THE FIRST PRIORITY FOR AUSTRALIA’S MINING INDUSTRY
ISSUE 11 - JANUARY/FEBRUARY 2021
Tyre management Mitigating critical risks
OFFICIAL MEDIA PARTNERS
Emergency response
Workforce management
Technology
Working at heights
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Comment Turning tyre management risks into an opportunity TYRE MANAGEMENT IS AN IMPORTANT MAINTENANCE DISCIPLINE THAT POSES A NUMBER OF SAFETY RISKS BUT ALSO OPPORTUNITIES.
BEN CREAGH
T
he safety of tyre management workers at mine sites carries its own unique risks. Having visited mine sites and watched tyre management teams in action, it is impressive to see the innovation being introduced in this area to improve safety. The level of sophistication that is being demonstrated in tyre bays is increasing at a rapid rate, putting one of the less glamorous areas of a mine site in the spotlight. Managing the risks posed by the sheer size of mining tyres, with some measuring up to four metres in height, remains at the forefront of tyre management. The weight of tyres and the tools used to manage them can potentially cause serious injury to both mine workers and tyre handlers without the proper safety awareness. With air pressure as high as 110 psi in mining tyres, they also hold an incredible amount of energy that must be controlled. A strong culture that includes training, awareness, tooling and
VANESSA ZHOU Tel: (03) 9690 8766 Email: vanessa.zhou@primecreative.com.au PUBLISHER CHRISTINE CLANCY MANAGING EDITOR BEN CREAGH Tel: (03) 9690 8766 Email: ben.creagh@primecreative.com.au JOURNALISTS SALOMAE HASELGROVE Tel: (03) 9690 8766 Email: salomae.haselgrove@primecreative.com.au
CLIENT SUCCESS MANAGER JANINE CLEMENTS Tel: (02) 9439 7227 Email: janine.clements@primecreative.com.au SALES MANAGER JONATHAN DUCKETT Mob: 0498 091 027 Email: jonathan.duckett@primecreative.com.au
safe work programs is essential for tyre management teams to effectively harness the risks around mining tyres. A complete approach creates a tyre management team that not only stays on top of scheduled activities, but also the reactive nature of this maintenance discipline when breakdowns or blowouts require a rapid response. This has pushed tyre management in mining beyond the typical day-to-day activities aimed at improving the safety and productivity of operations. Mining companies are pursuing METS (mining equipment, technology and services) companies that can offer innovation in this area. New technologies are being developed that monitor performance and help with the selection of tyres for safety and productivity purposes. Even more critical, innovative new tyre management tools and equipment are directly making maintenance an easier process at mine sites. They are also removing the
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limitations on who is capable of being a tyre handler, with tyre management becoming a more diverse and inclusive profession for workforces. In this edition, we include a special feature on tyre management, including an upclose look at the latest trends in the sector, as well as the new technologies and solutions that have been introduced.
Ben Creagh Managing Editor
FRONT COVER Kal Tire developing tyre management expertise. Image: Kal Tire
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In this issue Features
50
14 Mining companies
overcome challenges COVID-19, climate change, compliance risks to consider
18 Bracing for natural incidents
Western Areas puts out fire risks
22 NSW trials breakthrough
technology Real-time silica monitoring tech emerges
ME SAFE secures lost drill rods in up holes
technicians
HP, MinRes, Goldfields take B people-first approach
26 Technology makes tyre
Kal Tire helps solve hiring challenges
42 Communication as a
34 Eyes on automotive
monitoring safer
40 Removing drill rod hazards
32 Building next-gen tyre
24 Thriving during the pandemic
safety tool Sepura embeds innovation in TETRA
equipment Audio-visual offerings from Chipatronic
SM introduces TMSystems for L industrial tyres
radios
44 A home away from home
36 Managing heat stress
28 Stopping tyre corrosion
ITW introduces Rimtreat-X corrosion inhibitor
Wiluna, IGO put the spotlight on FIFO
Technology comes to the rescue
wellbeing
46 Staying alert at work
38 Long-term working at heights
solution Bend-tech Group addresses falls,
30 Introducing Titan220e Worry-free way to lifting haul trucks
trips and slips
Simple ways to reduce worker fatigue
48 Unveiling mental health challenges Gold Industry Group, LIVIN opt for simple approach
50 A positive take on crises
Austmine in conversation with Engenium
53 Towards zero tolerance for harm
Weir Minerals triumphs over high-risk environment
56 Intertwining safety with
hygiene
Industrial cleaning according to CRC
18
REGULARS
6 NEWS
12 PRODUCTS
58 EVENTS
SAFETOWORK.COM.AU 4 JAN-FEB 2021
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News Newmont to minimise technology distractions
The Boddington gold mine in Western Australia. Credit: Newmont
Newmont chief technology officer Dean Gehring has warned that the introduction of new technologies can cause distractions on site. Gehring, speaking at IMARC 2020, said mining companies needed to bring transparency to innovation to minimise distraction and maximise the benefits of new technologies. Newmont has built a centralised framework for its technology projects, which includes the three stages of diagnose,
design and deliver. It helps to ensure that operators take into account the unique characteristics of orebodies, operator skill levels and reliable control systems. “(Otherwise), you end up with a situation where the plant operator develops their own tricks and their own personal plant settings,” Gehring said. “They often feel they’re optimising the plant performance, but in fact,
many of those practices are overly conservative.” According to Gehring, this is why having a standardised control system design benefits a technology project. Newmont uses “the most talented subject matter experts” to develop a process control standard that maximises plant performance. “We have the scale to deliver large projects. We are also small enough to get all the top functional and operational leaders in the same room so we can have discussions in aligning tech strategies,” Gehring said. “At the end of the day, our objective is to safely and efficiently produce gold. There are many facets and complexities in doing this and I believe by having a strong but lenient and centralised technical services team is a key enabler to making this happen.”
Rio Tinto to reduce worker fatigue with Koodaideri airport Rio Tinto’s airport for the Koodaideri iron project in the Pilbara region of Western Australia is online, ahead of the proposed ramp-up of production at the site in 2022. Worker fatigue will be reduced through the airport, shortening travel times for workers arriving from an alternative regional airport. This will prevent worker fatigue and prevent worker interaction with vehicles and driving. The airport is expected to handle more than 600 workers a day at peak operating times and can facilitate a range of different aircraft, including Boeing 737s, Airbus A320s, F100s and King Airs.
The Royal Flying Doctor Service, Rio Tinto’s long-term partner, will also be given access for safe landing in the area. The Koodaideri airport offers four flights a week, with additional flights to be added to the schedule this year. Rio Tinto projects general manager Anthony Radici said the airport opening showcased the progress of the project. “You get a real sense of the immense size and scale of our Koodaideri operation once you fly into this new airport,” Rio Tinto projects general manager Anthony Radici said. “The construction phase of the project is progressing well with a
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significant amount of infrastructure now built, millions of cubic metres of material moved, a new access road, a significant amount of the rail formation installed, two new bridges constructed and now a brand new airport.” The Koodaideri operation has supported Western Australian businesses through the award of more than $2.3 billion in contracts. This has provided 2000 jobs during the construction phase, with the mining operation set to support around 600 ongoing jobs. The Koodaideri mine will have an annual operating capacity of 43 million tonnes of iron ore once it is operational.
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We have cameras for most vehicle applications, inside and outside and can customise a solution to focus on what is important to you. Wi-Fi and 4G enabled versions are available to allow remote connectivity API available to integrate with existing systems if required. Whether its long haul trucks, general transport or dedicated underground vehicles we can tailor a solution to suit most needs so contact us for a free online consultation to find out what we can do for you.
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News MinRes on path to reduce diesel reliance Mineral Resources (MinRes) is assessing its climate-related risks and opportunities due to the growing expectations of its investors. The company replaced diesel with gas, liquefied natural gas (LNG) and solar at its operations, which delivered a 19 per cent reduction in the company’s carbon intensity per tonne of material moved between the 2019 and 2020 fiscal years, according to MinRes chairman Peter Wade. Wade said with the world events of 2020, MinRes’ social licence to operate was more important than ever. MinRes had been relying on diesel as an energy source for its mining equipment, transportation and materials haulage and electricity generation. “In response to a growing expectation from our investors and stakeholders
had taken place at parts of MinRes’ Koolyanobbing iron ore operations in Western Australia. The company has also launched haul truck safety programs at its Iron Valley operations in Western Australia to reduce dust-related visibility hazards. “Safety remains a core focus for the company. During (the 2020 fiscal year), we retained our excellent record for our lost-time injury frequency rate (LTIFR) and reduced our total recordable injury frequency rate (TRIFR),” Wade said. MinRes also appointed a psychologist to develop its mental health strategy to manage the impact of the COVID-19 pandemic on workers. The company’s COVID-19 screening operation is also made available to all West Australian resource companies and has screened more than 50,000 resource sector workers.
Train loading operations at Koolyanobbing.
to understand and manage the climate-related risks and opportunities that affect our business, (MinRes) elected to align our climate-related disclosures with the recommendations of the taskforce on climate-related financial disclosures (TCFD) and made significant progress in implementing those recommendations,” Wade said in MinRes’ 2020 sustainability report. Personal dust exposure monitoring, as well as static dust monitoring
Monadelphous achieves safety record Monadelphous’ engineering construction division has recorded its strongest safety performance in the company’s history, with zero recordable injuries for 12 consecutive months during the 2020 financial year. This company division enables Monadelphous to deliver solutions at iron ore, coal, minerals processing, energy, infrastructure, marine and renewables projects. This includes construction work at Rio Tinto’s West Angelas Deposits C and D and BHP’s South Flank iron ore projects in Western Australia. Monadelphous’ focus on safety was recognised by customer Albemarle, for which the contractor completed works at its joint venture project with MinRes, the Kemerton lithium hydroxide plant.
“The division’s safety performance on the project has been commended by the customer with two safety awards secured to date,” Monadelphous stated. “Since the award, the division has made significant progress on the scope of work, which is expected to be completed in 2021.” During March last year, Monadelphous reported a serious incident at its Kalgoorlie services facility, which resulted in the fatality of a worker. “The company has taken a range of measures since the incident to understand what happened and has implemented actions to prevent a similar incident in the future,” Monadelphous stated. “To support the company’s
commitment to zero harm, the company undertook a detailed assessment of its safety governance practices, further enhancing its health and safety management standards.” Monadelphous has also been focussed on reducing its carbon emissions, with its scope one and two carbon emissions during the 2020 financial year down 20 per cent to 15,500 tonnes compared with 2019. “Monadelphous recognises the need to conduct its operations in an environmentally responsible manner,” the company stated. “The company’s overall footprint is deemed small, but it continues to look for ways to reduce its emissions. The company routinely collects and monitors carbon reporting data.”
SAFETOWORK.COM.AU 8 JAN-FEB 2021
News Newcrest continues safety transformation following Cadia accident
The Cadia gold operation in New South Wales. Credit: Newcrest Mining.
The New South Wales Resources Regulator has warned mine operators to review connection points for work that involves towing following an accident at Newcrest Mining’s Cadia gold mine last year. The accident happened at the New South Wales mine last August, where an electrician in the man-basket was struck in the torso by a broken handrail when a rope recoiled, causing blunt force trauma to his left side. The workers had installed a high voltage cable in an underground part of the Cadia East mine and were provided with verbal work instructions but had no documented procedure available. They used a process that was believed to be similar to the one used at another mine interstate, involving the use of an integrated tool carrier (ITC) to pull
the cable through rollers using a rope attached to a cable sock and man basket on the ITC. Following the incident investigation, the regulator stated that workers must be able to identify whether critical controls were required and implemented appropriately, regardless of whether there was a documented procedure for that task. “When planning a task involving towing or snigging, the working load limit of all components, including the connection points, is considered in the development of the workplan, risk assessment and procedures,” the regulator stated. “Towing points are to be engineered, rated, correctly installed, inspected regularly and labelled as a designated towing point for the applicable task.”
According to Newcrest chairman Peter Hay, the year of 2019 had been a busy period for the company as it improved its underlying safety and performance. In February 2018, the company announced plans to forge a stronger Newcrest by focussing on outcomes that would be achieved by the end of 2020, under five pillars comprising safety and sustainability, people, operating performance, technology and innovations and profitable growth. “I am pleased to report that we are now more than five years free of fatalities and life-changing injuries and in the (2020) financial year we had an industry total recordable injury free rate of 2.6 per million hours worked,” Hay said. “This significant achievement would not have been possible without the commitment of our people and the proven success of Newcrest’s safety transformation plan.” Following the impact of COVID-19, Newcrest made the safety of its people and host communities its number one priority. As a result of the company’s actions, it did not experience any COVID-19 related interruptions to its operations in the financial year.
Mining fatalities retain steady average The number of fatalities in the mining sector in 2019 has matched its five-year average from 2015 to 2019, according to a Safe Work Australia report. The mining sector experienced 2.9 fatalities every 100,000 workers in 2019, comparable to its five-year industry average of three fatalities. This placed mining on the fifth rank in its proportion of worker fatalities by
industry across Australia, following agriculture, forestry and fishing at number one (9.1 fatalities every 100,000 workers) and transport, postal and warehousing at number two (8.7 fatalities). During 2015-2019, the construction and mining labourers group accounted for 34 fatalities, representing 36 per cent of all fatalities.
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Most of the mining fatalities occurred in the primary mining jurisdictions of Western Australia and Queensland. Safe Work however stated that these might not necessarily fall within the jurisdictional responsibility of the state or territory where the fatality occurred. It defines a fatality as people who were lost each year from injuries arising through work-related activity.
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Products BOLLÉ COBRA TPR GOGGLES These goggles feature a thermoplastic rubber (TPR) positive seal and adjustable strap, protecting the wearer from dust particles and splashes, making them the ideal eye protection for harsh environments. Cobra TPR is available with a nylon or neoprene strap, the latter being particularly useful in petrochemical environments, being both non-stick and washable. Ultra-lightweight and comfortable, these goggles also give the wearer a panoramic visual field of 180 degrees for maximum optical clarity. Cobra is the essential all-rounder, available in clear or smoke for different light conditions, each offering the Platinum anti-fog, anti-scratch coating for longer wearability.
