On the producer side, Rio Tinto is one of the more notable proponents of the technology, having conducted its first autonomous drill system (ADS) tests in 2008. The miner today boasts a fleet of 20 autonomous drills at its Pilbara operations, including West Angelas and Yandicoogina. Operators at Rio Tinto’s remote operations centre (ROC) in Perth are responsible for monitoring the drills.

These wireless remote controlled rigs remove operators from the vicinity of the drilling area, eliminating the associated physical dangers, as well as ancillary dangers from dust, cabin vibration and excessive noise exposure. Through the use of cameras, the drill systems are also capable of providing an improved field of view during operations by providing cameras Peter Jacobs, Asia-Pacific vice president of French drilling company Foraco International, has commented in a Global Business Reports interview that the separation of people and equipment with remote drill rigs is “the key to diminishing risks”.

In reference to his own company’s drilling technology, Jacobs claims, “We thought that the operators

would present some resistance to the technology, but they much prefer to operate the rig from a distance.”

Technology helps to reduce risks in indirect ways as well. Plasma drilling, while a relatively nascent field in the mining and oil and gas industries, has the potential to offer several benefits, for example.

Plasma drilling ejects superheated plasma capable of cutting through steel and hard rock. This is beneficial not just for the potential performance efficiencies it could bring to mining once properly commercialised, but for safety as well. Plasma drills have no moving parts, which eliminate catching issues associated with rotating bits.

Massachusetts Institute of Technology (MIT) senior research engineer Paul Woskov has developed a ‘millimetre-wave’ gyrotron beam based on similar principles that is capable of cutting through hard rock.

Since the beam is capable of crumbling rocks such as granite at temperatures just below melting point, the technology could be applicable to delicate situations where explosives can’t be used or vibrations need to be kept to a minimum.

In addition, the beam could be shaped to meet the needs of the underground environment in order to increase the tunnel’s structural strength.

“The millimetre-wave beam does not rotate so the shape of the beam will determine the shape of the borehole cross section,” says Woskov. “By using circular or elliptical shaped launch waveguides we have produced circular and elliptical holes in basalt in the laboratory.

“Using an elliptical-shaped bore hole aligned with the asymmetric subsurface stresses will increase the collapse strength of a borehole by factors of 10 or more.”

Closer to home, Geothermal Industries Australia (GIA) is also

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A plasma drill made by Slovakian company GA Drilling.

investing in geothermal drilling technologies that can help to improve the environment by delivering energy solutions from heat found in the ground. GIA managing partner and general manager Clint Patzack says the company has invested in several drilling technologies to achieve its goals.

“In the geothermal space in Australia, for renewable energy cooling systems we are using multiple drilling technologies, one of which is a technology that allows us to install casing to deeper depths using dual rotary technology, which is contributing to the success of more and more geothermal boreholes,” he says.

This is just a small sampling of projects representing new ways to approach what is one of mining’s most essential activities.

Drilling is an important contributor to Australia’s mining success, and these and other continued developments in the drilling technology space are helping to contribute to an improved safety culture for both workers and the environment.

Innovation

Rio Tinto unveils safety innovation at Amrun operation QUEENSLAND’S NEWEST BAUXITE MEGA-MINE HAS INCORPORATED A FOCUS ON INNOVATION, SAFETY AND THE ENVIRONMENT DURING THE CONSTRUCTION PHASE. SAFE TO WORK WRITES.

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io Tinto has commissioned the Amrun bauxite mine in Far North Queensland with a focus on innovation, including a number of safety initiatives.

The project has been completed ahead of schedule and as global supply of the higher-grade bauxite the site

produces becomes scarcer.

Rio Tinto, which shipped its first bauxite cargo from Amrun last December, is replacing production from the nearby, depleting East Weipa mine with the $2.6 billion mine, processing and port facilities.

The company expects to reach

a full production rate of 22.8 million tonnes a year, with options to expand, during 2019.

Rio Tinto chief executive officer Jean-Sébastien Jacques says Amrun’s development has demonstrated the company’s productivity and innovation capabilities.

Copyright © 2018 Rio Tinto

Rio Tinto officially commissioned the Amrun project in March.

SAFETOWORK 46 APR-JUN 2019

Copyright © 2018 Rio Tinto

“By applying fresh thinking we also delivered safety, environmental, cost and timing benefits,” Jacques says.

“Amrun will provide jobs, support businesses and contribute to growth in the region for the next 50 years, building on $2.2 billion of contracts with local, state and national businesses [during construction].”

Rio Tinto’s focus on innovation at Amrun has included a one-kilometre facility built in modules off site that were then delivered to the operation for connection.

The facility reduced over-water construction and painting in the culturally significant and environmentally-sensitive region and reduced construction time by a year.

It also increased safety by removing the need for 300,000 work hours that would have been spent at height and over water.

Rio Tinto growth and innovation group executive Steve McIntosh says, “Game-changing innovations and collaborations such as these are vital for advancing the future of the mining and metals industry globally in a safe, costeffective and replicable manner.”

Amrun is 40 kilometres from the East Weipa operation. Rio Tinto approved the mine, plant and export facility in 2015, with a targeted start date of 2019.

At the peak of construction, 1200 people worked at the Amrun site.

The development also included the employment of close to 400 Aboriginal and Torres Strait Islander people.

Rio Tinto used creative engineering techniques to build the mine’s wharf in a way that was safer, faster and left a lighter footprint on the local environment than more traditional methods.

