A Continuous Commitment to Safer Mine Sites
An integrated approach incorporating technology, training, regulation and culture is crucial to keeping miners safe in the face of rapidly changing risks.

By Carly Leonida, European Editor


Safety is a multifaceted issue encompassing training, culture, technologies, regulation and systems.
(Photo: Caterpillar Safety Services)
Safety is the mining industry’s number one priority. While mine operators are continually implementing risk management systems, conducting training and striving to comply with regulation designed to guard against the occurrence of fatalities, injuries and near misses, the speed at which operations are evolving mean that the risks operators face are growing.

The combination of deeper mines, more geotechnically complex rock masses, faster and greater rates of extraction, and less experienced engineers, geologists and equipment operators, mean that the industry cannot afford to take its eye off the ball even for one second, despite the safety measures it has in place.

This is evident from various data published in the first half of 2024, the most prominent of which comes from the ICMM. The organization began collating and publishing information on its members’ safety performance in 2012 with the intention of driving transparency, learning and continual improvements. Not all mining companies are members of the ICMM. However, with a base representing approximately one third of the global market, its statistics are a reasonable proxy for wider trends. The 2023 edition of the ICMM’s safety report, published in July 2024, revealed an annual increase in fatalities; 36 people from ICMM member companies lost their lives at work in 2023, compared to 33 in 2022 and 45 in 2021.

This spike correlates with data from key mining jurisdictions globally. In the U.S., in 2023, the Mine Safety and Health Administration (MSHA) recorded the highest number of fatalities (42) in a decade. Meanwhile the rate of deaths and serious injuries recorded by Safe Work Australia has not decreased significantly over the past 10 years. Instilling safety is a multifaceted endeavor encompassing systems, technologies, training, culture, regulation and more, and it’s a sphere where progress affords zero complacency. In this article, we’ll explore some advances in each of these areas from the past 12 months.

Fostering a Culture of Safety
Caterpillar Safety Services provides a suite of consulting services that help companies and contractors, both in and outside of mining (regardless of whether they own Cat equipment or not), to further develop their organizational safety cultures. These are based on the four pillars of a resilient safety culture: system, mindset, leadership and ownership.

In March 2024, Caterpillar Safety Services launched two new programs. The first is an updated Safety Perception Survey which analyzes an organization’s safety culture. The survey incorporates updated language and modern concepts of safety culture excellence, with new questions related to psychological safety and human and organizational performance. The survey forms part of a process called Zero Incident Performance, or ZIP, through which companies aspire to reduce their safety incident rates to zero. It begins by assessing five safety activities across each organization: hazard identification, event learning, inspections, near miss and safety meetings. Eleven cultural indicators are used including, caring climate, employee involvement, feedback, management credibility, training effectiveness and risk reduction, to determine where each organization is at on its unique safety journey.


The four components of a resilient safety culture. (Image: Caterpillar Safety Services)
The survey also measures how safety is perceived differently among employees, supervisors and managers, and the resulting information provides a basis for continuous organizational improvements. Trinnie Cortez, industry consultant at Caterpillar Safety Services, told E&MJ: “We’ve been using our Safety Perception Survey for years — it’s a tried and tested process — but we wanted to modernize and streamline it to reflect what’s relevant to companies and job sites today. It starts with asking people what they think of their company’s safety culture and the survey captures both qualitative and quantitative information. That’s important because every organization operates differently and will be at different stages of cultural maturity.

“Once we have the results, we then work with the organization to develop a plan for continuous improvement in areas where they might like to better their safety performance and create manageable steps that can be implemented across the company.” These steps might include, for instance, revamping policies, procedures and risk management plans, coaching and development for leaders, and/or introducing new technologies to mitigate hazards. Cortez recommends that companies repeat the survey at regular intervals (say, yearly) to help track progress and provide direction for further improvements.

“The way that we work with clients is very fluid,” said Cortez. “It’s important to meet companies where they’re at, and we incorporate feedback from frontline workers, middle managers, and top leaders at every stage. Helping people come together to make improvements boosts an organization’s chances of success as well as team morale. Getting everyone involved really is the most effective solution to safety challenges.” Cortez pointed out that improvements in safety can have knock-on effects in areas such as talent attraction and retention too; some of the biggest challenges that the mining industry currently faces. The best workers naturally want to work at the safest operations, and companies that continue to put safety at the top of their agendas will also enhance their reputations as employers.