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HUMMINGBIRD AUDIO ALERT SYSTEM WARNS VEHICLES OF DANGER Hummingbird’s 16 channel audio alert system is helping to prevent vehicle collisions on mine sites, which accounted for 31 per cent of worker fatalities in 2018. This alarm system not only warns vehicle operators of when there is an issue but what the issue is, using voice commands rather than the usual alarm siren. By using voice commands rather than alarms, Hummingbird’s audio alarm system removes the confusion in finding out what the issue is, allowing operators to react quicker to emergency situations. Users can input 16 different commands into the system including basic temperature cautions, fasten seatbelt commands, apply handbrake notifications and engine fire warnings.
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LIFT ASSIST STAND TAKES SAFETY, EFFICIENCY TO NEW HEIGHTS With an impressive reach of three metres high, the all new self-propelled lift assist (LA) stand by Nivek Industries can take the existing benefits of the Lift Assist 40 arm into the tyre bay and beyond, enabling fitters to use it for wheel, tyre, rim and suspension maintenance on even the biggest of machines. The LA system will assist in reducing manual handling, fatigue, hand injuries as well as short and long term back and shoulder issues. The tyre technician has a far reduced need, if at all, to place their hands near any pinch or crushing points in the rim and wheelbase when using rattling or torqueing equipment.
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SAFETOWORK.COM.AU 12 JAN-FEB 2021
SY-KLONE’S RESPA-CF2 CAB AIR QUALITY SYSTEM The RESPA-CF2 is Sy-Klone’s most advanced cab air quality system, providing a pre-cleaner, filter and pressuriser in one unit, which can be customised according to the operator’s needs. Sy-Klone’s RESPA-CF2 unit offers high quality filtration and pressurisation, to keep dangerous air particulates out of cabins that can cause long-term lung illnesses to mine workers. The unit system extends maintenance intervals for heating, ventilation and air conditioning system in mining vehicles while extending filter life. The pre-cleaner allows operators to keep cabs and enclosures pressurised positively while keeping dangerous particulates out. Sy-Klone’s RESPA systems meet ISO and Australian standards.
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MINEARC’S STENCHGAS EMERGENCY ALERT SYSTEM SMELLS OUT TROUBLE MineARC’s StenchGAS emergency alert system uses the power of the human sense of smell to alert mine workers to emergency evacuations in noisy environments when sound alarms cannot be used. Available in manual or remotely operated electric configuration, the stench gas emergency alert system disperses powerful odours through underground mines to alert workers of coming dangers. StenchGAS carries 100 grams of ethyl mercaptan, a colourless organic liquid with a strong odour. This is then added to odourless gas to be used as a warning smell. MineARC also provides an anti-stench flushing agent and wintergreen to counteract the pungent gas smell once the all-clear is given.
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ATG MAXIFLEX’S HANDS ON PROTECTION FOR WORKERS’ MOST IMPORTANT ASSETS Mine workers must protect their hands to the greatest extent, which is what ATG’s MaxiFlex Ultimate gloves do by incorporating AD-APT to counter the challenge of keeping hands protected but cool. The AD-APT technology is activated by hand movement and increased temperature within the gloves, releasing a natural cooling agent to keep hands dry and 31 per cent cooler than standard gloves. MaxiFlex gloves reduces worker hand fatigue and injury rates, as workers are less likely to remove gloves due to being too hot or limited in their movements. The gloves are durable, exceeding the highest score required for abrasion resistance against the EN388 standard and provide a more flexible and precise safety solution for working hands.
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SAFETOWORK.COM.AU 13 JAN-FEB 2021
Industry outlook
Mining companies feel heat of community expectations
BEFORE THE PANDEMIC HIT, THE AUSTRALIAN MINING INDUSTRY RANKED CLIMATE CHANGE AND NATURAL DISASTERS AS ITS BIGGEST FUTURE RISKS. SALOMAE HASELGROVE FINDS OUT ABOUT A NEW SET OF RISKS THAT HAVE EMERGED AND WHAT COMPANIES CAN DO TO MITIGATE THEM.
I
n January 2020, as bushfires raged across Australia, KPMG quizzed mining executives on the leading risks to their business. It might come as little surprise that 46 per cent identified climate change and natural disasters as their top worry. A few other topics came up. The top 10 included a range of qualms, everything from regulatory and compliance changes at an official level, accessing capital to invest in new projects and global issues such as trade wars. Few mentioned the risk of a global pandemic. “Given how the world has changed in less than a year, it’s a challenge to make definitive forward predictions,” KPMG Australian mining risk assurance partner
Caron Sugars tells Safe to Work as 2020 came to a close. Safe to Work spoke with KPMG Australia upon its release of the Australian Mining Risk Forecast 2020/2021 report. Sugars notes how the pandemic has only added to the list of concerns for miners. COVID-19 impacted the way workplaces operate, with social distancing requirements and many employees either leaving the office or, in the case of fly-in, fly-out (FIFO) workers, having their rosters extended. Mining companies also had to contend with interruption to the global supply chain, as international and interstate travel was restricted to emergency or essential travel. The mining sector reacted with
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resilience. It responded quickly to the pandemic by gaining essential status and a licence to continue operating and supporting the Australian economy. As an industry that permanently operates with crisis management response plans in place, Australian mines swiftly introduced world-class testing regimes and constant monitoring. Even with the workplace secured, however, the global effects of the pandemic will no doubt impact the mining industry moving forward. The COVID-19 pandemic has only increased volatility, and Sugars says it will continue to influence commodity prices into 2021. “Looking ahead, KPMG Australia notes the increased interconnected nature of risk, with examples being price volatility,
Mining leaders identified climate change and natural disasters, commodity prices and global trade wars as some of its most anticipated risks for 2021.
global supply interruption, geopolitical issues and changes to demand patterns from both recession and stimulus,” Sugars explains. While mining companies’ focus – and global headlines – shifted during the pandemic, Sugars says it hasn’t taken away from the risks of climate change and natural disasters. In some ways it’s fateful that the survey was conducted ahead of the pandemic, in the heat of the bushfires, as a reminder of the heightened concerns over global warming that aren’t going away. Since that summer of the 2019-20 bushfires, Sugars says community expectations of mining operations has only escalated further. Most mining companies continue to discuss reducing emissions, as they feel the heat of greater community expectations. “Rightly or wrongly, the mining industry has had the finger pointed at it for being a contributor to global warming. Notwithstanding this, the image of a
‘dirty’ industry has prevailed,” she says. “This sentiment is driving greater community expectation, which escalated since the summer bush fires and community protests. “The KPMG mining risk forecast points to both the importance of social licence to operate and the concern around talent. Universities are saying enrolments into mining related qualifications continue to be low. One of the reasons is students are shying away from an industry that has attracted negative sentiment in relation to its climate impact.” With uncertainty surrounding the government and wider society’s response to climate change, Australian mining leaders are aware short-term profits are not the only measure of their success and they must demonstrate sustainable long-term value. The report points to how climate change will drive up costs in mining, requiring changes to the way companies operate. Water shortages will also impact availability and potentially water usage regulations in the coming years. The race is on for mining companies to decarbonise their operations, with large mining companies such as BHP, Anglo American and Fortescue Metals Group announcing their intention to provide significant funding into projects designed to remove carbon from their operations by 2050. “KPMG considers climate change to be a real risk for almost all sectors, not just mining,” Sugars says. “It also presents as an opportunity and we are seeing mining companies starting to actively embrace this opportunity.” The pandemic and climate change aside, Sugars notes that the list of other risks hasn’t changed much. “The key risks we see this year are largely similar as those of the past three years,” says Sugars. Global trade wars continue to rank highly, with miners ranking it their third biggest concern at 38 per cent, ahead
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KPMG Australia mining risk assurance partner Caron Sugars.
of economic downturn and uncertainty as their fourth at 35 per cent. With risks varying according to commodity, some mining organisations are more likely to attempt to alleviate the impacts while others will ride out the risk and await better days. “Miners on the whole are good at managing the impacts of price volatility,” Sugars says. “In times gone by, longterm contracts offered some protection. However, today the customer preference for more short-term options has removed this. “Apart from carefully managing costs and considering hedges, there are not many levers left for miners to use. Sugars offers some solutions to this ongoing problem. “Some organisations will use hedging instruments to mitigate impacts, particularly those who feel currency exposure gives a natural hedge,” Sugars says. “We think strong customer relationships and consistency of product quality and supply timing into contracts can insulate against market supply and demand imbalances.” Community relations and social licence to operate remained in the top 10 for the second year in a row, with 31 per cent of respondents placing it in their top five.
Industry outlook Furthermore, 75 per cent of respondents identified the need for the mining industry to better measure and report on their success beyond financial results, and base it on the recognition of a broader range of stakeholders, such as local communities. “By virtue of appearing in the top 10, this suggests (community relations and social licence to operate) are still being acutely monitored,” Sugars says. “Environmental, social and governance (ESG) is a core focus of the mining industry. Community relations and social licence to operate are integral to ESG, as is climate change. “Given what has occurred in relation to land access and community relations since the survey report was released, we are seeing risk functions focussing particularly on this area.” Following a year of unpredictability and change in 2020, the KPMG Australian Mining Risk Forecast 2020/2021 report found that optimism has decreased, with only 15 per cent of leaders feeling “very confident” in 2020-2021, compared to 40 per cent last year. However, most leaders reported a “cautiously optimistic” outlook, with only eight per cent stating they feel “not very confident” about their organisation’s outlook. Companies ranked organic growth as the most important
strategy moving ahead. Leaders are also targeting technology as an opportunity, rather than a threat moving into 2021. Innovation ranked as the second most important growth strategy, with strategic alliances, mergers and acquisitions and attracting and retaining talent rounding out the top five opportunities. “Mining companies are accustomed to looking ahead; to planning and accounting for mainstream risk and at the same time ESG and other non-financial risks,” Sugars states in the report. “As these attract more focus, technological innovation is helping the sector rise to the challenge and help support organisations and boards in understanding these risks proactively. “The focus on culture in the mining industry, born through strong management of health and safety, as well as an embedded approach to managing non-financial risks, has helped the industry work through COVID-19 and is expected to see risk transformed into opportunity by this innovative sector.”
The KPMG Australian mining risk forecast 2020/2021 report top 10 risks 1. C limate change and natural disasters 2. Commodity price risk 3. Global trade war 4. E conomic downturn and uncertainty 5. R egulatory and compliance changes and burdens 6. C ommunity relations and social licence to operate 7. A bility to access and replace reserves 8. A ccess to capital, including liquidity 9. E nvironmental risks, including new regulations 10. Health, safety and security risks
Community relations are essential for the mining industry to keep its social licence to operate intact.
SAFETOWORK.COM.AU 16 JAN-FEB 2021
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Emergency response
Firing up emergency response teams for bushfire season AFTER FACING THREE BUSHFIRES IN TWO YEARS AT THE FORRESTANIA NICKEL MINE, WESTERN AREAS KNOWS FIRSTHAND HOW INTIMIDATING IT CAN BE TO TACKLE BLAZES. SALOMAE HASELGROVE FINDS OUT HOW THE COMPANY IS PREPARING FOR THE 2021 FIRE SEASON.
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atching the rising smoke and roar of flames from Middle Iron Cap hill near the Forrestania mine in May 2018, Western Areas safety and compliance manager Grant Shearwin knew his emergency response team was about to face its biggest test. Since then, the Goldfields operation in Western Australia has fought two bushfires, in December 2019 and February 2020, but managed to escape relatively impact free. While 400,000 kilometres of Forrestania’s water pipe network was lost and some nickel deliveries to Kambalda were delayed due to highway closures, Western Areas maintained most of its communications infrastructure and had no damage to equipment or resources. Having recognised the risk due to
the bushy terrain of the area when he joined Western Areas in November 2016, Shearwin and the team were proactive in completing controlled burn-offs for fire prevention. “Western Areas completed a number of prescribed burns around the Cosmic Boy village, completely around the 520room accommodation area,” Shearwin tells Safe to Work. “We put a lot of effort into clearing in 2017, which is fortunate because we had our first bushfire in May 2018, which actually threatened the village. “Had we not put the fire breaks in and completed prescribed burns, there is a good chance we could have lost the village.” Western Areas continued its preparation during 2019 leading up to the December and February blazes,
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which each burned over 300,000 hectares of bushland. Both fires were initiated by lightning strikes, which meant Western Areas could not have prevented them from starting, but their proactive measures proved critical. With fires approaching from the north and the south, Western Areas’ fire breaks were integral in protecting the camp, as was the prior training of the emergency response team. “Aside from underground mine rescue, vehicle rescues and a range of other areas, our emergency response team need to be up to speed with tackling wildfire,” Shearwin says. “Every year we complete wildfire training, working with local bushfire brigades. At the end of every emergency we debrief, look at how things went and
Western Areas escaped the 2019-20 bushfire season relatively impact free due to its preventative burn-offs.
what could have been done better. “We’re continually fine tuning, to the extent that there is a certain comfort level that the people on site can get things under control.” Western Areas also updated its firefighting equipment to meet Department of Fire Safety standards. “We adopted the Department of Fire Safety halo system, which has sprinklers over the cabin of the fire truck, so if it gets caught in a wildfire, the team can activate crew protection,” he explains. “Water sprinkles down over the windows, and on the inside, they can roll down curtains secured with Velcro that reflect the heat. We’re not worried about the truck, just protecting the people inside.” With the Middle Iron Cap looming at an elevation level of 120 metres above the Cosmic Boy village, Western Areas takes advantage of the geology to set up a 360-degree view of any oncoming danger. Atop the hill, Western Areas has installed cameras to spot smoke and
identify bushfires in the region so it can fire up its response team quickly. “Preparedness is number one,” Shearwin says. “Complete a risk assessment then put in place controls to mitigate potential impact, for the resilience to get back to normal as quickly as possible after the event.” Following the 2019 and 2020 fires, Western Areas was resilient enough to produce 5399 and 5154 tonnes of nickel at Forrestania in the December and March quarters following the respective blazes. To get operations back to normal as quickly as possible, teamwork was essential, not only for the Western Areas emergency response team but with other respondents on the scene. Forrestania’s emergency call was heard by 15 local fire units, including Kondinin Volunteer Fire and Emergency Services (VFES). Kondinin captain and deputy chief fire officer Roger Northey works closely with the Forrestania team, providing truck familiarisation, burnover techniques and
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fire skills training to workers, ensuring their skills are up to scratch. With the closest fire brigade, Hyden, being 100 kilometres or a one-and-a-half to a two-hour drive from the site, Northey says it is essential that the Forrestania team can get on top of a fire before help arrives. “The emergency response team members change all the time because of rosters moving around, so I do a lot of private training to ensure we are all familiar with their site and locations,” Northey says. “Training can be difficult because there is always a different crew due to mine rosters, so getting a group trained consistently is really important so no matter who is on site, they are up to scratch in the event of an emergency.” Northey was also on hand for the controlled burn-offs that were completed in October 2020 to ensure fire breaks and containment lines between the 50,000 to 60,000 pockets of bush in the area. “We learned a lot from that first big fire in 2018. We knew we needed
Western Areas work, health and safety superintendent Paul Fitzpatrick watches the oncoming 2019 blaze near Forrestania.
through the surrounding valleys, hills and bushland. This also identifies any critical exploration infrastructure like drill rigs that need to be spared and any mining tracks that could be useful for emergency vehicles. Combined with the VFS’ hot spot mapping equipment, this gives Forrestania the best chance of minimising the risk of fire for the 2021 season. Northey says due to their remote
location and tough terrain, mining companies must be prepared with bushfire training and equipment to ensure the safety of workers. “Bushfires aren’t a matter of ‘if’, but ‘when’ they’re going to happen. All you can do is prepare with fire breaks, clear grounds, tidy camps and bushfire training. There is no point going out and responding to a fire on-site if you can’t be safe about it,” he concludes.