The company’s bauxite integrated operations centre has been developed to oversee the way Amrun will run in real time.

According to Rio Tinto, the operations centre team uses the latest technology

Amrun is ramping up to produce 22.5 million tonnes a year of bauxite.

and tools like predictive maths, clever computer code and powerful software to run the site safely.

Rio Tinto’s focus during development has also been on the local environment.

The company has worked with Traditional Owners, independent ecologists, scientists and academics to help protect native animals like the red goshawk, the palm cockatoo and the northern quoll.

The company‘s first shipment to its alumina refinery at Gladstone in Queensland, achieved six weeks ahead of schedule, featured more than 80,000 tonnes of bauxite.

Australian Minister for Resources and Northern Australia Matt Canavan says the higher-grade bauxite being mined at Amrun is becoming scarcer around the world. “…at the same time, world consumption of alumina is forecast to escalate in coming years,” Canavan says. “These factors will underpin the future success of the operation, which is expected to have a 50-year life span.”

Rio Tinto’s bauxite-to-aluminium supply chain invests $3.7 billion in Australian wages, suppliers and community contributions every year. The aluminium business supports 5600 jobs

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across Australia, including more than half of these roles in Gladstone, Queensland.

Queensland Premier Annastacia Palaszczuk says Weipa’s bauxite will be used to make aluminium for mobile phones, aeroplanes, vehicles and many other applications around the world.

“The Amrun project is one of the sector’s proudest achievements and I am delighted to be visiting this amazing mine and its workers once again,” Palaszczuk says.

Canavan describes the development of Queensland’s bauxite resources as a fabled part of the state’s history.

“It was this development that spurred the growth of Gladstone as an aluminium powerhouse, and the creation of the best port in Australia,” Canavan says.

“Australia should not just export bauxite but refine it into higher valued products like alumina and aluminium.

To do that we must harness our clean coal resources too. Together, bauxite and coal deliver thousands of jobs, billions of dollars in wealth and a strong manufacturing sector to Australia.”

Rio Tinto produced 50.4 million tonnes of bauxite in 2018, making it the world’s leading miner of the commodity.

Materials handling

An exploded view shows Vayeron’s Smart-Idler technology inside a roller.

A new era for conveyor safety TECHNOLOGY IS MAKING CONVEYOR IDLER CHANGE-OUTS SAFER AND MORE EFFECTIVE FOR MAINTENANCE STAFF. SAFE TO WORK EXPLAINS.

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t is important to make sure idlers are kept in good working order to maximise the effectiveness of conveyor setups. Idler rollers go through a lot of wear and tear at mine sites as they support the locomotion of conveyor belts that often bear the weight of heavy loads.

Once spent, these conveyor rollers require changing, a manual handling process that can put site workers at risk in a variety of ways. Rollers can also catch hands, hair and clothing at various nip points, particularly in the spaces between the belt and carrier rollers, near drive pulleys, sprockets and other components.

Change-outs also present working

at height risks for elevated conveyors, as well as the risk of back injury and strains associated with lifting the rollers (which can easily weight between 20–50 kilograms each, depending on the roller type in question). The lifting of heavy conveyor belts to gain access to the rollers underneath can also prove a cause for concern in this regard.

“It is not unheard of for rollers to be lost off the edge of a walkway gantry and fall to the ground below, causing a serious drop hazard,” says Ryan Norris, co-founder and chief executive officer of Mackay-based tech company Vayeron.

“If we can cut-down on the quantity of rollers being changed in the industry, the frequency of these

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events will be reduced.”

Vayeron is responsible for the SmartIdler, a technology embedded inside conveyor rollers that provides real-time monitoring that can alert staff to roller failures. The company went through five years of research and development before launching last year.

Aside from the potential safety issues, which are of utmost importance, idler roller changeouts can also bring pain to the mine sites themselves due to the reduced productivity associated with production stoppages as people work to replace the components.

According to Norris, mines are wasting time, money and introducing the risk of staff injuries through excessive

A Vayeron Smart Roller installed on a conveyor at a coal handling preparation plant.

roller maintenance.

“The industry generally changes more conveyor idlers out than is necessary,” Norris says.

“Large batch change outs as a pre-emptive maintenance strategy is common and is not only wasteful but also comes with additional expense.

Additionally, batch change outs mean that personnel are engaging in a higher number of manual handling tasks than is really necessary.”

There are several companies working in the Australian mining space who are attempting to improve this situation for workers through automation. One of the more prominent examples is Sandpit Innovation, which has developed an autonomous robot called the Spidler, which can change conveyor rollers on the fly, eliminating the need for workers to become involved.

The machine sits above the conveyor on a specially built gantry system and lifts the belt while it is still running before using a robot arm to remove the old roller to replace it. The majority of the belt length can be serviced by the Spidler, which also influences the upstream part of the process.

Company director Aaron Carter says that the Spidler was developed as part of Sandpit’s vision for the “conveyor of the future” in response to a mining client that had endured several staff injuries as a result of batch roller changeouts.

While other robotic roller changers,

they are usually truck-mounted, which means they lack the improved access of Spidler’s gantry-mounted system.

“Obviously everyone likes to think of the production benefits of not having to stop a belt but from a safety benefit perspective it’s also significant,” Carter tells Safe to Work. “On any given mine site they’re changing thousands of rollers by hand, so the whole concept behind the Spidler was to remove the lifting of the belt and the manhandling of replacing a roller along 90–95 per cent of the length of the belt.”