Developing Leadership
The second new offering from Caterpillar Safety Services is a framework based on human and organizational performance. This feeds into various Caterpillar Safety Services offerings, such as the Leadership Development and Coaching program. The program, which includes a mix of workshops, assessments and individual face-toface sessions, helps leaders to understand their strengths and areas for development in safety management, and provides them with personalized development plans. The new framework provides a structured way to talk about safety within this and aims to build more error-tolerant systems by teaching leaders that expecting perfection from workers, processes, or procedures is not realistic. It helps leaders to learn from team mistakes, and creates an environment where employees feel empowered to speak up to share their ideas, struggles and mistakes.

In this way, the organization learns to improve its safety system continuously and workers’ positive contributions are recognized. The result is a more engaged workforce and proactive safety culture with improvements in morale, retention, efficiency and profitability. Cortez explained: “Most mining organizations have very robust safety programs, but the risks can be dynamic and situational, and companies are always striving to do better. Human and organizational performance isn’t a new concept. It’s been a part of our safety workshops and training offerings for some time, but the modernized framework formalizes its incorporation into our services, making them stronger and more holistic.”

He emphasized that ZIP is a continuous aspirational process rather than a formal path to be followed. Creating safe companies and workplaces is an ongoing and evolving endeavor, but by maintaining a commitment to continuous improvement and seeking outside help where necessary, it’s possible to stay on top of risks and empower teams to be responsible for their own safety.

Emerging Technologies Offer New Solutions
Epiroc recently expanded its Live Work Elimination (LWE) product portfolio with the release of several new products. The LWE product portfolio has three key objectives: first, to prolong product life and reduce the frequency of risk exposure, which means less chance of encountering hazards. Second is to develop remote diagnostic tools that reduce the potential for injury. And third, to harness emerging technologies to complete tasks remotely that could otherwise expose people to potentially harmful situations. This is where automated solutions are key as are new developments in equipment design.

The latest LWE additions are the Boom isolation kit for Direct Control System (DCS) drill rigs and Spool valve guard kit for blasthole drill rigs. Both are retrofit kits that can upgrade the corresponding machines for safer operations. The Boom isolation kit isolates the feed, boom, and rock drill functions without impacting operational cycle time. A machine can continue to run on electrical or diesel engine mode while all boom functions are isolated. “The solution makes it safer for an operator to enter the drilling area for maintenance work,” explained Kajol Singh, global product manager – LWE.


Most mining organizations have very robust safety programs, but the risks can be dynamic
and situational. (Photo: Caterpillar Safety Services)
The Spool valve guard kit locks out the 2, 7, 8, and 11 spool valve manual actuation points and reduces risk exposure for personnel working on the machine. Singh added: “By leveraging automation, remote operation, and other advanced technologies, we are enabling safer operations in mining and construction.” The earlier released Hydraulic Operated Bit Basket System (HOBBS) for the Pit Viper 270 series has also been made available for Epiroc’s DML rotary blasthole drill rigs.

“The [HOBBS] solution takes away the need of having an operator working under a suspended load, a rotary head, while changing a drill bit on the deck,” said Singh. “We are constantly developing new products and tools to ensure safety by combining innovative technology with our culture of safety and continuous improvement. Based on this, we have now launched HOBBS for DML machines.” Epiroc’s long term 2030 sustainability target for ‘People – Health and Safety’ is to have no work-related injuries. To contribute to this, the company has also established a LWE program, which is wider than the product offering.

Lori-Anne Fleming, program manager- LWE, explained: “The goal of our LWE program is to make sure that when people work on our equipment, they are not exposed to any energy that would put them in harm’s way and cause injury. Our product portfolio is part of this, but it’s also about change management and reinforcing the safety culture in our industry.”

Keeping Emergency Responders Safe
Safety technology specialist, Dräger, recently debuted a new positive pressure closed circuit breathing apparatus for use in mine rescue activities — the Dräger BG ProAir — which it said, “combines uncompromising safety with the highest level of breathing and carrying comfort.” Kent Armstrong, global business development manager-mining at Draeger Safety Canada, told E&MJ: “The Dräger BG ProAir is an exciting launch for Dräger. The product has launched globally, and we’re hopefully just a few months away from release in the U.S., pending NIOSH and MSHA approval.”