Image: Paul Fitzpatrick.
a lot of mitigation breaks to make the accommodation a safe zone,” he says. “Now, every year we burn another section; staying on top of it and eliminating the risk more than anything as much as you can is critical.” As well as mitigating the risk, controlled burn-offs provide a valuable training opportunity for mine workers. VFS representatives like Northey are able to show them how different types of bush burn, for example low scrub which may burn with more intensity than taller trees. “Controlled burn-offs show mine employees how quickly things can go wrong and people can get injured if they’re not careful, which is why they’re a good training exercise,” he says. “It’s good for the people working there to appreciate the difference between different tree types. A lot of workers have lived in the city all their life and have never seen a bushfire up close before.” Western Areas also provides VFS respondents with geology maps of the area, so they can understand the contour of the land and how the fire will travel
Image: Paul Fitzpatrick.
Emergency response
Western Areas works with fire brigades to ensure its team is prepared for bushfires.
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THE SOLUTION FOR
LOST DRILL RODS ME SAFE’s Long Hole Plug safely & effectively addresses the common workplace hazard of lost drill rods in ‘up holes’ without demobilisation of the production drill rig. In the underground mining industry lost drill rods in ‘up holes’ are a common workplace hazard as they can fall from the hole without warning posing a serious risk to personnel and equipment working below. The Long Hole Plug (LHP) addresses this hazard by providing an engineered, safe, cost effective and easy to install solution. The LHP is installed instantly with the production drill rig that lost the rods on the
job, removing people from the line of fire and allowing mine production to continue virtually unaffected. When struck by falling drill rods the LHP transfers the vertical forces of the drill rods horizontally into the rock mass. The LHP’s are robust units designed to live in the harshest underground environments until they are required. The LHP is made in Australia and available in all standard hole sizes.
VISIT OUR WEBSITE FOR MORE DETAILS
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Technology New South Wales is tightening its grip on workers’ exposure to silica dust.
Seeing the unseen through technology SAFE TO WORK SPEAKS WITH SAFEWORK’S CENTRE FOR WORK HEALTH AND SAFETY ABOUT A TRIAL OF TECHNOLOGY THAT PROMISES TO ACCURATELY MONITOR SILICA IN REAL TIME. THE ARRIVAL OF A RELIABLE DEVICE MIGHT NOW BE IMMINENT.
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f there is one thing that hinders the mining sector from minimising the level of workers’ exposure to respirable crystalline silica, it is the lack of an accurate real-time monitoring device. It is challenging enough that silica particles are not visible to the naked eye. But there’s also no tangible evidence that tells workers they might be inhaling silica. The highly non-reactive nature of silica except under extreme heat and pressure adds to the complication, making the environment both dangerous and difficult to reproduce in a workplace setting. Aside from this, a spokesperson for SafeWork’s Centre for Work Health and Safety points out that the challenges faced in detecting silica in
real time include the interference of other particles from the base material and restrictions in technology. This is potentially about to change through a collaboration between the New South Wales Government and University of Hertfordshire in England. The partners have started a trial of a world-first technology that can accurately monitor silica dust levels in the air. “When we began this project, the New South Wales Government’s Centre for WHS (Work Health and Safety) conducted a horizon scan to see what was happening around the world in testing for RCS (respirable crystalline silica),” the SafeWork spokesperson tells Safe to Work. “At time of scan, there were no
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successful studies which had accurate, real-time RCS detection. This device is world-first technology and the New South Wales Government is proud to be the lead research partner on this project.” The Centre for Work Health and Safety considers the technology to be a world first primarily due to its use of silica’s refractive qualities to accurately detect the particles in the air. In the past, other technologies have used raman (a light scattering technique) and nuclear magnetic resonance (NMR) spectroscopies. Unfortunately, there was little success using this technology in real-time detection. But the technology being trialled now uses algorithms that can turn incoming detection data into a concentration
reading in milligrams per cubic metre. According to the spokesperson, the technology uses particle counters and filters to measure the size and concentrations of the silica in the air. The project is taking place in the United Kingdom and Australia, with phase one encompassing a test of a technological prototype in both laboratory and field environments in the United Kingdom. This includes quarried rock crushing plant with high silica levels, brick production plant that uses silica sand, as well as an artificial stone worktop processing plant. The government has overcome the challenges associated with conducting air sampling and tests in a testing facility usually required for silica detection, by using a real-time detector from global particulate monitoring device
manufacturer, Trolex Nome. The trial has enjoyed early successes, with the detector shown to produce accurate real-time exposure readings in all five sites where it was tested. New South Wales will host the second phase of the project, with the Centre for Work Health and Safety identifying suitable test sites in the mining sector alongside the state’s resources regulator. This phase will test the technology’s durability within Australian settings and develop the algorithms so that interference of other particles is minimised. The success of the trial will mean that the device will be commercially available for companies that work with stone products for use on their sites. Trolex Nome Australia director Nathan Owen says there’s already legislative guidance on what companies should
Mining processes such as blasting release crystalline silica dust into the air.
be doing to protect their employees. He expects the legislation and regulation will rapidly evolve in the coming months and years. And when the trial eventuates, the industry can anticipate good news that a real-time silica monitoring device is available to help minimise workers’ exposure to dust particles.
LIFT ASSIST STAND
LIFTING SAFETY TO NEW HEIGHTS The all new self-propelled LA Stand can take the existing benefits of the LA40’s reduced manual handling, postural benefits, hand protection and fatigue reduction into the Tyre Bay and beyond, enabling fitters to use it for wheel, tyre, rim and suspension maintenance on even the biggest of machines. •
3m high reach.
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Pendant control mode enabling operators to adjust the height of the mast whilst remaining on a personnel access platform.
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Workforce management
Winning the COVID-19 battle BHP, MINERAL RESOURCES AND GOLD FIELDS HAVE OVERCOME THE CHALLENGES OF COVID-19 BY PUTTING THEIR PEOPLE FIRST. VANESSA ZHOU WRITES.
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peed of reaction is everything when an uncontrollable force such as COVID-19 strikes. Combined with intentionality, mining companies have stayed afloat and remained a key pillar of Australia’s economy when other industries have come to a grinding halt. In fact, the sector’s reaction to the global pandemic was a highlight of the International Mining and Resources Conference (IMARC) program in 2020. With a laser focus, companies such as BHP, Mineral Resources
and Gold Fields have risen above the COVID-19 challenge. Program director of the BHP Operating System and Improvement, Tony Ottaviano, says many view the world’s largest mining company as bureaucratic, but the COVID-19 pandemic has helped prove the strength of its processes and systems. “If I were to summarise our approach, it’s best summarised as: put your people in communities first, trust your systems and processes and empower your leaders,” Ottaviano, speaking during IMARC, says.
MinRes has opened its COVID-19 testing facilities to other companies in the resources sector.
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“It is our duty to put an emphasis on those key elements. We had to take the stress and anxiety out by saying to people, ‘You are safe at work, with your job secure.’” BHP also acted quickly to identify high-risk employees and provide workers with “the best possible communication and care” that the company could muster. The key in this is authenticity, according to Ottaviano. Recognising that the company’s leaders aren’t mental health professionals, BHP has recruited a specialist to provide the education they need.
On top of that, the company has provided scientific-based communications, where its chief health and safety officer and company doctor talk to the team around the scientific elements of COVID-19. “We wanted to break the myths and fake news out there that was creating anxiety,” Ottaviano says. “We didn’t want to replay what was already on the press.” This goes in addition to early and regular communication by the company’s chief executive, Mike Henry, who Ottaviano says was upfront with his messaging early on. In addition to the changes introduced because of COVID-19, BHP has also increased its investment in workplace flexibility. “We have been a first mover in terms of our flexible working arrangements,” Ottaviano says. “There was significant investment made over the last five years in pushing for flexibility in the workplace and pushing for greater diversity and inclusion. “It doesn’t come for free. We have to commit leadership’s time and invest in technology.” Outside of BHP’s inner circle, the company has supported its key stakeholders. Ottaviano says there are expectations from society for a company of BHP’s scale to lean in and provide broader support to the community. While there are various ways to do this, BHP has chosen to establish a resources fund and recruit additional employees during the pandemic. Mineral Resources (MinRes) is another company that has taken action, establishing 11 screening facilities across Western Australia. “Our decision to open up the screening process to other companies is to ensure this pandemic does not force the closure of Western Australia’s mining industry, which employs tens of thousands of men and women
MinRes protects its workers by protecting their communities.
and is the economic lifeblood of the state,” MinRes explains. More than 60 resources companies and 80,000 people have accessed and undertaken swab screens in the facilities. It’s not only generosity that helps to keep the mining sector afloat, but also companies’ pursuit of excellence in delivering the utmost safety. For example, MinRes has secured United States-made and “gold standard” testing equipment that is capable of performing one of the most accurate COVID-19 tests in the world. The company has also employed more than 40 nurses and collectors that have been trained in the swab. Internally, the screening facility applies to MinRes’ fly-in, fly-out (FIFO) workforce and site visitors to ensure that anyone travelling to site is free of the virus. MinRes managing director Chris Ellison, speaking at the company’s 2020 annual general meeting, says the company’s management of COVID-19 is one of the single most important things the business has achieved in its history. Company chairman Peter Wade adds: “In a period where redundancies and job uncertainty have been widespread, not one Mineral Resources position has been
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made redundant.” A priority on the workforce is also evident at Gold Fields, where a crisis management team was quickly created to support its people. Gold Fields executive vice president: Australasia Stuart Mathews says the company acted to retain 100 per cent of its workforce across the world right through the pandemic. “We made that obligation very quickly and early,” he says during an IMARC presentation. “Every three days, at least, I would be sending messages to people so they get consistent messaging, and to really reach out to people who feel removed so they know they are truly supported.” This also helps solidify workers’ confidence in the security of their jobs, Mathews says. Moving forward, office workers at Gold Fields will enjoy a new working environment that’s “more conducive to flexible work”, which the company had started to develop previously. These initiatives by mining companies have lined an unprecedented crisis with a greater sense of unity and refreshed the appreciation they have for their employees.
Tyre management
LSM’s TMS saves tyres, fuel and lives INDUSTRIAL ROAD TYRES CAN BE POTENTIALLY DANGEROUS TO WORK AROUND DUE TO THEIR LARGE SIZE AND MAGNITUDE OF AIR OR GAS PRESSURES. LSM TECHNOLOGIES TELLS SAFE TO WORK HOW ITS HEAVY-DUTY TYRE MONITORING SYSTEM (TMSYSTEM) HELPS TO MITIGATE THE HAZARDS OF WORKING WITH PNEUMATIC TYRES ON ANY TYPE OF VEHICLE. Tyre monitoring systems decrease maintenance and equipment costs in addition to improving safety.
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MSystem is quickly becoming a mandatory safety control for all on and off-road vehicles, as authorities and industry standards demand for the risk of vehicle accidents to be mitigated. Due to the many severe incidents caused by tyres, occupational health and safety (OH&S) regulators are beginning to recommend or even mandate the use of TMSystem. LSM’s heavy duty TMSystem allows any company operating heavy vehicles to enhance the safety of their people and equipment using technology to monitor tyre pressure and temperature.
This not only protects workers from potential injuries from these enormous tyres but also reduces maintenance time to re-pressurise tyres, cuts costs for operators, avoids vehicle roll-overs and crashes and allows their machinery to keep rolling safely for longer. LSM Technologies was the first provider of such technology to the Australian tyre industry, according to chief executive officer Peter Woodford. “Over the years there have been numerous tyre-related incidents, some of which sadly resulted in fatalities,” Woodford tells Safe to Work. “Tyre-related accidents and fatalities
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involving vehicles utilised in such industries as mining have highlighted the importance of continuous, virtual monitoring of tyre pressures and temperatures with TMSystem to aid in mitigating potential tyre-related vehicular accidents and incidents. “TMSystem is quickly becoming a mandatory industry safety control measure for all vehicles using pneumatic tyres, as authorities and industry standards call for such technology.” The company has been a proud lobbyist of tyre safety, having influenced many Australian OH&S authorities to
adopt TMSystem to protect vehicle operators and occupants. LSM Technologies is a member of the Australian Road Transport Suppliers Association tyre management working committee, and was invited to attend the National Heavy Regulator’s heavy vehicles fire roundtable conference. With its influential position, LSM has completed field evaluations to prove the benefits of its TMSystem, for example, when it was selected by Transport for New South Wales (TfNSW) for approximately 3500 buses. This was to mitigate bus fire-related issues such as tyre and wheel wells, locked brakes, tyre pressurisation and wheel bearing failures. LSM provides TMSystem to a range of other working equipment, including cranes, elevated working platforms, scissor lifts, dangerous goods and chemical and fuel transportation. The two major components that make up LSM’s TMSystem are the incabin monitor and the tyre sensor. The in-cabin monitor allows the operator to set up the TMSystem and provides live monitoring of the tyre sensor data, as well as pressure and temperature alerts.