The Spidler can also offer indirect safety benefits through its condition monitoring technology, which can check the rollers’ operating temperature with thermographic imaging.

Conveyor belts can catch fire as can combustible material transported via a conveyor. Common causes of conveyor fires include friction due to misalignment or a loss of belt traction, as well as belts that have combustible residue on their surface. However, conveyor roller

failure is a leading cause. The motion of conveyors can also cause fire to spread quickly, which is an additional incentive for effective monitoring.

“We can get really good, reproducible scans of temperature over time,” Carter says. “For example, we can see the same temperature in the same operating environment on the same roller multiple times a day or once every day, so that understanding of the temperature zones is really good for detecting a threshold breach or abnormality in temperature.”

Norris says Vayeron’s heat monitoring is particularly beneficial for underground coal mining operations, where manual monitoring of rollers is not always practical.

“In Australia, there is a statutory requirement to monitor and limit all surface temperatures to below 150 degrees Celsius,” Norris says. “Until now, this has been impossible to do for conveyor rollers due to the sheer quantity of bearings that needs to be tracked and as a result, underground coal mines would routinely break their statutory obligations. Smart-Idler now provides them a way to ensure that no conveyor roller bearing overheats to these limits and goes unnoticed.”

Automation and condition monitoring technology could revolutionise conversations concerning conveyor safety over the next few years as the pace of mining’s digitisation continues to pick up and companies such as Vayeron and Sandpit are well met to meet these safety needs.

A CG model of Sandpit Innovation’s second-generation Spidler.

SAFETOWORK 49 APR-JUN 2019

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Workforce management

Mining finds competition when attracting and retaining skills SKILLS SHORTAGES CONTINUE TO BE AN ISSUE FOR THE MINING INDUSTRY AS IT SEARCHES FOR WAYS TO ATTRACT THE TALENT NEEDED IN THE INDUSTRY. SAFE TO WORK REPORTS.

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ecruitment agency Hays expects skills shortages in mining to be a major concern as the sector competes with other growth industries around Australia.

The agency has this year revealed that a wide range of mining jobs are in demand due to escalating skills shortages.

Hays’ findings confirm that the shortages have become a national issue after they first re-emerged in the key mining states of Western Australia and Queensland up to 18 months ago.

A Hays report shows that South Australia, New South Wales and the Northern Territory have several areas of concerns, including engineers, geologists, operators and electricians.

The mining resurgence in Tasmania and Victoria has meant that those states are also starting to feel shortages as activity increases.

Hays WA state director Chris Kent says with many skills transferring to the civil infrastructure sector there is no doubt that sourcing talent is a national concern for the mining industry.

“As more major transport projects ramp up in 2019 in Australia’s most populous cities of Melbourne and Sydney, several multibillion dollar mine expansions will be looking to lure engineering and construction

Recruitment for FIFO positions has ramped up.

talent to our mining regions. Wage pressure is inevitable over the coming months,” Kent says.

Kent adds that mining and METS (mining equipment, technology and services) companies are looking at new recruitment methods to source employees and overcome the skill shortages.

“More broadly the sector is trying to attract new talent by demonstrating the social impact of their products on a clean energy future i.e. lithium and copper as vital components of electric cars,” Kent says.

“Experienced workers are being enticed by more family friendly

SAFETOWORK 51 APR-JUN 2019

‘even time’ rosters, as well as more technology focused, city-based roles as automation reduces high risk, remote work.”

Fitzroy Australia Resources has taken the approach to target workers without previous mining experience for its Ironbark No. 1 underground coal project in Queensland.

The company will require 350 workers for the operation, with the employees expected be an even split of new and experienced personnel.

METS companies join miners like Fitzroy in seeking ways to avoid skills shortages that could impact their contracts or service offering.

Workforce management

Automation provides job competition of a different kind to mining.

Kent says all companies in the mining supply chain are being affected to some extent.

“At the moment it is impacting mining services companies, specialist contractors who don’t have the margins to increase wages, as well as the junior to mid-tier operators who don’t have the brand to attract new talent,” Kent says.

Kent recommends that mining and METS companies focus on their employer value proposition with a multi-pronged approach for bringing in new talent from TAFEs or universities to help source workers.

As skills shortages emerge, the impact of automation on the industry is gradually changing the type of talent that mining companies must source.

Kent sees automation already being regularly used to take over the repetitive, routine and often dangerous aspects of jobs in sectors such as the Pilbara iron ore industry.

The global miners in the Pilbara have significantly changed their operations

to include dozens of automated trucks and drills at some sites. In the coming years, other sectors such as coal and gold are expected to follow iron ore in this direction.

Kent believes the increasing use of automation in these areas is freeing up people’s time to focus on the higher-value job responsibilities, removing some of the risk of working in these conditions.

“However, there’s a catch – people need to upskill to ensure their skills remain relevant and employable,” Kent says.

“Given the world-class nature of the Pilbara’s mining region and the companies and workers operating there, their local knowledge will remain highly sought after even as the nature of the roles change.

“There’s some debate over who is responsible for this upskilling – employees or employers. I think the answer for organisations is probably a combination of looking for people

SAFETOWORK 52 APR-JUN 2019

with a constant learning mind set and upskilling existing staff in the areas they’ve identified through a skills assessment as essential to the organisation’s future.”

Kent says the transition to automation will mean employers and employees partner on their career longevity for mutual benefit. The employer will train staff in the skills lacked at the company or that are suffering from skills shortages.