Designed for long-duration deployments, the BG ProAir features a positive pressure breathing circuit which prevents hazardous substances from entering the sealed breathing system. As wearers exhale, carbon dioxide is removed through a CO2 absorber, and prior to inhalation, the air is cooled and enriched with oxygen at a constant rate. Optionally, the oxygen can be dosed according to work rate, thus providing responders with longer duration at low work rates. “Ergonomically designed with safety and visibility in mind, the BG ProAir’s weight is evenly distributed due to its smart carrying system making it easier and more comfortable to wear during longer missions,” Dräger explained. “Additional safety features on the housing include highly visible reflectors and a buddy light system which helps team members to see you and know the status of your apparatus.”

Cooling options include a state-ofthe- art regeneration material as well as a simplified ice system to reduce the temperature of the inhaled air without the need to open the breathing loop or remove components while in use. The larger surface area of the cooling elements provides comfortable breathing air for a longer period of time. To further improve breathing comfort, key components in the breathing loop have been redesigned to significantly reduce breathing resistance.

Blue color-coded touchpoints throughout the breathing apparatus make the handling more intuitive and therefore reduce responder training efforts and equipment downtime. Dräger added that some of the system components from its well-known PSS BG 4 apparatus can be carried over, including the FPS 7000 full-face mask, inmask communication, test equipment, oxygen booster pump, and Drägersorb. With the BG ProAir, reading vital information, such as cylinder pressure, in-use warnings and time to whistle, is simpler and clearer. Its high contrast, full-color display is plainly visible even in difficult environments. The BG ProAir’s integrated RFID assists in absorber status tracking and, in addition to time calculations, such as time to whistle, Dräger has integrated recognized features, like PASS and temperature readings.

To reliably protect against toxic ambient gases, the BG ProAir continually provides positive pressure even when the wearer’s breathing rate increases. It’s further enhanced by smart onboard electronics, which include a low-pressure sensor. This warns when there is a lack of oxygen to ensure safe breathing and can also provide a low-pressure leak test of the breathing system. Dräger said that plug ’n’ play connectors make the BG ProAir easy to assemble and disassemble, while spending less time on training. No tools are required for maintenance and service frequency is conveniently reduced, such as only replacing the reducer every 10 years.

“We have simplified every cleaning aspect of the BG ProAir,” the company added. “It’s completely machine washable and you have fewer parts to clean and disassemble. The waterproof harness can be effortlessly disassembled from the housing, making it even easier to clean and quick to dry.”

The cooling logistics have also been re-engineered, making it more straightforward to reuse the ice packs and regeneration material. The new ice pack system simplifies the freezing process without the need to handle water; while the regeneration material does not require ice and can be stored in the apparatus at temperatures below 25°C / 77°F.

Intelligent Lighting Boosts Safety
In both surface and underground mining operations, effective work lighting is crucial for safety and productivity. Dust, rain, snow and fog can impair visibility and white light, which is available as standard with most LED work lamps, is not always suitable due to its reflective tendencies which can cause glare. To solve this challenge, lighting and electronics specialist, FORVIA HELLA, has developed the RokLUME 280N SMART for mining and construction vehicles. This has a number of intelligent functions. For instance, the lamp allows the light color to be adjusted depending on the environment to maximize visibility.


The new RokLUME 280N SMART work light for
mining and construction vehicles offers intelligent
features. (Photo: FORVIA HELLA)
The RokLUME 280N SMART offers three color variants: white-green, white-amber and white only. Green or amber light is useful when visibility is very limited, e.g. in high dust levels or various weather events, as the colored light can penetrate dust, rain, snow and fog better than conventional white light. The improved visibility reduces the risk of accidents and relieves the strain on workers’ eyes. Another advantage is that the color temperature can be continuously adjusted from warm white to cool white. Warm white light minimizes eye strain and fatigue in reflective environments, while cool white light is perfect for clear vision during night-time work in good weather conditions. The dimming function allows the work lamps to function economically as daytime running lights. This reduces power consumption and CO2 emissions.

HELLA said that if the RokLUME 280N SMART is retrofitted to a vehicle, the smart functions are controlled via a control panel mounted on the dashboard in the vehicle. An integrated memory function allows up to three individual light settings for the work lamps to be saved, which can be called up at the touch of a button. Operation is intuitive and the buttons are dimensioned so that they can be easily operated even when wearing gloves. For OEMs, operation can be integrated via the human machine interface (HMI).