The tyre sensor is a radio frequency sensor that communicates temperature and pressure data to the in-cabin monitor. LSM’s TMSystem can monitor up to 180 tyre sensors and provides the operator with visual and audible alerts for drops in pressure by 19.3 kilopascals in less than 12 seconds, if the pressure in any tyres drops by 12.5 per cent, if it increases more than 25 per cent or if the temperature exceeds 80 degrees Celsius. For more accurate monitoring of tyre pressure, LSM’s TMSystem can be partnered with its Fleet Safety Manager (FSM) web-based portal that integrates into the TMSystem, as well as other OH&S technologies. As well as a fleet asset tracking system, FSM provides integration to OH&S safety mitigation controls, 24/7 monitoring of the system data, data collection for reporting, analysis and compliance, immediate alerts via email and SMS and full user administration and alert set ups and reports. In addition to safety, LSM’s TMSystem and FSM system support major cost decreases by targeting the re-pressurisation of tyres. “Some larger fleet customers have LSM is helping mining companies to prevent tyre-related accidents with its heavy-duty tyre monitoring systems.
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LSM’s TMSystem and SmartLink Tablet tool are used for maintenance and checking of tyres.
up to 3000 tyre sensors reporting into their FSM and this saves them massive dollars as the FSM report provides them with targeting data of the tyres that require attention,” Woodford explains. “Alternatively, if they had to check every tyre for air pressure once a week it would take two workers more than 150 hours to complete this task, which is virtually impossible, let alone cost prohibitive.” Other advantages of using LSM’s vehicle safety division and TMSystem are peace of mind, vehicle protection, increased fuel economy, extended tyre service life, decreased maintenance, reduced roadside downtime, enhanced stability, braking and handling, reduced casing damage and increased vehicle performance. “There is a dramatic difference in TMSystem technology designed for domestic vehicles versus industrial applications,” Woodford says. “Robustness, fit for purpose and heavy-duty requirements are needed to ensure reliability and longevity of TMSystem in the industry.”
Tyre management
ITW stops mining tyres from tiring out CORROSION IN WHEEL RIMS CAN LEAD TO PREMATURE FAILURE AND INCREASES THE SAFETY RISKS THAT MUST BE CONSIDERED WHEN REMOVING MINING TYRES FROM A DAMAGED RIM. SAFE TO WORK SPEAKS WITH ITW POLYMERS & FLUIDS ABOUT THE IMPORTANCE OF HAVING THE RIGHT CORROSION INHIBITOR IN MINING FLEETS.
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any tyres used on mining equipment are filled with compressed air, which inherently contains moisture. If left untreated, the moisture causes corrosion and cracks in wheel rims, creating a series of safety concerns for mine workers. Corrosion also leads to shorter rim life, meaning mining companies are hit with the costs of cleaning or replacements more often. Additionally, the corrosion makes removing tyres from the rim difficult, exposing workers to the risks associated with these tyre changes. With the tyre bay one of the most dangerous locations on a mine site for workers, increasing tyre life is an essential part of controlling risks for tyre fitters. ITW Polymers & Fluids’ corrosion
inhibitor solution, Rimtreat-X, has been developed by the company following several decades of research and development. The company has constantly updated the solution over the years with more advanced formulas, keeping it in line with how mining equipment has evolved. ITW Polymers & Fluids technical manager – field services Graham Astbury says modern mining trucks are larger and carry increased loads, making it essential for the company to keep its corrosion inhibitor solutions up with the higher capacities. “We have spent many hours at testing to improve our corrosion inhibition mechanisms, particularly as trucks get larger and larger,” Astbury tells Safe to Work.
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“As payloads increase, this also causes an increase in temperatures associated with the internal tyre conditions, so we have had to modify our formulas. “The Rimtreat-X corrosion inhibitor we have designed prevents that corrosion on the rim, which maintains the rim life and also improves the tyre life.” With extensive corrosion control testing, the Rimtreat-X inhibitor makes sure rims are kept in working order for longer, increasing longevity of the rim and, as a flow on effect, the tyre itself. Rimtreat-X also makes visual inspection of rims easier and improves lubricity in the rubber of the tyre, reducing the likelihood of premature tyre failure. ITW Polymers & Fluids tested and
ITW Polymers & Fluids tests its Rimtreat-X corrosion inhibitor for 1000plus hours to ensure it is fit for use.
monitored the Rimtreat-X solution for more than 1000 hours in its laboratory simulation unit, which examined its original formulation, as well as modified alternatives to find the hardiest solution. “ITW Polymers & Fluids put our corrosion inhibitor through the simulation process of heating and rolling on corrosion and rubber coupons, then monitored the corrosion rates for more than
Without an appropriate corrosion inhibitor, tyres can become corroded and prematurely fail.
1000 hours,” Astbury explains. “We then took the inhibitor to a trial site for many hours of actual trial in the field and monitored the rim conditions over time.” ITW Polymers & Fluids has updated its corrosion inhibitors by introducing a yellow metal inhibitor that actively prevents bi-metallic corrosion from occurring between the wheel rim and valve stem. The company has also created a dispenser that eliminates the necessity for workers to handle the chemicals used in the inhibitors, enhancing safety in this area and giving operators a more accurate dispense volume of product to avoid over- or under-dosing. “We are also comfortable that our Rimtreat-X doesn’t interfere with other technology that has been developed around the remote monitoring of tyres and tyre pressures, including sensors,” Astbury says. “From a productivity perspective, it’s obviously far easier to dismount, mount and change tyres over if there is no corrosion in the rims, so vehicles are being returned to production quicker. “Tyre rims are a massively expensive component of the truck so reducing the requirement to change, clean and sand blast rims improves cost efficiency across the whole tyre
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management process.” Increasing tyre longevity not only reduces the likelihood of accidents and replacement costs, but also puts mining companies in a strong position in the event of a tyre shortage, as occurred some 10 years ago. In addition to tyre longevity, the increasing size of vehicles and payloads is creating a harsher environment for the tyre management process. “This means there is much more focus on safer handling and safer ways of managing tyres, and this is also where our equipment comes into the fold,” Astbury says. By keeping rims cleaner and free of corrosion and managing the chemical handling process, ITW Polymers & Fluids ensures that mining tyres are rolling for longer and more safely with the continued development of Rimtreat-X for the next generation of vehicles. “From a technology standpoint, we have beefed up our general corrosion inhibition package whilst maintaining tyre integrity to create improved corrosion treatment. By improving the longevity of tyres and rims under the extreme circumstances in which they are operated, we can make sure tyres are safe to use for longer,” Astbury concludes.
Rimtreat-X by ITW Polymers & Fluids helps mining companies to identify corrosion or cracks in wheel rims.
Tyre management The Titan220e is a remoteoperated, battery-powered truck jacking system.
Specialized Maintenance Equipment reduces tyre jacking risks SPECIALIZED MAINTENANCE EQUIPMENT (SME) HAS ALLEVIATED THE SAFETY AND PRODUCTIVITY RISKS OF ULTRA-CLASS TYRE MAINTENANCE WITH THE DEVELOPMENT OF A HEAVY-DUTY JACKING SYSTEM.
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ME, a subsidiary of Nordic Minesteel Technologies, has removed the necessity for tyre technicians to manually drag heavy jacks and multiple safety stands under ultra-class haul trucks during maintenance. The company has introduced a remote-operated, battery-powered truck jacking system called the Titan220e that can lift and secure the complete front or rear axle of the world’s largest haul trucks. Titan220e incorporates an all-inone truck jack, safety stand and work platform that can be used for the 240-400 ton (218-363 tonne) class haul trucks. “The Titan220e is a technologically advanced machine,” Nordic
Minesteel’s global product and innovation manager Wayne Desormeau tells Safe to Work. “Mining haul trucks keep getting bigger and bigger, so our equipment needs to catch up with the trucks of today, and that’s what Titan220e does. “You can drive in this equipment, lift your truck, lock it in place within seven minutes, versus the 45 minutes to an hour that’s usually taken to perform this type of work.” By saving an average of one hour per lift on a two-point lift, mine operators stand to gain from greater uptime and truck availability. Workers are also removed from the line of fire and protected from the high risks of getting sprains, strains or pinched from using traditional
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jacks and safety stands. The jack’s use of battery power also provides greater worker health and environmental benefits to a mine operation, as it can be used in workshops without emitting fumes like diesel-powered equipment. It is also equipped with mechanical locking arms so technicians can visually confirm that the Titan220e is locked in place and the truck is supported, instead of relying on clumsy internal locking features. “The other thing is, when you lift the truck with our system, the complete front or rear axle comes to a level position that makes it easier for the tyre technician to introduce the lateral load from a tyre handler. They can do a straight pull, instead of lying up equipment on an
Mine operators save around an hour per lift on a two-point lift when using the Titan220e during haul truck maintenance.
angle,” Desormeau says. With over 35 years’ experience providing custom solutions for the global mining industry, the Titan220e has evolved with a base of knowledge from past projects and concerns brought forward from customers. As a subsidiary of Nordic Minesteel Technologies, SME had the opportunity to collaborate with a team from different cultures, experience and educational backgrounds. This has proven to be a driving force that led SME to develop outside the box solutions, benefitting safety, productivity and the environment. In 2017, two diesel prototypes were developed and sent to be tested at mine sites in the high-altitude mountains of Latin America. With feedback from those models, the battery version of the Titan220e was produced and tested at haul truck proving grounds in Arizona in the
United States. Desormeau says the introduction of Titan220e is timely for the mining industry, which is embracing greater diversity and inclusion in the workplace. “This equipment removes the limitations of needing only big guys to perform such a physically demanding job. Even they can get hurt,” he says. With mine operators slowly transitioning to remote work, SME has also introduced the capability to perform remote diagnostics on Titan220e when required. Its North American team is trained to diagnose and troubleshoot the equipment wherever it is in the world as long as there is a Wi-Fi connection. “Everyone has to adapt and do things differently, including Specialized Maintenance Equipment, during this global pandemic,” Desormeau says. “We can perform a software update and respond to any enquiries on
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technical abilities, warranties or even a request for an upgrade remotely.” This includes unique requests such as a customising the control panel of Titan220e, which SME provided instantly to a South American mining company last year. The company has also developed video training that guides the use of Titan220e, enabling operators to be trained anywhere in the world. Nordic Minesteel’s marketing coordinator Heather Johnston says the Titan220e has received positive feedback from mining companies. “A lot of our customers are excited to receive a battery powered, remote operated solution that lets them keep up with larger trucks,” she says. “It also promotes equal opportunity in that it doesn’t matter your size, age or physical ability, you can use the remote control to operate the system and perform your job.”
Tyre management
Kal Tire breaks down barriers for trainee technicians AS A REGISTERED TRAINING ORGANISATION, KAL TIRE IS INVESTING IN ITS NEXT WAVE OF TYRE TECHNICIANS, PREPARING THEM WITH THE KNOWLEDGE AND SKILLS REQUIRED TO WORK IN THIS ROLE, WHILE DIVERSIFYING THE INDUSTRY.
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raditionally, recruiting experienced and quality earthmover tyre fitters has been a challenge for the mining industry. Kal Tire’s registered training organisation status enables delivery of quality training and qualifications
that are nationally recognised, helping facilitate the growth of its business and improving access and quality of new team members. This approach allows Kal Tire to train new recruits to the highest standards, with safety always at the forefront of all their learnings.
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Internal training within the company also allows Kal Tire to familiarise new recruits with the workshop-based training and mentoring from an experienced team. As Kal Tire’s training coordinator Nigel Watson explains, this allows trainees to connect with more experienced members of the team to learn on the job, as well as
Two Kal Tire tyre technicians inspect tread depth on a tyre on site.
Kal Tire team members ensure all necessary tyre maintenance is performed while a haul truck is in the bay.
the theory component of their course. “Most of our trainers and assessors are part of a team in the tyre bay, so if we can find level-headed, eager new team members and pair them up with an experienced trainer, we can recruit people with minimal previous experience and put them through a first-class training program,” Watson tells Safe to Work. “This has enabled Kal Tire to expand its workforce in line with the growing tyre management business.” Kal Tire’s training program teaches new recruits how to safely complete the tasks of a tyre technician, consistent with the current industry processes and applying the company’s most up-to-date tools and equipment. With the training taking place in Kal
Tire workshops, they become familiar with their teammates, equipment and the protocols of Kal Tire as a company and their site. “As all training is done at their appointed own site, using familiar tools and equipment, it is a huge benefit because it gives students that familiarity while they’re starting to learn the trade,” Kal Tire human resources manager Dominique Kesler explains. “Another big plus is majority of the time the trainees are residential to the area, so there is that initiative of supporting local communities, which is a big part of our aims for Kal Tire.” Trainers are also able to pass along feedback to Kal Tire’s upper management to continuously improve the training programs. “Given Kal Tire’s global and national reach, we’re really well positioned to identify best practice when it comes to tyre maintenance,” Kesler says. “Kal Tire is able to prepare reports for customers which identify opportunities for them to improve safety and optimise performance. “By implementing these recommendations, not only are the team members performing to a higher standard, the tyre bay is functioning
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more safely and efficiently.” Kal Tire’s training has already proven to improve and maintain high safety standards at Australian mine sites. “A huge success story for us is a Kal Tire mine site bay in South Australia, which is quickly approaching 25 years of no lost-time injuries,” Kesler says. “That site is our largest in terms of team members and trainees. The vast majority of that team started their career with Kal Tire in a trainee role at that site, which speaks volumes.” As well as improving safety on site, Kal Tire’s training program is helping the company to create a more diverse industry, recruiting groups who may not have previously had an opportunity to work as tyre technicians in the past, such as women. “In the past, tyre fitting has been a very male-dominated industry so finding experienced women is almost impossible, they just haven’t had that opportunity to enter the industry,” Watson says. “It allows Kal Tire the opportunity to create a much more balanced workforce.” Kesler adds that Kal Tire has already attracted and retained female tyre fitters in trainee roles in Western Australia, Queensland and South Australia. She says breaking the barriers to diversify the industry is really exciting. “We have had several women come on board in traineeship roles and what is great for us is we’re able to grow and diversify our team,” Kesler says. “It is exciting to offer that opportunity that wouldn’t have been there before.” By providing new tyre technicians from all backgrounds and experience levels, Kal Tire is rolling out a new wave of workers in the heavy tyre maintenance industry, while providing the training, knowledge and skills to keep them safe on the job. “We are extremely proud to be a registered training organisation and with that, our ability to improve and maintain a high safety standard within the industry,” Kesler concludes.