Employees, meanwhile, will have to learn skills that keep them relevant and employable once the repetitive and routine aspects of their job are automated.

“Employers must be open and honest in their communications with staff and offer appropriate upskilling.

Provided employers upskill workers who have had their routine tasks taken over by automation and help them become a more highly-skilled employee, then it could have an overall positive impact,” Kent concludes.

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Miners offer a helping hand for Queensland

(Image: Robert Hiette/Shutterstock.com)

THE MINING INDUSTRY HAS SHOWN ITS SUPPORT FOR NORTH QUEENSLAND FOLLOWING THE FLOODING THAT DEVASTATED THE REGION OVER SUMMER. SAFE TO WORK WRITES.

Floods impact the suburb of Annandale in Townsville, Queensland in February.

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ueensland was privy to some of its worst flooding in years when a monsoon trough battered parts of the state in January and February.

In certain communities, such as the northern centres of Townsville and Ravenswood, the deluge destroyed houses and other buildings, leaving hundreds homeless and causing millions of dollars of property damage.

The rains started on January 25 and

by February 1, Queensland Premier Annastacia Palaszczuk declared an emergency situation in Townsville.

Mining companies were also affected by the flooding, including Resolute Mining, which luckily avoided

damage at its Ravenswood gold mine.

For Glencore, it was a different story.

The company announced on February 6 that production was impacted at the Collinsville and Newlands coal mines because of flooding.

A Pacific National train, which had been stuck on a section of track at Nelia on the Queensland Rail Mount Isa line for a week, was inundated by floodwater along a section of the Mount Isa line the following day.

The incident caused the train, carrying 80 wagons of copper anode, zinc and lead, to derail and spill product into the water.

Queensland Rail swiftly responded with repairs to the line between

SAFETOWORK 54 APR-JUN 2019

Cloncurry and Richmond.

The 1000-kilometre rail line services companies such as South32, MMG, and Incitec Pivot, which estimated the outage would contribute to a $100120 million hit to its Phosphate Hill operations near Mt Isa. Palaszczuk launched an appeal with a $200,000 donation, with the Australian Red Cross, Salvation Army, UnitingCare and the above-mentioned St Vincent de Paul Society Queensland as non-government partners.

Several mining companies also donated to the flood recovery effort after the appeal was launched.

Queensland Resources Council chief executive Ian Macfarlane stresses the

mining sector’s support for Queensland during the crucial period, saying that “every dollar” helps North Queensland towards a strong recovery.

He references a government announcement that revealed more than $4.4 million has been donated to the recovery.

“I am proud the resources sector has contributed more than $3 million – or almost three quarters – of those donations,” he says.

Glencore, one of Townsville’s largest employers, donated $1 million towards the cleanup. The company has worked with Queensland Rail to identify and manage the impacts from the spill of the train’s minerals into local flood waters.

South32, which has a large workforce based in and around Townsville, also donated $1 million to the St Vincent de Paul Society Queensland flood appeal to help with food and accommodation for displaced residents. South32 chief executive Graham Kerr, who has lived in Townsville, says seeing the flood images highlights the impact on the community and basic services.

“My thoughts are with our employees, their families, and everyone affected by this disaster,” Kerr says.

MMG donated $250,000 for Townsville and Cloncurry, while Incitec Pivot, affected more than most by the floods in the financial sense, donated $100,000. Anglo American donated $200,000 to Queensland not-forprofit GIVIT, and QCoal Foundation and Adani Australia $100,000 each.

In addition, BHP and Aurizon also contributed $250,000 each.

According to Aurizon managing director Andrew Harding, the company wanted to play a helping hand in the recovery as many of its employees live and work in the region.

“Supporting charities and community groups and the important work they do is something we are proud of at Aurizon,

Aurizon supported its presence in the region by helping with the recovery.

“I am proud the resources sector has contributed more than $3 million – or almost three quarters – of those donations.” and never is it more important than at a difficult time like this,” Harding says.

By mid-February, donations from resources companies reached the $3 million mark of a total $4.4 million, according to the Queensland Government.

The floods heavily affected farmers, in particular, due to the devastating loss of livestock. The number of cows that died as a result of the floods is estimated at around 500,000, a situation requiring mass organisation simply to arrange disposal of the animals.

Glencore provided access to the Ernst Henry copper-gold mine site northeast of Cloncurry, including the use of loaders and forklifts, to support hay (fodder) drops for cattle. South32, likewise, organised the use of heavy equipment for farmers to help with the disposal of the carcasses.

SAFETOWORK 55 APR-JUN 2019

By early March, repair crews had opened the Richmond to Hughenden section of the Mount Isa line. These repairs allowed Glencore to truck its product to Hughenden for rail transport to Port Hedland, with Incitec Pivot doing the same via Richmond.

The line between Cloncurry and Richmond is still under repair, however, at the time of writing.

Queensland Rail has estimated that the entire line will reopen sometime between late April and mid-May. The company has also partnered with the Queensland Department of Public Works and Housing to build worker camps capable of housing over 400 workers at Richmond and Julia Creek.

While the floods may have left an indelible mark on the landscape of North Queensland, they have served to bring people together in a time of need.

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ME L B O U R N E CO N V E N T I O N & EXHIBITION CENTRE

Lighting

Shining a light on mining safety

A CG model of a P&H rope shovel using the Danger Light.

LIGHTING COMPANIES ARE FULL OF BRIGHT IDEAS WHEN IT COMES TO SAFER MINING. SAFE TO WORK REPORTS.