Another feature of the RokLUME 280N SMART is its ability to communicate via powerline communication (PLC). Unlike systems that rely on wireless connections, such as Bluetooth, PLC ensures a stable, reliable and interference- free communication channel. This wired communication method utilizes existing power lines on the vehicle, removing the need for additional harnessing. This makes installation simple and straightforward. A central control unit (gateway) is installed in the vehicle, which reaches each work lamp via PLC.

The RokLUME 280N SMART work lamp and gateway have protection classes IP6K8 and IP6K9K, preventing dust and liquid from penetrating the housing. The control panel also has a robust IP6K7 rating and is designed for a working range of -40°C to +90°C meaning it can withstand even the coldest and hottest conditions. The RokLUME 280N SMART is available in six different light distribution variants: with long-range, close-range, pencil beam, diffuse flood, tunnel flood or ZEROGLARE illumination. The intelligent lighting system is also equipped with a lifetime warning. This provides a timely warning before the service life of the individual work lamp expires, thus preventing unplanned downtime. Anti-theft protection is also integrated.

Helping Mines Make Sense of MSHA Rules
In today’s fast-moving environment, keeping up with the latest health and safety regulations can be challenging. In the U.S., MSHA introduced a new rule in December 2023 which significantly changes safety practices, especially for surface mobile equipment users. “The new rule introduced by MSHA marks a significant step in enhancing safety in mining operations,” the team at Driver Industrial Safety explained in a recent thought leadership article. “This rule mandates mine operators to develop and regularly update a comprehensive written safety program. This program is specifically designed for all surface mobile equipment, not including belt conveyors, at both surface mines and areas of underground mines. The focus is on a collaborative approach, where the safety program is crafted with valuable insights from miners and their representatives. This ensures that the program is not only effective but also resonates with those it aims to protect.”

In its article, the team highlighted key requirements of the program. These include clear steps to identify and mitigate risks associated with the operation of surface mobile equipment. “This involves analyzing potential hazards that could lead to accidents, injuries, or fatalities and implementing strategies to reduce these risks,” it said. It added that, to remain effective, safety programs must be updated regularly. This is crucial in adapting to new technologies, changing mining conditions, and emerging safety concerns. The rule does offer some flexibility, “allowing mine operators to create safety programs that are specifically tailored to their unique mining conditions. This flexibility acknowledges that each mining operation has its own challenges and risks, and a one-sizefits- all approach is ineffective. Operators have the autonomy to design a program that addresses their sites’ specific needs and hazards,” stated Driver Industrial.


Emerging technologies offer the chance for remote working, removing people from potentially harmful
situations. (Photo: Epiroc)
Programs must also be performancebased, requiring at least four types of actions aimed at reducing accidents, injuries, and fatalities. “These actions could include enhanced safety protocols, advanced safety equipment, rigorous training programs, and regular safety audits,” explained the team. “A crucial aspect of these programs is the integration of existing training provisions. This means that training is a periodic activity and a fundamental, ongoing part of the safety culture. It ensures that all personnel are consistently up to date with the latest safety practices and equipment handling techniques.”

MSHA district managers now play an important part in helping the mining industry understand and implement this new rule, offering compliance assistance, providing guidance and support to mine operators in developing and maintaining their safety programs. “Additionally, MSHA plans to collaborate with various stakeholders to build templates for these safety programs, providing a foundational structure that mine operators can build upon to suit their specific needs,” Driver Industrial said. The company offers various solutions that cater to the needs of mining and heavy-duty work environments. “Our range of products, including Toro Heavy Duty Wheel Chocks, Helios Warning Lights/Beacons, Safety Whips, and NVIZN VIDs, are each designed to address specific safety challenges, providing a comprehensive approach to compliance,” said the team.

“The recent implementation of the new MSHA regulation has emphasized the importance of comprehensive, adaptable, and industry-specific safety solutions. Our approach to compliance is highly customized – we listen, analyze, and create solutions tailored to each worksite’s specific requirements. Our team of experts is equipped to provide bespoke consultations, guiding you through the complexities of the new MSHA regulations and helping you develop a safety program that aligns with your unique operational context.”

It added that this approach extends to product customization, including adapting products to specific vehicle types or unique site conditions. “The new MSHA regulation is more than a regulatory update; it’s a call to action for a fundamental shift in the approach to industrial safety. This shift is not just about adhering to new rules — it’s about fostering a culture of proactive safety management, where safety becomes an integral part of every operation,” it concluded.