Mining equipment
Chipatronic gives mining vehicles eyes everywhere SAFE TO WORK FINDS OUT HOW CHIPATRONIC IS VISUALLY ARMING MINING COMPANIES WITH ADVANCED CAMERA SYSTEMS DESIGNED TO IMPROVE SAFETY, PRODUCTIVITY AND COMPLIANCE.
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echnology has steadily improved how people can monitor workplaces, limiting the biases of human nature. Chipatronic, a leading provider of automotive audio-visual products, provides the Australian mining industry with a solution to witness and record vehicle operation, including any incidents. Its range of industrial video recorders are strong enough to withstand the rugged conditions of Australian mines, allowing operators to review footage from vehicle accidents, production losses or other unexplained incidents. “The advantage of a video system is you’ve got fixed eyes,” Chipatronic director Stephen Walsh tells Safe to Work. “Humans tend to look around even when they are concentrating. When you’ve got a camera set up, it sits there and is recording, constantly picking up on things a human may not.” Following incidents on a mine site, the first priority is finding out what happened and whether it can be attributed to human error, equipment failure or site conditions. “Accurately seeing time frames is probably the most underestimated area when humans are recalling events, especially while driving,” Walsh says. “People often believe they have time. And even afterwards, they reflect and think that time is shorter or longer
With attached GPS systems, Chipatronic’s cameras can embed locations into footage for accurate monitoring.
depending on how they saw it at the time. Humans have quite a poor innate sense of time. “Often, the first thing that happens after an incident is that someone will sit down and explain what was happening at the time, as they saw it. You will get a perfectly honest answer from them but then they look at the video, (and) it often appears differently to how it was recalled.” Chipatronic’s systems are equipped with solid state hard drives, which can save between two and six weeks of footage, depending on a mines’ operating hours. Cameras are able to be situated anywhere that can be reached by cables, and Wi-Fi transmission kits are also available if required. The cameras are the “eyes” and Chipatronic uses high end Sony image sensors with Wide Dynamic Range
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(WDR), which captures both light and dark areas and then balances these on the fly for the best quality video footage, up to 1080 pixels. This footage can then be provided to investigators immediately following an incident, helping them draw evidence-based conclusions and make the right recommendations to the company. In addition to reviewing incidents after they occur, the footage can also be used for compliance and training, to help prevent future incidents from happening. Walsh says that in an industry like mining, which has a range of procedures that need to be followed across a site’s variety of operations, visual training is a beneficial addition to formal training sessions. “When there are procedures that need to be followed, such as loading a
vehicle, Chipatronic’s vehicle cameras allow workers to review the process and check (whether) it was carried out according to best practice, appropriate precautions were taken and corners weren’t cut,” he explains. “From compliance, you move into training. If you have video footage, you can use a review showing a noncompliant instance, followed with a footage on how to do it correctly. “The important part is that any non-compliance is followed by the correct process as this is not meant to be just looking for problems, and video evidence is just as useful to show correct procedures were being followed, which can highlight other elements that may otherwise have been passed over.” Chipatronic mobile digital video recording (MDVR) systems can also have a GPS attached into the system, embedding location coordinates into video files, to accurately confirm the location. A geofence can be set up in the online platform, which connects to the MDVR, and alerts can be raised should the vehicle go outside this area. In addition to helping review a vehicle’s movements after an incident, Chipatronic technology can also help a driver during operation. Its fixed video systems monitor external areas. This is commonly used for reversing systems, giving operators clear vision from inside a vehicle cabin but can also be used for hitches, powered accessories and other areas where the operator does not have a clear vision. With some large mining vehicles having limited visibility from the front cabin, this provides a better view for safer movement around the mine site or workshop. One of Chipatronic’s coal mining clients uses the company’s pan tilt zoom (PTZ) camera system, which is attached to a boom to view areas that
are considered dangerous on site. “In this instance, the coal miner has fixed a PTZ camera on the end of a boom which goes out over the face of the coal mine, which is considered a hazardous area,” Walsh explains. “People aren’t permitted to get close to the coal face. So, with one of these cameras on the end of a boom, the operator can use the camera joystick control to spin it by 360 degrees and pan backward, forward and zoom in by 20 times to get a close-up view of particular areas.” Chipatronic’s technology is not only advanced, but well suited to the conditions of mining operations. The most popular application seen in the mining sector is four and eight channel mobile digital video recorders, which can be installed into any vehicle in the mining sector, including front end loaders, telehandlers and underground dozers. They are also designed to use the latest technology that eliminates the need for additional casing and protection, keeping them small in size. “Older alternative products use quite large, chunky cases with vibration protection,” says Walsh. “Chipatronic’s range has changed completely to solid state drives with no moving parts, which means they are less susceptible to vibration. The whole product can be made smaller because it doesn’t need to have those large anti-vibration housings. “It also means heat and humidity don’t affect the components to the same extent as (they do) some other electronics.” With miners’ responsibilities growing as sites become more technologically advanced, having an extra set of eyes can help to minimise vehicle collisions and accidents. “For operators in vehicles to be able to see better and even zoom in on what’s going on rather than
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Chipatronic’s cameras can capture footage to aid with mine incident investigations.
putting a person in close to the action, you can get a much better grasp on current conditions safely, while being far away enough not to be in danger,” Walsh concludes.
Footage on Chipatronic’s captures can be used for compliance and training for mining employees.
Technology
Overcoming the challenge of extreme temperatures HEAT STRESS MANAGEMENT IN MINING, A SECTOR THAT IS HIGHLY EXPOSED TO HOT CLIMATE CONDITIONS AND THE THREATS OF CLIMATE CHANGE, IS BENEFITTING FROM THE USE OF ADVANCED TECHNOLOGIES. VANESSA ZHOU SPEAKS WITH EXPERTS FROM THE AUSTRALIAN INSTITUTE OF OCCUPATIONAL HYGIENISTS ABOUT THE DEVELOPMENT.
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dvanced technologies have penetrated areas of a mining operation beyond the much-publicised uptake of automation. Inherent to the extreme mining conditions in Australia, large mining companies are leading the way in the use of technology to help workers manage the risks of heat stress. Their goal in adopting today’s technology is to alter a mining environment so that it becomes a safer workplace, signalling a change in industry focus when it comes to heat stress. “Where the traditional focus has been around when to stop working when it reaches a certain temperature, and how long one can safely continue working before taking a break, companies are now looking at how they can control the environment,” Ross Di Corleto, a member of Australian Institute of Occupational Hygienists (AIOH), tells Safe to Work. “It’s no longer just a case of adjusting individuals to the environment, but changing the environment to suit the individuals so that they can work safely and be more productive.” Health and safety professionals are increasing monitoring in the field to identify environmental and other potential sources of heat, such as tasks and processes that specifically induce
heat strain in an individual. Mining companies are looking for data to help them identify controls to eliminate or reduce the risk. They are being helped by mine workers who are increasingly open to using technology that tracks personal bodily changes. One such example is a telemetry pill that is ingested, to measure the impact of environmental factors on workers in real time by measuring core body temperature. According to AIOH member, Jodie Britton, there is a growing interest in telemetry pills among mining and other resource industries across Australia. The approach relies on workers volunteering to be monitored, and more of them are offering to participate as they see the benefits of the technology. “You can watch the worker and be viewing the information in real time on your phone, making it much simpler to identify specific tasks that are inducing heat strain,” she says. “There’s nothing better than data that can pinpoint where the issues are in the workplace. “I have first-hand experience in seeing data collected that leads to very significant changes in the workplace. And now I’ve got workers asking questions about it because they can see how the data has resulted in changes that have improved people’s wellbeing.” In addition to the telemetry pill,
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the proliferation of technologies in the area of heat stress also includes smart garments that collect personnel’s biometric data. Information such a person’s heart rate, temperature and breathing rate is relayed back to a control room or central location to indicate how they are coping with the heat stress. In addition to monitoring workers’ reactions to heat, new technology is also helping keep these workers outside of hot zones in the first place. Drones are being used to access hot areas such as roofs and mining pits to perform inspections remotely and to deliver goods to work sites to limit worker movement. Britton says the use of drones is becoming more common in the mining industry to inspect the blast areas, significantly reducing heat stress. “I’ve talked to mine workers in Western Australia who said that drone technology had been an absolute gamechanger from a heat stress and safety perspective. They no longer have to go down to the pit as often,” Britton says. AIOH’s Di Corleto, who has four decades of experience in the mining industry, says miners are not only motivated by safety and health impacts to improve heat stress management, but productivity as well. “I would love to say that it’s solely
aimed around protecting the health of our workers, but that’s not the only target,” he says. “People are starting to acknowledge that our environment is only going to get hotter, so we better start managing our work and people’s exposure to heat. “And by looking after our workers, we’re improving productivity and quality of work in the workplace. It’s a win-win situation.” According to Di Corleto, every increase in temperature of a few degrees leads to a significant drop in productivity. Managing heat stress therefore leads to improved productivity, while reducing workplace incidents and injuries. This is because as the temperature heats up, employees lose concentration, their fine motor skills depreciate and
their cognitive function reduces. Other early indications of heat stress include fatigue, as well as reduced hand-eye coordination and problemsolving skills. At the most extreme level, high temperatures can lead to heat stroke, which is a serious medical condition where a person’s control systems and organs begin to shut down. They endure significant impairment such as kidney damage and the haemorrhaging of blood vessels, and it can ultimately result in a fatality. Di Corleto adds that there is also a proven link between heat stress and safety incidents and injuries. “Heat illness can occur at surprisingly low temperatures if the right combination of high humidity and low wind speeds are present,” he says.
Hydration level is not the only determining factor of heat stress.
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Britton, who has worked in the heavy industry for 28 years, says most mining companies are today training and educating their workers about the risks of heat stress. This is a welcome shift, as many years ago companies struggled to recognise the signs and effects of heat stress. “Companies are now taking the issue of heat stress seriously,” Britton says. “People in leadership roles benefit from education as do project leaders and engineers, due to their key role in the design and planning of mines. “Likewise, workers would benefit from a greater understanding of the long-term, chronic effects of heat stress. After all, heat stress is a lot more than just about being well-hydrated.”
Working at heights
Bend-tech keeps watch from above for safety FALLING FROM HEIGHTS IS A PARTICULAR HAZARD FOR WORKERS IN THE MINING INDUSTRY, WITH FALLS, TRIPS AND SLIPS ACCOUNTING FOR 26,000 SERIOUS INJURY CLAIMS IN THE 2019-20 PERIOD. SAFE TO WORK SPEAKS TO BEND-TECH GROUP ABOUT HOW A LONG-TERM FIX IS THE BEST WAY TO PREVENT FALLS ON MINE SITES.
Bend-tech’s solutions meet Australian Standards for working from heights.
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ccording to Safe Work Australia data – Key work health and safety statistics, Australia 2020 report – 21 Australian workers lost their lives falling from heights in 2019-20, which accounted for 11 per cent of all workrelated deaths in this period. Additionally, 23 per cent of all serious injury claims were put down to falls, trips and slips during this period. However, there is a long-term, effectively engineered solution to prevent workers falling from heights. Bend-tech designs, engineers and manufactures handrails, guarding and access platforms to protect workers from potential falls and give them the confidence to complete their tasks from
heights in a safe environment. “If a worker falls from high enough, it’s going to present a significant risk, especially in height risk scenarios in areas associated with other potential risks like crushing incidents,” Bendtech representative Rhys Werndly tells Safe to Work. “It is also important to consider that the risk of falling from heights is not just about falling onto the ground or surface below, there could be a lack of protection or hand railing that present other risks of lost time injuries or ultimately deaths. “Without Australian Standard compliant hand railing or another mitigation solution they cannot work safely.”
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Besides the risk of injuries or fatalities, not having appropriate hand railings as a point of contact for people working from heights can make them feel uncomfortable to complete tasks. “If people feel like they cannot work safely and aren’t confident to do their jobs, outside of the number one issue of it being a safety hazard, it flows on to their productivity,” Werndly explains. “If workers do not feel safe and confident, they are not going to be working efficiently.” With its talented team of designers and engineers, Bend-tech provides the mining industry with handrails, guarding and access platforms to eliminate the hazards of working from heights. Bend-tech’s solutions are all designed and fabricated to meet Australian Standards, to provide a longer-term solution than other methods such as scaffolding. “If a mine site has a working at heights hazard present, our team’s approach is to visit the site and understand the issue to provide a solution that meets Australian Standards,” Werndly says. “We team up with the site to understand what they want to achieve. We work together on consultative, engineering and design levels to present a solution with ongoing value and efficiency, which ultimately creates a safer scenario.” Bend-tech’s range includes handrails
for fixed plant scenarios, guarding and railing for underground mine machinery and a range of hand rails for decks of mining equipment. The risk of accidents occurring while working from heights can increase if sites have solutions in place that are poorly designed and controlled, or a short-term solution is left in place for the long-term, like scaffolding. Scaffolding must be erected and inspected on a regular basis to ensure it is effective protection for employees working from heights and often requires extra non-company personnel on site, at least three scaffolders to both build and break down the structure, in addition to hire costs. These parts and personnel are not always readily available and are not a permanent form of access or support. “Any scenario can become unsafe if it is not designed correctly,” Werndly says. “Having a fixed or mobile platform in place for a safe working area eliminates the need for scaffolding, so the area is safe, and personnel can work
efficiently and safely. “Bend-tech’s aim is not about creating short-term fixes; we are about eliminating hazards for the longterm and creating safer scenarios on work sites.” Once mines have implemented a permanent safeguard for work at heights, Werndly encourages ongoing maintenance to ensure it works for the long-term, to ensure ongoing safety for all workers. “To continue to eliminate risk, there is a range of training that needs to be implemented so people look around for themselves to see if there is anything dangerous in their workplace that needs to be documented and actioned,” he says. “Each site has its own inspection frequency but it should be ongoing, with everyone in the workplace feeling empowered to identify risks and improvements as needed.” With Bend-tech ensuring workers are looked out for from above, mining companies can continue to operate with confidence that their workers will return
Bend-tech provides long-term safety guards for people working from heights.