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hether it’s the late shift at an open pit or a deep delve into an underground tunnel, mine sites can be dark and dingy working environments.

It is therefore important that operators maintain sufficient lighting standards to keep workers safe from danger.

A dark environment not only introduces the risk of trips, falls and other physical injuries, but can also be bad for the eyes.

When 33 miners were rescued from the collapsed San José coppergold mine in the Atacama region of Chile in 2010 after more than two months underground, they were given sunglasses as a precautionary measure to protect their eyes from the reintroduction to sunlight.

Likewise, miners’ nystagmus, a vision-impairing disease causing involuntary movement of the eyes — while now essentially unheard of in the

industry — was noted to be a common affliction among coal miners in Britain in the early- to mid-20th century In Australia, there is not one overriding safety standard when it comes to mine lighting. The closest equivalent legislation is the Australian Standard AS/NZS 1680.2.4:2017, which is a general application related to interior and workplace lighting.

Queensland has perhaps the most stringent mining-specific rules in place for lighting among Australia’s states and

territories. The Coal Mining Safety and Health Act 1999 and the Coal Mining Safety and Health Regulation 2017 apply to coal mining in Queensland, while the Mining and Quarrying Safety and Health Act 1999 and Mining and Quarrying Safety and Health Regulation 2017 apply to Queensland mineral (i.e. non-coal) mines.

“Under this legislation, mines must manage risk to an acceptable level, which involves undertaking risk assessment specific to the activities

The Danger Light was released globally last year.

SAFETOWORK 57 APR-JUN 2019

Lighting

Mineglow’s x-Glo lights installed in a tunnel at the Grasstree mine in Queensland.

they are undertaking,” a Department of Natural Resources, Mines and Energy (DNRME) spokesperson tells Safe to Work.

“This legislation may call up other standards which may directly or indirectly apply to risk management in respect of lighting, depending upon the particular circumstances.”

In open cut mines, the biggest lighting needs to come from night-time operations, particularly for haul truck and mobile plant operators, which represent the largest collision risk.

United States company Phoenix Lighting worked with a South American mine to develop a safety light tailored for hydraulic rope shovels. The result of the project is the Danger Light, a product released globally last year.

The Danger Light is designed to provide a bright red outline of the radial danger area surrounding the shovel, which can also be extended to similar hydraulic rotating machinery such as drills and excavators.

Phoenix marketing director Melissa Stephany says collision prevention is the key safety benefit of the technology.

“We did an extensive trial in the field to ensure that we hit all the needs

of operators and truly did enhance safety,” she says.

“The Danger Light provides a visual border around the shovel so haul truck drivers can see where the danger zone is and won’t get struck during the loading process. This would also apply to pedestrians or other vehicles in the area.”

New South Wales-based Mineglow is another lighting company seeking to improve lighting conditions, from open pit dangers to the depths of the underground, both in Australia and overseas.

Mineglow has created the x-Glo system, a form of cabled LED strip lighting that is wrapped up and unspooled where required, providing a low-maintenance alternative to typical underground lighting setups.

The LEDs inside the product’s tubing — available in either PVC or silicone — provide a 180-degree spread of light by design at a range of 12-60 LEDs per metre.

The company’s client base includes several Tier 1 operators in Australia, such as Rio Tinto, Newcrest Mining, Evolution Mining and BHP. Mineglow’s Carinne Pater says the

SAFETOWORK 58 APR-JUN 2019

lights have been specced to provide daylight conditions underground.

“The lights can roll out to emit anywhere from 42 metres to 168 metres of continuous light in encapsulated PVC or silicon,” she says.

“It exposes areas where there is insufficient light. You’re not going to trip over anything, you can see everything properly and it makes working underground feel better.”

The lights also don’t generate heat, which makes them well suited to underground environments that contain flammable gases and other combustible materials (particularly coal mines). In addition, the setup of the lights helps to cut down on cable management, further reducing trip hazards.

The company has experimented with the x-Glo lights in other ways, too. The lights were used in trials of a safety evacuation system at FreeportMcMoRan’s Grasberg gold-copper mine in Indonesia. The lights were designed to pulse during tremors to alert workers to the direction of the exit.

While the testing was successful, the project did not develop beyond this stage into commercialisation. x-Glo subsequently found renewed purpose, however, as a traffic system at an open cut mine in Africa designed to help haul truck drivers navigate safe braking distances on inclines.

“Our system alerts drivers to say, ‘Once you’re in the green zone, start applying your retarder brake’,” Pater explains. “‘Then, once you’re in amber, you should already have the brake engaged, and once you get to red you need to have started braking already.”

Mining technology is continually improving, and lighting is no exception.

As long as the industry continues to prioritise safety as its top concern, designers will step up to show the light at the end of the tunnel.

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THE FIRST PRIORITY FOR AUSTRALIA’S MINING INDUSTRY

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2019 | APR-JUN | ISSUE 03

Published quarterly, the magazine includes interviews with prominent industry figures, and profiles on people and companies innovating and developing a safer industry.

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Culture

Making relationships a high priority CURIOSITY IS THE NEW EMPATHY IN THE WORKPLACE. AN AUSTRALIAN EMPLOYEE ASSISTANCE PROVIDER TELLS SAFE TO WORK OF SIMPLE WAYS TO INCREASE EMPATHY AND CREATE A MORE INCLUSIVE WORK ENVIRONMENT FOR BOTH LEADERS AND TEAM MEMBERS.