Service Contractors: Results Come Down to Training
High-volume belt conveyor systems are among the most hazardous pieces of equipment in mining operations. Maintaining the balance between production demands and efficiency can be a challenge for internal maintenance teams. To control labor costs and improve safety, operators often enter servicing agreements with outside contractors to perform routine maintenance or to retrofit new equipment during a shutdown.

Although outside contractors may be experienced, they can lack the proper training and specific knowledge needed to offer adequate servicing and installation of modern equipment designs. Moreover, this gap in expertise might limit what recommendations to common problems they offer, causing them to default to antiquated equipment or debunked solutions. This is why it is so crucial for contractors to have ongoing training that ensures they use modern techniques, install the latest equipment and operate to workplace safety best practices.

Martin Engineering explained in a recent article: “Our technicians are often invited to offer solutions to serious conveyor issues. For example, a common complaint from customers is that the belt cleaners currently installed on the belts are ineffective. Upon inspection, the technicians often find the equipment was not installed properly, not adequately maintained (improper intervals, over-tensioned, etc.) and/or, inappropriately specified. All these issues can be addressed through proper training.”


Dräger’s new positive pressure closed circuit breathing apparatus for use in mine rescue
activities – the Dräger BG ProAir. (Photo: Dräger)
Martin Engineering ensures its technicians are up to date on the latest techniques and bulk handling technologies by conducting regular, intensive weeklong 28-hour training sessions for both new and veteran technicians. The latest iteration took place in the spring of 2024. The company recommends that at every visit, service technicians, whether internal or external, should: 1. Walk the Belt to identify safety issues and obstacles to system efficiency. 2. Carry the correct certifications to provide the service safely. 3. Have the training required to properly complete maintenance and installation tasks. 4. Observe workplace safety best practices for every project including lockout/ tagout/tryout and assistance-required procedures. 5. Possess the knowledge and experience to identify/offer economical solutions. 6. Provide a Walk the Belt report with photos tracking the project and any recommendations.

The team emphasized the importance of conducting training not just in the classroom but also hands on, working with operational life-sized equipment specifically designed to simulate real world environments. For example, Martin Engineering’s most recent training week featured product training (install and maintenance), safety training (confined space entry, energy isolation, manlift, first aid and CPR), and skills training (welding). Martin Engineering has one of the most comprehensive onsite and on-line conveyor training programs in the world. It also has the largest free online archive of training resources in its Foundations Learning Center, presented by knowledgeable and engaging trainers.

“The Learning Center uses a mix of text, graphics, videos, webinars, online events, and live experts available to answer questions,” the company explained. “These free resources have democratized conveyor safety training globally, allowing for refreshers among both internal staff and contractors if questions about conveyor maintenance arise.”

App Offers Customized PPE Recommendations
In June 2024, DuPont launched the new app version of DuPont SafeSPEC, its online personal protective equipment (PPE) selector tool. The app is designed to help busy safety managers and end-users, using custom hazard parameters to identify PPE with the appropriate level of protection for each application. SafeSPEC simplifies the selection process and makes it easier to identify workplace safety solutions, particularly when out on site. “The SafeSPEC app offers an intuitive and convenient way for safety professionals to sift through vast amounts of data and help to quickly arrive at an appropriate protective garment solution,” said Dave Kee, Global Business Director, DuPont Personal Protection. “It puts the power to protect literally in the palm of your hand.”

SafeSPEC enables users to access a comprehensive database containing thousands of potential chemical threats and all the current PPE options available in the Tyvek, Tychem, and ProShield ranges of DuPont protective garments, including coveralls, aprons, shoe covers, and other accessories. Users simply enter basic hazard scenario information, and the app offers customized protective clothing recommendations. A search can be initiated by entering the type of hazard, or by following the on-screen guide to identify the most appropriate PPE options. Once users have entered their hazardous environment details, their search can be saved for future reference. In addition to providing ‘once only’ data entry, SafeSPEC also can enable safety managers and other responsible persons to test different scenarios, ensuring that protection requirements have been considered for any eventuality. Once the scenario is created, users can easily share the recommended products for that scenario as a PDF.

The DuPont SafeSPEC app allows ready access to content, such as the latest product information, technical datasheets, and a regularly updated permeation database. This means all relevant product data is available with downloaded information available offline. This enables users to discover enhanced protection and make informed decisions on selecting protective apparel anytime, anywhere. DuPont SafeSPEC app is now available in nine languages, as well as multiple localized formats, for download on Apple Store and Google Play Store.

As featured in Womp 2024 Vol 09 - www.womp-int.com