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Bend-tech’s handrails, guarding and platforms give workers the confidence to complete working from heights in a safe environment.
home from each shift safely. “The way Bend-tech goes about safety is to engineer a solution that mitigates and eliminates hazards,” Werndly says. “At the end of the day, inadvertent things can happen to equipment but with control measures in place, safety can be achieved to prevent lost time injuries and deaths on site.”
Innovation
ME SAFE’s long hole plug eliminates the hazard of lost drill rods in up holes. LOST DRILL RODS IN UP HOLES ARE A COMMON PROBLEM IN UNDERGROUND MINING. CURRENT INDUSTRY SOLUTIONS TO ADDRESS THIS HAZARD HAVE SAFETY IMPLICATIONS, ARE TIME CONSUMING AND EXPENSIVE, AND INTERRUPT MINE OPERATIONS. ME SAFE HAS AN ANSWER TO THIS PROBLEM.
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E SAFE was born out of a potential accident stemming from lost drill rods in up holes. The rods have the potential to fall out without warning and pose a serious safety threat to personnel and equipment working below. Current industry practices to alleviate the hazard include grouting the hole to lock the rods in place or to plate over the hole with a rock bolt. Both of these methods are time consuming and require additional resources, negatively impacting the mining operation. In response, ME SAFE has developed the long hole plug (LHP) to safely secure lost drill rods in up holes, which eliminates the hazard without wasting valuable production time and capital. “The LHP, when struck by falling drill rods, behaves similarly to an expansion shell anchor, transferring the axial forces from the falling drill rods horizontally into the rock mass,” ME SAFE director Sam Thomas says. “It is installed using standard production drills, allowing work to safely continue with little interruption.” The LHP is a much safer solution than grouting a hole as it removes
ME SAFE won a Prospect Award in 2020 for the long hole plug (LHP).
employees from the line of fire around the bottom of the hole during grouting works. If the heavy drill rods fall out without warning, it can result in catastrophic consequences. Thomas says the other conventional method of plating over lost rods with a rock bolt is also ineffective, as it provides a false sense of security. “There have been several incidents
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in the underground mining industry where this solution has failed, resulting in lost drill rods falling from a hole without warning,” he says. “It is common for these holes to contain hundreds of kilograms of drill rods, which have the potential to fall out of the hole at any time without warning. “The LHP removes this personnel exposure as the plug is inserted into
the hole remotely with the production drill, thus removing personnel from the line of fire.” The idea to develop the product started when Thomas identified that lost drill rods in up holes were a common problem that had no effective solution. Thomas and his business partner at ME SAFE, Gerry Noonan, then developed the LHP and presented their findings during the Australasian Institute of Mining and Metallurgy (AusIMM) Underground Operators Conference in 2017, where their paper won the Best Conference Paper award. “I worked in the underground mining industry for approximately eight years prior to starting ME SAFE with (Noonan). We recognised that lost drill rods in up holes were a common safety problem, and so developed the concept for the LHP,” Thomas says. “We received a lot of interests for the product after presenting at the AusIMM, which drove us to start a commercial entity now known as ME SAFE.” Since the LHP’s launch in 2017, the technology is now used as the standard solution to remove the hazard of lost drill rods in up holes in approximately 60 mines globally. With a strong presence in Australia, ME SAFE is now setting its sights on expanding and strengthening its presence in North America. The company also won the Schenck Process Excellence in Mine Safety, Occupational Health and Safety (OH&S) title at the 2020 Australian Mining Prospect Awards for the LHP. “It was a surprise to win the Australian Mining Prospect Awards, but we are very pleased, excited and grateful for it,” Thomas says. “It’s great to be recognised when you’re doing something for the good of the industry and helping companies
The LHP is installed using the production drill rig to secure lost drill rods in up holes.
increase safety and productivity through the technology.” ME SAFE pipped fellow finalists BHP, Austar Coal Mine and New Hope Group to win the Schenck Process Excellence in Mine Safety, OH&S category. BHP was nominated for eliminating live work with Dash Maintainer Tools, Austar for its coal burst management system and New Hope for its Fit for Change program following the closure of the Jeebropilly mine. AusIMM chief executive Stephen Durkin, a judge of the 2020 Prospect Awards, says ME SAFE addressed a specific and dangerous industry problem with a clever and costeffective solution. “This sort of creative problem solving is the backbone of our industry and its continued growth and improvement,” Durkin says.
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“As well as improved safety outcomes, the significant cost savings provided by the solution show the clear benefits for the industry.” Max Wijasuriya, the managing director for Australia at Schenck Process, sponsor of the Excellence in Mine Safety, OH&S category, says making sure all mine workers get home safely to their loved ones in the same state that they left in is a daily focus for the industry. “Our people work in some of the harshest and most demanding environments that industry has to offer,” Wijasuriya says. “Sponsoring the Excellence in Mine Safety category is our way to recognise and celebrate the hard work and leadership that gives the Australian mining industry its reputation of being a leader in safety.”
Innovation
Breaking barriers with next-gen TETRA radio TERRESTRIAL TRUNKED RADIO (TETRA) SYSTEMS GO BEYOND THEIR TRADITIONAL FUNCTIONS TODAY, AND THANKS TO THE INNOVATION OF COMMUNICATION SPECIALIST SEPURA, THIS EXTENDS TO KEEPING MINE WORKERS SAFE WHILE PERFORMING THEIR JOBS.
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here are very few things that can help stop a 700-tonne dump truck from speeding, and when there is, you wouldn’t expect it to come in the form of a 250-gram radio. The new TETRA radios from Sepura, however, have broken traditional boundaries. A radio is no longer simply a device for voice communication, but one that can help keep workers safe, thanks to built-in safety features to protect lone workers or those in distress. The radios can now be enhanced with the addition of a new application, AutoMate, which enables the radio to take pre-defined actions based on a chosen trigger which may be according to the current condition or location. When a miner enters a blast zone to join a working group, the radio app – prompted by a geofence zone definition – automatically switches
Integrating data into radio solutions reduces the need for unnecessary voice communications.
to the correct talkgroup so they can communicate with that team In the control room, their location and status are logged, and if that individual is not allowed in the blast
zone, warnings can be shared with the operational team to take appropriate action. Similarly, a vehicle that enters an underground work area to collect some materials and loses the network signal can also maintain constant communication, as the radio automatically switches to direct mode operation (DMO). An additional app can connect the radio to secure Wi-Fi networks, enabling the control team to send emergency messages over Wi-Fi. In this way, both voice and emergency communications are maintained, and the team only needs one communication device to monitor. ENHANCING EFFICIENCY One of the key advantages of using a radio network for such emergency notifications is that the automatic alerts can be shared with team leaders
The radio can detect the location of a vehicle that exceeds its speed limit and sends a warning to the driver.
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“The main benefit of OTAP is that you no longer need to bring 200 or so radios into the office or physically go to each vehicle and input the changed parameters every time you’d like to make an update,” Sepura business development manager Colin Bresnahan explains. “If the blast zone area is modified, the radio’s settings can be updated while the vehicle is parked overnight or in between team shifts. A safety professional doesn’t need to get a permission to pull the vehicle up and isolate it to the side of the road while technicians come and reprogram the radio. “This could save the mining organisation several thousands of dollars in downtime.” Sepura can help overcome the communication challenge in underground tunnels.
or a supervisor, improving situational awareness. In addition, the application reduces the burden on staff to perform mundane tasks such as changing talkgroup or confirming location and status, meaning they can better concentrate on operational tasks. “From a safety perspective, the faster the site emergency teams can be notified of an incident, the better,” Sepura sales engineer Ash Hunter tells Safe to Work. “With such large machinery on site, hazardous environments and the vast scale of many sites, it is vital that alerts are quickly and effectively shared with not just the vehicle operator but also other people that can assist.” AN EVOLVING SOLUTION The power of AutoMate lies in its flexibility to be adapted to suit an organisation’s needs, and to evolve with these over time according to the work being done. These are typically done in-house and enable quick and efficient changes
to allow for seamless operations. “Using the example of the blast zone; if blasting activity moves to a new area or the zone is extended, the geofences can be updated and added to the radio software, ready for the start of the new shift,” Hunter says. “The application will allow users to reconfigure and adjust their geofence positions weekly or even daily, if they need to. The sheer amount of flexibility at its heart is a very powerful tool to support operations. “Similarly, if a mining contractor changes sites, it is a simple process to update their radio setup. Radios can be programmed to react differently according to the team’s work priorities, or to react differently in different areas, or for different users.” WIRELESS PROGRAMMING In a further significant operational advantage, changes to radio settings and software updates can now be uploaded via secure Wi-Fi, using Sepura’s Over The Air Programming (OTAP) solution.
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FUTURE TECHNOLOGY With the ever-changing requirements of mining companies, Sepura is already anticipating the future of safety technologies as it sets its sights on exploiting the maximum potential of the radios. Future use cases could include pairing together radios with additional safety equipment, such as oxygen monitors or devices to identify gas leaks (using Bluetooth). Through the connectivity allowed by the TETRA network and the connection to Wi-Fi networks, information such as this can inform team leaders immediately of a potential issue. “Using applications, our latestgeneration of radios are smarter, more intelligent and have more potential than ever,” Bresnahan says. “Developing these apps allows us to work closely with our mining customers to support operations and preserve staff safety in a cost-effective manner. “AutoMate is just one example in an ever-growing stable of Sepura applications that can be tailored to individual customers’ requirements.”
Health & wellbeing Wiluna Mining aims to provide a social atmosphere at its camp.
Creating a home away from home for FIFO workers FLY-IN, FLY-OUT (FIFO) WORKERS NOT ONLY HAVE TO MANAGE WORKING LONG, PHYSICAL SHIFTS, BUT ALSO EXTENDED PERIODS OF TIME AWAY FROM THEIR FAMILIES. SALOMAE HASELGROVE FINDS OUT HOW COMPANIES ARE CREATING A ‘HOME AWAY FROM HOME’ TO ENSURE EMPLOYEE WELLBEING.
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hen the Western Australian Government enforced a hard border closure from April to December 2020, many FIFO workers faced the tough decision of taking on longer shifts or even semipermanently relocating from their home and family for work. This put mental health and the quality of FIFO camp life on the radar to make sure mine workers had a positive experience while spending more time at work than usual. Wiluna Mining is a company that knows the difference between simply offering a mine camp and a home away from home for FIFO workers at its Western Australian gold mine. Situated on a hillside, surrounded by lush trees and green lawns, it is easy to mistake the Wiluna mine camp outdoor
area as a regular backyard. This extends to the inside of the camp, with facilities such as a tennis court, swimming pool and gym, then a modern kitchen and mess area, where workers dine side by side with management staff in a social atmosphere. By putting together a people-minded team of leaders, Wiluna chairman Milan Jerkovic has created a homely environment at the Wiluna site. “The Wiluna camp was established a number of years ago when people virtually lived at a camp before FIFO became popular, so it is designed accordingly,” Jerkovic tells Safe to Work. “It’s different when you go to some of the larger camps – there’s a less personal approach. As a smaller company we can be more flexible in our approach.
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“If you go to our site on any given day after work, one of the managers will always be there having a meal or a drink with the workers, so it’s very easy to pick up whether or not someone is struggling as it’s a very intimate set-up.” To ease the challenge of longer periods away from home, Wiluna became more flexible on which days workers could fly in and out to site, having an airstrip close to the mine site and bus transfers to a larger facility 80 kilometres away. “We picked up pretty early that our interstate workers, being on slightly longer rosters, was starting to (experience) some fatigue towards the end of the stretch,” Jerkovic says. “With the added mental stress of employees being isolated from their families, we made the decision to change back to normal rosters pretty
quickly and being a relatively small and nimble company, we were able to do so without any issues.” With an intimate community atmosphere and people-minded leadership team of Jerkovic and operations director Neil Meadows, Wiluna did not need to change much about camp life to ensure its workers were feeling included and cared for during the challenges of the pandemic. Wiluna holds frequent social events and barbecues, including for workers and their families, in an effort to create a home and community feeling. “As a small company with a demand for skills and leadership competing against larger, more well-known companies, we aim to give workers as much creature comfort while at work,” Jerkovic explains. “For us, it’s about having a community environment, providing a workplace in which employees have a sense of belonging and feel like everyone from the executive chairman down is fully engaged with them, giving them a purpose of why they want to work for us.” Nickel miner IGO is another company that prides itself on its culture. IGO head of people and culture Sam Retallack says the COVID-19 pandemic travel restrictions may have changed some company priorities, but it did not affect its broader focus on culture. “One of the things we found in the beginning stages (of the COVID-19 pandemic) was that it helped to define that culture even more if possible, because we knew people were faced with a lot of uncertainty,” Retallack, speaking during the 2020 International Mining and Resources Conference, explains. “IGO tried to reduce the stress on people in many ways. Obviously, health and safety was the number one priority but the company brought in things like a special type of ‘COVID leave’.
“We also encouraged flexible working arrangements across the business and had the technology available for people to do that so we could send them home and not worry about ambiguity in the early stages.” Conscious that workers were no longer having daily face-to-face connection, IGO implemented a range of mental health programs to support both its office workers in Perth and remote FIFO employees. IGO created a COVID-19 support survey to find out from workers firsthand if they required additional support and built its response around the feedback to ensure their needs were met.
period of separation. “We just tried to keep it real,” Retallack says. “We communicated with people that they should express their feelings and we were real about expressing ours. “We know many of our employees have young families or care for older relatives, so we tried to help them manage their expectations about what they could realistically achieve while working from home or out on site.” Although stressful in terms of hours and long periods of time away from family, offering a new community of like-minded colleagues is one of the pluses to the FIFO lifestyle, as explored by Curtin University Centre
Wiluna Mining’s FIFO camp in Western Australia’s Goldfields.