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howing interest in an employee’s life and background creates a more harmonious workplace – a gesture that is not only reserved for home and family life.

The desire to know a person more intimately – also called empathic curiosity – significantly improves workplace culture and makes workplace relationships stronger.

When asked respectfully and with curiosity, questions help to improve connection and relationships. In turn, stronger connections lead to improved teamwork and collaboration, while increasing morale and productivity.

Empathetic leaders often display increased emotional intelligence and are better at creating a more inclusive workplace, according to clinical director at employee assistance provider AccessEAP Marcela Slepica.

“It is said that ‘nobody cares how much you know until they know how much you care’, and this is certainly true in a workplace setting,” Slepica says.

A study in the United States shows that nine in 10 employees are more likely to stay with an organisation that empathised with their needs, and 80 per cent will be willing to work longer hours for an empathetic employer.

Empathic curiosity, instead of just wondering what people do for a living or feeling empathetic, allows one to wonder why they do it. It’s this conscious, careful

and wonder of empathetic curiosity that allows people to learn what it’s really like to live in others’ shoes, according to AccessEAP. “Employees who feel cared for and are valued are more productive, innovative and loyal,” Slepica says.

“Without growth and innovation, businesses stagnate and fade away. By understanding others, we develop closer relationships and start to build trust which is essential for success in every business.”

Thankfully, empathy is a trait that can be developed. Slepica says empathetic leaders spend more time listening than talking, as they want to understand the difficulties other face.

Organisations should create opportunities for dialogue between leaders and employees where everyone speaks their mind in an open environment.

Asking questions also shows others that one is giving them attention, cares about what they say and it makes them feel like they are being heard. This will make them feel more valued.

“In conflict situations, asking curious questions leads to better outcomes as people are given an opportunity to have their side heard, which in turn helps understanding and may avoid assumptions,” Slepica says.

Embracing different backgrounds, genders, cultural heritage, ages and working styles can further create

SAFETOWORK 61 APR-JUN 2019

Genuine curiosity can create a more inclusive work environment.

empathy in the workplace.

Being respectfully curious about the backgrounds and particular needs of one’s team will help them feel more valued and bring the best out of them.

Understanding different cultures and their styles allows for more effective management.

A leader should also respect the need for flexibility by taking time to understand the need for time off for personal or family issues, or the need for flexible working hours.

“Often people leave managers, not jobs,” Slepica says.

Empathetic curiosity is also a learned skill that can grow with practice, so individuals have a chance to be more inquisitive in day-to-day activities and interactions through words and actions.

This is essential in today’s workplaces where five generations are working side by side.

Working at heights Employers should be aware of minimising the amount of working at heights activity that needs to be done, wherever possible.

Safe and secure above ground SAFESCAPE GENERAL MANAGER ALLISON DEADMAN TELLS VANESSA ZHOU ABOUT THE IMPLICATIONS OF WORKING AT HEIGHTS WHILE KEEPING SAFETY IN FOCUS.

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afescape commenced in 2010 with the first installation of an escapeway ladder at Kirkland Lake Gold’s Fosterville underground mine in Victoria.

The ladder, known as Laddertube, is made of strong yet lightweight plastic that is more easily and safely installed in underground mines, as opposed to traditional steel escapeways. Laddertube is fully enclosed so it keeps out rocks, water and salt build up.

Safescape now has over 700 ladders in more than 100 mines across 19 countries, contributing to the 30,000plus metres of Laddertube escapeway installed since the company was founded nine years ago.

Safe to Work speaks with Safescape general manager Allison Deadman about the considerations for working at heights.

What has been your journey to becoming a leader at Safescape?

I have around 20 years of experience in the mining industry in both contract mining and mining companies. My involvement with Safescape came about as a result of working with the owner and managing director of Safescape Steve Durkin in a previous company. His experience with escape way ladders in a contract mining environment motivated him to look at a different way to do things, to change a job that he knew was intrinsically

SAFETOWORK 62 APR-JUN 2019

dangerous. His understanding of the risks associated with installing steel ladders in a harsh underground environment led him to invent the Laddertube. When he was ready to commercialise it, he invited me to come on board. That was in 2010. I love the industry and the people that work in it.

There’s always something interesting or exciting happening.

You said there were dangers associated with ladder installation in underground mines. Care to elaborate?

Traditionally, you’re talking about either a wooden or steel ladder being installed in a raise, whether that be a blasted

“There will always be people who are required to work at heights. It’s a matter of ensuring we have the right solution for the job, the circumstances they’re facing and the industry they’re in.” or raise bored. So you’ve got people working in conditions where they’re exposed to open ground. Laddertube is installed from the top down. That means installers are working above the rise or hole, or inside the ladder as it is anchored to the footwall. The process is quicker and safer. For users, it means they are not exposed to rock and water in an open raise as they climb, in addition to climbing on a flat step using fall arrest.

that companies are doing everything within their power to provide the appropriate training, ongoing support and equipment that employees need to stay safe in their jobs.

How has fall prevention technology evolved?

There’s a huge shift since the time I started working in the mining sector, from very simple things such as the

What are the most important things that employers and workers need to pay attention to while working at heights?

There’s an expectation that workers are provided with appropriate training for jobs with work-at-heights exposure.

As employers, we need to continue educating our employees and minimise their exposure to working at heights, where possible. Employers also need to make sure workers are aware of the tools and equipment that are available to keep them safe, while remaining conscious of the environment they’re in.

Do you think companies have been proactive in educating their workers in this respect?

Definitely, I think it’s a given these days. I don’t think there’s any question

Laddertube is made of strong, lightweight plastic, instead of the traditionally used stainless steel.

SAFETOWORK 63 APR-JUN 2019

clothing we wear, right through to the systems that are made available to keep people safe. On the most part, there’s such a range of options now to ensure we can find something suitable for specific applications. This means we can provide people with safety equipment that is both comfortable and effective.

What future considerations should people be mindful of?

Being able to minimise the amount of working at heights work that needs to be done wherever possible, and what we can do to minimise those risks when work at heights is necessary.

I think there will always be people who are required to work at heights.

It’s a matter of ensuring we have the right solution for the job people are doing, the circumstances they’re facing and the industry they’re in. I believe that producers of fall prevention equipment are really conscious of this, and are continually providing new and improved products.

Product focus

A disposable glove like no other

The Megaman glove is tougher than most disposables, offering level 2 abrasion resistance.

AUSTRALIA’S LEADING SUPPLIER OF HAND AND EYE PROTECTION, SAFETY MATE, BRINGS UNPRECEDENTED STRENGTH TO THE HUMBLE DISPOSABLE WORK GLOVE WITH SW SAFETY’S MEGAMAN RANGE.

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brasion resistance is not typically synonymous with disposable gloves. Megaman is setting a new standard, not only in terms of strength, but hand health and environmental sustainability.

Despite being disposable, the range offers level two abrasion resistance for improved working durability.

Most disposable work gloves only

offer level one abrasion resistance (up to 100 cycles), or no abrasion rating at all. Megaman offers five times the number of cycles, providing a significant advantage in this regard.

However, proprietary technology means that the glove goes beyond serving as a barrier from the elements. SW’s patented hand health technologies actually protect skin,

SAFETOWORK 64 APR-JUN 2019

managing the things that cause irritation, dryness and chapping in an occlusive environment.

Safety Mate national sales manager, Wade Roberson says the line has been particularly popular with companies’ maintenance divisions, which have a need for disposable gloves that can withstand an unusual degree of punishment.

“Level two abrasion resistance is a unique feature of the Megaman glove. That level is more akin to a nondisposable glove,” Roberson tells Safe to Work.

“Sweat management and hand health are also standout features of the range. Not only do these technologies keep hands drier and more comfortable, they also greatly reduce the chance of chemicals being absorbed through the skin. Thus, avoiding contamination which can lead to painful reactions and long-term health issues.”

The fully-textured Megaman glove is made of latex-free nitrile and is also dermatologically approved by the Skin Health Alliance.

Unusually for a disposable glove, Megaman is flock-lined with natural cotton fibres to help with sweat and comfort. The textured grip provides improved handling for users. The cuff is also beaded to make the glove easy to don and remove.

The proprietary technologies that the manufacturer has included in the glove are DriTek, TouchTek, MilTek and EcoTek. DriTek lining wick’s away moisture inside the glove to improve comfort levels and reduce slippage. TouchTek helps to take care of the hands by protecting from irritants and contaminants.

It does this by removing chemicals used in the glove’s manufacture from the final product, increasing external protection while neutralising the inside of the glove.

The post-processing process used to remove these chemicals can leave the glove up to 75 per cent ‘cleaner’ than other gloves on the market.

EcoTek relates to the gloves’ biodegradability, ensuring that 96 per cent of the glove will break down within the first three years of disposal.

“A specialised production process ensures the thickness gradient across fingers, palm and cuff gets as close to zero as possible.”

“From an environmental perspective, there are more disposable gloves sold in the world than every other type of glove combined.

Biodegradability is a huge benefit as it will breakdown when it does eventually go to landfill – we won’t have loads of gloves sitting in landfill for thousands of years,” Roberson explains.

MilTek, meanwhile, delivers improved consistency of thickness across the entire glove, minimising thickness differences from finger to palm and palm to cuff. This feature also helps to improve the overall durability and tactility of the glove.

A specialised production process ensures the thickness gradient across fingers, palm and cuff gets as close to zero as possible.

It is especially beneficial as the consistent lining means that the material is less likely to break at the cuff, which is usually the weakest part of a disposable glove’s construction.

“Typically, when a glove is manufactured they dip a ceramic former into the material that runs down the fingertips. It’s a common theme with disposable gloves that you tend to break a lot of cuffs,” says Roberson.

“This is because there’s more thickness at the fingertips and less thickness at the cuffs. Having consistency across the entire glove from finger to cuff ensures that the cuff is a lot stronger with less chance of a breakage.”

SAFETOWORK 65 APR-JUN 2019

SW Safety’s other gloves in the product line of disposables include the PowerForm S6, Stellar S6 and Aloetuff glove, all of which are dermatologically approved by the Skin Health Alliance.

Aloetuff also includes ACTIValoe to help skin health while PowerForm S6 is designed for laboratory environments.

Roberson says the Megaman glove, however, is as close as a disposable glove can get to breaking out of its category.

“It’s so easy to don and easy to take off so you can reuse it over and over again. It is classified as a disposable product but we’ve pretty much named it a ‘reusable disposable’ because it’s a strong, durable glove that offers great dexterity for work environments,” Roberson concludes.

Fast Fact Megaman is one of several single use gloves offered by SW Safety.

Others include the Powertuff, Powerform, Neotuff, Aloetuff, Color-Q, Hydrex and Hypersense lines, among others.

Founded in 1984 by Madam Kao and led by her daughter Belle Chou, the California, United States-based company is now considered a leading hand protection company.