The company held regular communications sessions via telephone or video call, providing social stimulation for workers and clear framework for the company’s response to the pandemic. “This way we were able to provide framework to help our people make sense of what the external world was doing and how it related to the internal world of IGO,” Retallack explains. By reconnecting its people to their purpose within the company and wider Australian economy, IGO was able to boost engagement levels during this
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for Transformative Work Design director Sharon Parker and research fellow Jess Gilbert. “Being in the middle of nowhere doing a really tough job, having a group of people who understand your experience because you’re experiencing it as well can be really helpful,” Gilbert says. “A lot of FIFO workers have described it as having a second family to rely on. It can be really fantastic for forming meaningful bonds and having a sense of comradery and mateship at work.”
Health & wellbeing
Fighting the war against fatigue IN AN INDUSTRY WHERE THERE IS AN INHERENTLY HIGHER RISK OF FATIGUE, MINING COMPANIES NEED ALL THE HELP THEY CAN GET IN COMBATTING EMPLOYEE FATIGUE. SAFE TO WORK DRAWS SOME INSIGHTS FROM SLEEP HEALTH FOUNDATION DIRECTOR ANDREW TUCKER.
Fatigue risk management is a key priority in the mining sector today.
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ould a good night’s sleep be as simple as changing a lightbulb? It might be, according to Andrew Tucker, director for Sleep Health Foundation (SHF)’s Australian Sleep and the Alertness Consortium (ASAC). “Lighting has quite a big impact on the body,” he tells Safe to Work. “It helps reset our body clock, improve our mood and affect our alertness, therefore affecting our safety at home and in the workplace. There are technologies now where you can adjust the light to promote either alertness or promote sleep during break time, in one light fitting.” Tucker offers this advice as SHF has relaunched its WorkAlert website to provide guidance for employers in
Sleep Health Foundation director Andrew Tucker.
the mining industry wanting to address the issues associated with employee fatigue. It gives advice on areas to look at including lighting solutions, scheduling, sleep management and sleep disorders The website is the first of its kind in Australia, providing free and updated strategies to employers and employees,
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informed by ASAC research. This was driven by a concern of employers to invest in better sleep for their workers to enhance mental functioning and immunity level, especially during the COVID-19 pandemic. Mining operators can adjust factors such as light intensity, quality of light, light spectrum and blue light content to help workers perform safety critical tasks, which is especially important in an environment such as mine sites. Changes are as simple as swapping light bulbs for others that help increase concentration, performance and mood. “If workers need to be resting, you don’t want to be having bluerich light as that can impact on their sleep,” Tucker says. Mining operators can adjust factors such as light intensity, quality of light, light spectrum and blue light content to help workers perform safety critical tasks, which is especially important in an environment such as mine sites. Aside from lighting technologies and strategies, Tucker encourages
mine operators to review whether time rotations are fatigue friendly. Their design of work schedules can determine how workers can cope with the rosters, and therefore needs to take into account people’s chances of getting adequate time off and sufficient sleep outside of work. Tucker suggests that employers take into account a worker’s commute time as it contributes to their total wake time. It is total wake time, and not total work time that determines their sleep opportunity, according to Tucker. “A worker that takes three hours to get ready and commute to work each day would have been awake for 15 hours by the end of their 12-hour shift,” he says. “While long shifts and night shifts are common, a straight, quick turnaround from an evening to a morning shift limits the amount of sleep opportunity that can be attained before the next shift starts. You can end up with a worker that doesn’t have enough sleep.” In response to problems like this, ASAC has conducted research
to support the development of new rostering systems. They take into account biological principles that underpin alertness and sleep quality. For example, employers need to rotate shifts in a forward motion, i.e. from morning to evening. But what’s harder to detect, according to Tucker, is a worker who is suffering from a sleep disorder. “An undiagnosed sleep disorder poses a risk and needs to be taken into account in a safety-critical environment,” he says. According to the WorkAlert website, around 40 per cent of truck drivers are at high risk of a form of major sleep disorder known as obstructive sleep apnoea. The results of a sleep disorder are dangerous for a workplace. Insomnia is associated with a twofold increase in workplace injuries, as well as an average of eight days of lost work performance per person. This not only poses a danger to the person suffering from a
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sleep disorder, but also to their colleagues and the general public. “One thing mine operators can do is to get their employees to fill out sleep questionnaires that have been validated over time through research for their ability to detect sleep disorder risk,” Tucker says. “By doing so, it will help detect sleep disorder risks, and provide results and recommendations for workers.” Tim Ekert, chief executive of SmartCap Technologies, a company that specialises in the development of fatigue monitoring wearables, praises mining operators for their recognition of the nuance of fatigue impairment. This has led to positive developments in the areas of shift rostering, technological controls and workforce/ leadership culture. “The mining sector is managing fatigue reasonably well,” Ekert says. “The tragic history of fatigue-related fatalities and injuries has ensured that fatigue risk management is a key priority for mining organisations and contractors alike, which continues to drive improvement. “Several areas of progress have been made in the past decade, the greatest of which is an improvement in education in awareness for mine workers.” However, Ekert says one key challenge the industry is still facing today relates to the old adage, “you can’t manage what you don’t measure”. With the bulk of historical data related to fatigue being incident records, the mining sector has a growing need for meaningful data to assess fatigue risk factors, as it works to achieve a balance between a healthy sleep routine, family life and healthy diet. Given the remote working environments associated with mining, companies are more ready than ever to embrace technology solutions that seek to address different aspects of the fatigue problem.
Health & wellbeing
The Gruyere team participated in the LIVINWell workshop during the Gold Industry Group’s national tour in 2019.
THE GOLD INDUSTRY GROUP PARTNERED WITH NON-PROFIT ORGANISATION LIVIN TO BRING MENTAL HEALTH SUPPORT SERVICES TO GOLD MINES AND OFFICES ACROSS AUSTRALIA. SAFE TO WORK SPEAKS WITH FORMER MINE WORKER AND LIVIN CO-FOUNDER CASEY LYONS ABOUT THE LIVINWELL PROGRAM.
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he fear of judgment has driven people who live with mental illness to remain silent. Statistics show that approximately one out of every two Australians experience a mental health challenge during their lifetime, with many struggling to deal with their issues alone. Casey Lyons, co-founder and chief executive of non-profit organisation LIVIN, says there are plenty of service providers, but the stigma, particularly self-stigma around mental illness keeps people quiet. When Lyons lost his friend to suicide in 2013, he decided to help lead people back to a healthy, joyful life.
He can also relate, being a mine worker himself over a period of three years previously. “I can relate to it first-hand,” Lyons tells Safe to Work. “I worked in mine sites before co-founding LIVIN. I was isolated from family members, friends and milestone events, and there was irregular communication with my support networks that slowly gave way to insecurity and declining self-worth. “You wonder what your partner is doing and where she/he is; you’re not able to do what you want, when you want it and that’s difficult.” With this first-hand knowledge, LIVIN, a chosen Gold Industry Group
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community partner, delivered more than 50 LIVINWell workshops across Australian mine sites on a national tour in 2019. LIVIN has grown from a team of two co-founders to 26 facilitators across Australia and plans to expand further to almost 50 facilitators by mid 2021. The team already had the capacity to deliver 20 sessions on a Western Australian mine site in a week as of 2018, with up to 500 people in attendance including those at management levels. “When we talked to an employee assistance program provider on that mine site, she told us about the number
Credit: Gold Fields/Gold Road Resources/Gold Industry Group.
A simple way to support mental health
A LIVINWell workshop being delivered to Newmont’s Boddington gold mine in 2019.
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Credit: Gold Fields/Gold Industry Group.
used a technique learned during the LIVINWell program to help someone who they thought was struggling. “Others said that they had developed a better understanding of the warning signs of mental illness and were comfortable with accessing support sooner.” This speaks to the expertise of the LIVINWell facilitators, with Lyons saying that every facilitator is trained around their limitations and capabilities in delivering the program. They all need to have foundational training in mental health intervention and receive coaching as required by a qualified psychologist, in line with LIVIN’s top priority for safety and governance. The facilitators are also trained to teach attendees on the basics of when, how and where to have a difficult conversation and to lend initial support to a friend or loved one. “We always make a point to normalise conversations around mental health so that people feel comfortable to access or provide support to a loved one, because it can be quite hard to begin a conversation when you have fear of judgment, misinformation, poor emotional literacy and self-stigma, to name just a few of the barriers,” Lyons says. He also shares practical advice on
LIVIN facilitator David Neagle presenting to Gold Fields in Perth.
living on a mine site. “Your routine is your best friend on mine sites,” Lyons says. “I used to go to the gym after work even when I didn’t want to, but living in a mining camp is all about making healthy choices. “You can go down the healthy route or the unhealthy route – this is something that is within your sphere of control. I implore all people to try and make healthier choices that serve them well more often than not. “Practice self-care daily, whatever that may look like to you, be it limiting the amount of bad food you eat or the alcohol you drink, because our lifestyle does affect our mental health.”
Credit: Newmont/Gold Industry Group.
of people that had entered her room, or known who she was and the services that she and her organisation provided, because they had attended our workshop,” Lyons says. “She said she never had so many people come into the room for brief intervention or enquire about her services. That’s just a great example of the effectiveness of our program – it breaks down barriers so people are more willing to speak up.” What sets the LIVINWell workshop apart from other mental health programs is the bare simplicity of it. Lyons says people only need a basic understanding of how to help others or themselves when they first recognise a mental health issue. “We don’t overload people with complex information that they don’t require,” Lyons adds. “They don’t need to know the different types of mental illnesses or how to diagnose someone. “What they need to know is how to help someone who might be struggling at that moment and link them in with professional support if required. We all have the power to save someone’s life.” The LIVINWell workshop is highly relatable, delivered by experienced facilitators who share personal stories of living through the loss of a loved one to suicide, going through mental illness themselves, or knowing somebody else who has. Lyons believes this approach helps to normalise conversations surrounding many different aspects of mental health. He also says that by having facilitators talk with, instead of at the audience, adds to the workshop’s appeal. “We undertook a social impact validation project with Ernst & Young last year, and some of the findings they had uncovered were truly rewarding for our team,” Lyons says. “Eighty-five per cent of survey respondents who attended our workshop indicated that they had
Industry comment
Industry Q&A: CRISIS management with Engenium
AUSTMINE SPEAKS WITH ENGENIUM ABOUT ITS POSITIVE APPROACH TO CRISIS MANAGEMENT AND USE OF THE INTERNET OF THINGS (IOT) TO ASSIST MINING COMPANIES IN CAPTURING DATA SAFELY.
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ith an increased focus on reducing capital expenditure and driving down operating costs in today’s environment, many mining companies must extend the service life of their ageing infrastructure. Running assets beyond intended design life is a difficult proposition to manage, but is nevertheless commonplace in the mining industry. However, strategies and procedures can be implemented to mitigate the risk of asset and infrastructure failure. This includes maintenance and/ or remedial work activities that support the asset to achieve desired functionality, serviceability, safety,
operational and commercial outcomes for its required service life. Austmine discusses this paradigm and Engenium’s Critical Review and Inspection of Structures requiring Increased Service (CRISIS) methodology with the company’s executive general manager Newcastle, Heath Baker. THINKING DIFFERENTLY IN TRICKY TIMES The global pandemic has shifted the focus of mining businesses around the world, and for suppliers, this has meant adapting quickly and driving new expertise. Speaking of these challenges,
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Baker highlights Engenium’s approach to servicing clients during these tricky times. “Our Newcastle office has exceptional innovative engineering design capability,” he says. “However, the global pandemic continues to drive the need for many of our clients to think differently when planning their future. This has therefore shifted thinking to extending the effective life of their assets.” With new capital expenditure in the Australian mining industry somewhat harder to come by, investing in services to prolong the life of assets is where Engenium delivers value and results.
MANAGING WITH CRISIS We have all become adept at managing a crisis in 2020. However, Engenium has developed a more positive CRISIS for its mining clients. “As we explored our strengths in structural and corrosion risk of infrastructure further, we developed an assessment methodology that can help our customers across the entire mining life cycle,” Baker said. “With some miners running assets beyond their design life, and operating in highly corrosive environments, an impetus was placed on monitoring this infrastructure more effectively. Hence, CRISIS was born.” The CRISIS methodology combines Engenium’s expertise in structural engineering and corrosion engineering. Baker makes the important distinction between these two capabilities when managing infrastructure, stating, “Structural risk is not the same as corrosion risk.” He explains: “Assessment of infrastructure that confirms active corrosion and the mechanism(s) of the corrosion is crucial because the presence of corrosion does not necessarily indicate an unacceptable structural risk. “One method used to mitigate corrosion degradation is by putting in place simple to follow surface treatments suitable for the medium and the environment. “Establishing accurate findings and recommendations requires specific processes and procedures appropriate for each asset type and location, and this is what we prioritise with our CRISIS methodology.” Engenium’s CRISIS methodology also aims to provide effective control and governance of assets to realise value through managing risk and opportunity. This achieves the desired balance of cost, risk and performance as stated in
ISO55000:2014 Asset Management – Overview, Principles and Terminology. CRISIS includes a three tiered approach to the assessment of assets. This assessment evaluates the viability and consequences of service life extension. The three tiers consist of initial appraisal (or helicopter study using engineering judgement; conditionbased assessment); and detailed investigation (non-destructive testing and desktop engineering analysis). A sound understanding of the threetiered approach allows the risk to be appropriately evaluated for the asset stakeholders. Desktop structural assessments (pre- and/or post-inspection) provide meaningful outcomes that enable targeted future inspection and assessment guidelines. The desktop structural assessment involves, but is not limited to, finite element analysis (FEA) of the asnew structure, with scenario analysis to confirm structural redundancy magnitudes for asset elements. This determines what corrosion can be afforded, if any, to individual members, and therefore provides guidelines regarding tolerable structural losses for future inspections. This assessment can be used with site inspection findings to determine risks for the asset and a suitable maintenance program. The timing and nature of repairs and/or strengthening remedial works, together with any ongoing inspection requirements would be detailed. Desktop assessments enable a targeted approach to field-testing. Depending on the type of asset being considered and the potential risks involved, field-testing could be in the form of visual inspection, non-destructive testing (NDT), invasive testing and field mapping and sampling.