It also manufactures chemicalresistant and cut-resistant reusable gloves through its GraphEx, CoreSafe and TexSolv lines, respectively.

Events CONFERENCES, SEMINARS & WORKSHOPS EVENT SUBMISSIONS CAN BE EMAILED TO EDITOR@SAFETOWORK.COM.AU

AUSTMINE 2019: MINING INNOVATION: THE NEXT HORIZON, BRISBANE, MAY 21–23

QUEENSLAND MINING INDUSTRY HEALTH & SAFETY CONFERENCE, GOLD COAST, AUGUST 18–21

Austmine is taking its biennial conference to Brisbane in 2019. The event will continue to feature the best in innovation from around the world. Over the course of three days there will be workshops, presentations, case studies, networking and Austmine’s mining industry awards. The comprehensive program features a high calibre selection of international and Australian speakers, paired with first-class and innovative content. The exhibition will present a stellar display of technology, services and solutions that can be discussed in a face-toface environment.

• austmineconference.com.au

The annual Queensland Mining Industry Health and Safety Conference is hosted jointly by the Queensland Government, Queensland Resources Council, and mining unions (CFMEU and AWU). The threeday conference continues to be one of the largest health and safety conferences in the southern hemisphere. It is designed to provide Queensland resources companies with valuable information on critical issues that may impact on the sector. The gathering also celebrates the ingenuity of practice homegrown safety through state-wide innovation and health awards. The event will start with a luncheon on Sunday August 18 and conclude with the conference dinner on August 21.

• qldminingsafety.org.au

NSW MINING HSEC CONFERENCE AND AWARDS DINNER, HUNTER VALLEY, AUGUST 5–7 With over 600 delegates in attendance in 2018, industry leaders, senior government representatives, as well as health, safety, environment and community (HSEC) professionals will be back again this year.

Discussion will be held to address operational and regulatory challenges, issues and opportunities in the NSW resources industry.

Topics range from risk, communications and safety to rehabilitation, mine closure planning and community engagement. The NSW Mining HSEC Awards recognises leading practice and celebrate innovation and excellence.

• nswmining.com.au

MINE VENTILATION CONFERENCE 2019, PERTH, AUGUST 26–28 Ventilation controls are one of the core risk activities in mines. Significant developments in practice and research in recent years have helped ensure we maintain and improve levels of safety within our underground mining sector. The Australian Mine Ventilation Conference 2019 calls on expertise to present these developments, explore achievements and build a better industry. The conference will give presenters the chance to exchange information on topics such as: ventilation planning, main and boster fans, heat and refrigeration, coal mine ventilation, hard rock mine ventilation, sulphide dust explosions, and more.

• minevent.ausimm.com

SAFETOWORK 66 APR-JUN 2019

AIMEX, SYDNEY, AUGUST 27–29 The largest free-to-attend mining conference in Australia returns to Sydney in 2019.

The conference is designed as a platform to facilitate discussions around mining techniques and deliver operational improvements. Key themes of the conference include developments in drilling and blasting, processing and bulk materials handling; automation and digital advancements to improve operational efficiency and maintenance; and fleet performance and tyre management. The program offers visitors the opportunity to create a personalised program that addresses specific areas related to their job function or site.

• aimex.com.au

2019 AUSTRALIAN MINING PROSPECT AWARDS, BRISBANE, OCTOBER 10 The Australian mining industry’s biggest awards celebration is heading to the Sunshine State for the first time this year. With coal becoming the nation’s biggest mining export this year, the timing couldn’t be better to celebrate the industry’s contribution in Queensland. The 2019 Australian Mining Prospect Awards will take place at Moda Events in Brisbane on October 10, honouring the best and brightest of an industry that prides itself as a cultural and economic cornerstone.

• prospectawards.com.au

THE FIRST PRIORITY FOR AUSTRALIA’S MINING INDUSTRY

ISSUE 3 - APRIL-JUNE 2019

2019 | APR-JUN | ISSUE 03 SAFETOWORK.COM.AU

Risk management Safety around mining tyres Dust suppression

Training

Technology

Materials handling

Throughout the cycles of the mining industry there is one constant for everyone involved in the industry – safety. A safe workplace is critical to the continued success of your business.

Launched in 2018, Safe To Work provides a high-quality, multi-platform publication for the Australian mining sector, with safety as its key focus.

Safe To Work’s promotional features deliver a forum for organisations to showcase the role each aspect of safety plays in helping the industry achieve the industry’s No. 1 priority.

TO BOOK IN SAFE TO WORK CONTACT JONATHAN DUCKETT NOW JONATHAN.DUCKETT@PRIMECREATIVE.COM.AU | 0498 091 027

A SHINING LIGHT: HOW MINEARC IS REVOLUTIONIZING THE CAP LAMP INDUSTRY The new SiriUS Cap Lamp by MineARC Systems redefines wearable lighting designed for underground environments.

Specially engineered to improve efficiency and visibility; ensuring safe operations, the cap lamp is an essential element in Personal Protective Equipment (PPE). SiriUS provides a quality and reliable lighting solution; combining dual beams, superior colour rendering and a robust design.

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ROBUST & RELIABLE DESIGN TWO UNIQUE BEAMS MULTIPLE MODES FOR EVERY SITUATION UNPARALELLED COLOUR ACCURACY COST SAVING CHARGING SOLUTION RFID TRACKING WATERPROOF AND DIRTPROOF

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www.minearc.com