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Drone technology assists in the safe inspections of remote and challenging terrains.
BRINGING THE IOT TO CRISIS MANAGEMENT As mining gears up for digital transformation, Engenium is bringing this forward by using unmanned aerial vehicle (UAV) technology to capture important aerial data. Exploring this technology, Baker discusses the application for Engenium’s mining clients. “Engenium is working with Phoenix Drones to deliver greater value to our customers,” he says. “We have now been capturing data for a range of projects, including degradation mitigation and integrity assessments on fixed plant and port infrastructure. “Phoenix Drone Services captures data in remote and challenging terrains, providing absolute accuracy while maintaining a safe working environment. This has created additional value for our clients, including time savings, removing the need to work from heights and greater data capture for 3D modelling and surveying. “We are now capturing underwater data, (using) remotely operated vehicles (ROVs) to remove the human factor from surveying hard-to-access areas, including water reservoirs, tanks, towers and canals, et cetera.” For more information on ageing assets and coastal asset management, visit www.engenium.com.au/knowledge/ insight
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Workforce management
Striving for zero harm across Asia Pacific NO INJURY GOES UNNOTICED FOR WEIR MINERALS REGIONAL MANAGING DIRECTOR ASIA PACIFIC TERESE WITHINGTON, WINNER OF THE PROSPECT AWARDS FLEXCO SAFETY ADVOCATE OF THE YEAR AWARD. SHE HAS BEEN COMMENDED FOR HER EFFORTS IN DRIVING ZERO HARM OPERATIONS.
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eir Minerals regional managing director APAC (Asia Pacific) Terese Withington has taken home the Flexco Safety Advocate of the Year honour at the 2020 Australian Mining Prospect Awards for her relentless push to improve the company’s safety processes. Withington is instrumental in raising the safety of Weir’s operations across Australia, the Pacific, Southeast Asia, China and India. This is no small feat, with 2000 employees working in nine manufacturing centres, 19 service centres and 31 sales offices across seven countries. Withington keeps safety standards high in the workplace by introducing initiatives across the region. This includes safety kaizens and learnings, where she is personally involved in the review of and learning from every incident to achieve zero harm. Specific tasks, such as the movement of heavy SAG and ball mill liners that are manufactured in Weir’s Artarmon foundry to various locations, do not evade Withington. She has been the driver behind the introduction of lugs on the mill liners – an anchor point from which to lift the equipment – to reduce the safety risks associated with the task. Withington also ensures that Weir
Terese Withington at Weir Minerals’ Artarmon foundry in Sydney – the largest ferrous foundry in Australia.
employees, maintenance technicians and operators follow the correct lifting procedures using certified equipment in regards to lifting Warman centrifugal pumps. As some pump components weigh more than five tonnes, Withington leads the introduction of training
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videos to demonstrate the correct techniques, with education pieces also published on the company website and LinkedIn page. During Safety Week in September 2019, Withington set the focus of the event on hands and finger injuries, which account for the largest
Workforce management proportion of injuries at Weir. As a result, all APAC teams focussed on finding and eliminating hazards that pose risks to hands and fingers at their safety stand-downs, with the Clayton facility introducing guards on rubber lining machines to prevent injuries. Weir’s Clayton service centre achieved two years without an injury, while hitting 23 years lost-time injury (LTI) free and three years medical treatment injury free (MTI). These high achievements are also demonstrated at Weir’s technical centre, which completed eight years LTI free and MTI free. Under Withington’s leadership, Weir’s Asia Pacific operations halved their traumatic incident reduction (TIR) during 2019-20. However, the high achievements don’t slow Withington’s ambitions as every injury is one too many in her eyes. She continues to drive Weir’s safety culture and progress its journey to becoming a zero-harm workplace. At the outbreak of COVID-19, Withington introduced additional safety measures and regular communication with all employees. Placing their physical and mental wellbeing at the core, she holds daily meetings with senior leaders to formulate decisions and procedures for keeping employees safe. She works with country managers to highlight the measures required to ensure the safety of all employees according to local regulations. Under Withington’s leadership, she ensures that positive stories of exemplary performance by Weir employees are shared within the Asia Pacific region, initially every week and then maintained every fortnight. There have been no infections at Weir’s 19 facilities across Australia, with a total of seven infections recorded across Weir’s six other
Weir Minerals regional managing director APAC Terese Withington.
“The quality of nominations was high, especially given the current disrupted environment from COVID-19.” operating countries in the Asia Pacific (at the time of her nomination). In 2020, Withington broadened the safety indicators into the APAC regional key performance indicators to include lag indicators, as well as lead safety indicators. CSIRO mineral resources principal research engineer Mark Dunn says all Prospect Awards nominees should be commended for their efforts to improve safety, sustainability and productivity in the Australian mining industry. “The quality of nominations was high, especially given the current disrupted environment from COVID-19,” he says. Flexco managing director Mark
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Colbourn congratulates the finalists of the category, including WesTrac health, safety and environment manager Natalia Trewin; CITIC Pacific Mining health and safety specialist Madeleine Holloway; and Yancoal Mount Thorley Warkworth mine dragline, drill and blast officer, Melissa Cedelland. “Each year, Flexco takes pride in sponsoring a safety focussed awards category; it’s our top business priority as a global organisation and is always our biggest focus when we develop and launch new products,” he says. “It’s at the core of everything we do, and we applaud those who take on the additional responsibility to advocate for safety in their workplace.”
THE MINING INDUSTRY HAS MOVED TO A NEW PHASE FOLLOWING THE MINING BOOM, ONE WHERE PRODUCTIVITY, INNOVATION AND SAFETY HAVE EMERGED AS ITS KEY PRIORITIES PROSPECT AWARDS MINING SERVICES VOLUME 112/11 | DECEMBER 2020
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Product spotlight
Miners benefit from safety-first electrical cleaning solution CRC INDUSTRIES DOES NOT ONLY PROVIDE CLEANING SOLUTIONS FOR ELECTRICAL COMPONENTS. ITS PENCHANT FOR INNOVATION ALSO EXTENDS TO THE HYGIENE OF AN ENTIRE ROOM, EQUIPMENT AND COMMERCIAL VEHICLES.
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hen considering safety at a mine or quarry site, the protection of electrical components plays an important role in preventing potential hazards for workers. As dust and dirt build up on electrical components, it makes the maintenance tasks a challenge in the absence of a suitable cleaning solution.
For McLennan Earthmoving quarry manager Ben Warwick, the solution for this problem comes in the form of a blue-capped aerosol, labeled: CRC CO Contact Cleaner. Warwick, who was first introduced to the product through BSC, says the CRC CO Contact Cleaner has proven very useful for McLennan in maintaining their electrical components. Adequate protection of electrical components helps to keep dangers at bay.
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“Every time we have an electrical issue and we need to inspect a switch or a connector or a greased up circuit, we just spray the CO Contact Cleaner on the equipment to clean the grease, so that we can attend to the problem safely,” he says. “The product is plastic safe, so we have the peace of mind that it does not damage any of the components. It also evaporates quickly, which makes the maintenance job easy for us.” McLennan Earthmoving, a familyowned earthmoving business based in the Clarence Valley in New South Wales, has been working with BSC’s Grafton branch for over 20 years. A BSC sales representatives visits the McLennan Earthmoving site regularly to make sure they are well supplied with their required products. BSC Grafton branch manager, Colin Johnson says the CO Contact Cleaner is one of the most popular CRC products for cleaning electrical parts. “You can use the CO Contact cleaner for cleaning relays, switches, circuit breakers, alarm and signal systems, printed circuit boards, connectors, generators, contacts, laboratory and test equipment and more. The aerosol contains COZOL, which enhances the cleaning power without damaging plastics,” he says.
CRC Fogger Sanitiser can kill the germs that conventional cleaning techniques miss.
CONTINUING TO INNOVATE CRC national business development manager for mining David Bailey says CRC is constantly developing new products to enhance the safety at mine and quarry sites. “CRC is known to be a responsible supplier of cleaning products to the
CRC CO Contact Cleaner is one of the most popular CRC products for cleaning electrical parts.
mining industry and as such, we continue to broaden our product range by moving towards more consumerfriendly and environmentally-safe products,” he says. One such innovation by CRC is the introduction of the CRC Fogger Sanitiser – an Australian-made industrial
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strength sanitiser that kills 99.9 per cent of germs and provides long lasting, residual protection. Bailey says the CRC Fogger can be used by mines and quarries to easily sanitise an entire room or the inside of a commercial vehicle. “When drivers of a commercial vehicle end their shifts or when a mining accommodation is vacated, you can just activate the CRC Fogger and then leave the enclosed space. The product will start working, getting into all the hard to reach spots to kill the germs that conventional cleaning techniques miss,” Bailey says. “You can use the CRC Fogger on a range of surfaces. CRC Fogger Sanitiser starts working instantly and it can sanitise a whole room in as little as 30 minutes.” CRC Natural Degreaser is another product specifically suited to the mining industry, Bailey adds. “The CRC Natural Degreaser consists of 60 per cent D-Limonene, which is a citrus-based natural heavyduty cleaner and extremely effective for dissolving and removing grease, oils, lubricants, adhesives and contaminants. You can use the Natural Degreaser during the decommissioning of draglines and it can effectively clean the black jack grease from all parts and components,” he says. With CRC offering such a wide range of cleaning products, Bailey says CRC and BSC can work together to help optimise the number of cleaning products used in mines and quarries. “As part of CRC’s collaboration with BSC, CRC team members often accompany BSC representatives to their clients’ sites and survey the cleaning products inside a workshop’s cabinets, helping eliminate any redundancies. This will ensure that the BSC customer is aware of the suitable CRC products for their needs and can stock them accordingly,” he concludes.
Events CONFERENCES, SEMINARS & WORKSHOPS EVENT SUBMISSIONS CAN BE EMAILED TO EDITOR@SAFETOWORK.COM.AU
UNDERGROUND OPERATORS CONFERENCE 2021 | PERTH | MARCH 15-17 The Australasian Institute of Mining and Metallurgy (AusIMM) Underground Operators Conference 2021 will bring together mining engineers, operators, technical service managers and consultants to share their underground operational experience and practices. Underground Operators 2021 will feature internationally recognised keynote speakers, including BHP asset president, Olympic Dam and chief geoscientist Laura Tyler, CommChain executive chairman Gary Zamel and rock engineering consultant, Sweden Knut Garshol. The program will cover key discussion topics on process transformation, innovative mining methods and practices, health and safety, revolutionising the traditional mine and more. Underground Operators 2021 will be held at the Perth Convention and Exhibition Centre on March 15-17. • undergroundoperators.ausimm.com
makers and innovative thinkers. The 2021 theme of harnessing intelligence will provide the opportunity to reflect, discuss and consider the future of the mining industry following a period of significant disruption. Austmine 2021 will explore the importance of the interaction between people, processes and technology over two days of keynote speeches, interactive sessions and panel discussions. The event has welcomed BHP onboard as its principal sponsor for 2021, highlighting BHP’s continued commitment to technological excellence in the Australian mining equipment, technology and services (METS) sector. • austmineconference.com.au
SAFETY IN ACTION | ONLINE | MARCH 22-26
MINE WASTE AND TAILINGS CONFERENCE 2021 | BRISBANE AND ONLINE | JULY 1-2
Safety in Action has been the meeting place for the Australian health and safety industry for more than 20 years. In 2021, Safety in Action will be delivered in a fully virtual format on March 22-26, allowing the industry to meet, connect, learn and explore the latest innovations in the space. Using events and networking platform, Swapcard, the event will retain its large-scale exhibition to allow people to browse the newest products, technologies and services. It will also provide access to the same thoughtprovoking conferences and seminar series. Swapcard’s matchmaking function will enable attendees, exhibitors and partners to connect and network with leaders and decision makers in the work health and safety industry. • safetyinaction.net.au
The AusIMM and the University of Queensland have joined forces to host the Mine Waste and Tailings Conference as a hybrid event this year. Building off the success of the previous conferences in 2015 and 2018, the 2021 conference aims to set the benchmark for sharing knowledge and insights on mine waste and tailings management, sustainable practice and facility closures on a global scale. Over two days, the conference will feature selected technical papers with a strong operational focus, an exhibition showcasing the latest innovations as well as networking functions. There will also be a pre-conference workshop that provides additional professional development opportunities. • tailings.ausimm.com
AUSTMINE 2021: HARNESSING INTELLIGENCE | PERTH | MAY 25-27
QUEENSLAND MINING INDUSTRY HEALTH AND SAFETY CONFERENCE | GOLD COAST | AUGUST 22-25
Austmine’s Mining Innovation Conference and Exhibition returns in 2021, creating a key gathering point for industry leaders, change
Representing an initiative to promote health and safety in the Queensland
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mining industry, the conference provides attendees with the opportunity to exchange information, network and foster proactive health and safety management techniques. This year, the event returns with the theme “Together we collaborate, innovate and educate”. The conference will retain presentations planned for 2020 and promote the ingenuity of home-grown safety through the Safety Innovation Health Awards. It follows a bumper year for conference attendance, with almost 1000 people joining the event in 2019. The conference featured seven keynote presentations, 50 concurrent presentations and 60 trade displays. Held at The Star Gold Coast this year, the Queensland Mining Industry Health and Safety Conference will conclude with a Safety Innovation Health Awards and gala dinner. • qmihsconference.org.au
BULK 2021: AUSTRALIAN BULK HANDLING EXPO | MELBOURNE | SEPTEMBER 8-10 The Australian Bulk Handling Expo, conference and awards will take place in 2021 to bring together the bulk handling industry into a standalone exhibition that shares the same location as MEGATRANS, which integrates intrinsically with the logistics and multimodal freight sector. It is supported by the Australian Society for Bulk Solids Handling (ASBSH), which will host an industry conference, while the trade expo will showcase the latest in bulk materials handling equipment and technologies. Exhibitors include Vega, SEW-Eurodrive, Mideco, Bonfiglioli, Minprovise and ESS Engineering. BULK2021 will take place at the Melbourne Convention and Exhibition Centre over a period of three days. BULK2020 ticketholders will be able to use their tickets to join the rescheduled expo. • bulkhandlingexpo.com.au
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