Mining 10 Handbook Final

Queensland Mining Industry
Health & Safety Conference
SIMPLE
solutions
to
COMPLEX
problems
22 - 25 August 2010
Townsville Entertainment
& Convention Centre
(TECC) and
Jupiters Townsville
HANDBOOK
This Handbook is proudly Sponsored by Performance Training Pty Limited
Sponsors
The Queensland Mining Industry Health and Safety Conference Committee wishes to thank the following organisations for their
generosity and continuing support of this event.
The above Sponsors were confirmed at the time of printing.
Displays
ABSC Group Pty Ltd LifeAid Pty Ltd Respiratory and Sleep Specialists
ADT Security List Premier Education Pty Ltd RightCrowd Software Pty Ltd
Coal Services Health & Safety Trust M5 Project SAFEmap Australasia
Coal Services Pty Limited Mater Foundation Safety Equipment Australia
Confiance Learning McCullough Robertson Lawyers SICK Pty Ltd
Corporate Bodies International/Ford Health MICOMM Simtars DEEDI
Down Under Training Minerals Industry Safety & Health Centre Southern Engineering Services
Drake Workwise Pty Ltd Mine Site Technologies Sparke Helmore Lawyers
Field Enviro, Field Engineers Moldex Steelblue
Foster OHS MSA (Aust) uvex Safety Australia
GCG health safety & hygiene Performance Training Wesley Corporate Health
Gemini Medical Services Q-COMP Workplace Solutions
Hostile Environment Services Quality Building Management Xstrata Zinc & Copper
2 HSEplus
The above Displays were confirmed at the time of printing.
Welcome
A special welcome to all,
On behalf of the Conference Committee it is my great pleasure to welcome you to the 2010 Queensland Mining Industry
Health and Safety Conference.
Over the next few years our industry is predicted to enjoy unprecedented growth especially with the expansion of the Surat
Basin and the Galilee Basin and the Metalliferous projects in the North West. There is little doubt that this growth will put all our current
systems under pressure.
Therefore our theme this year Simple Solutions to Complex Problems has been chosen to raise the awareness of all to the urgency of
determining ways and means of simplifying our processes and procedures so they are clear and concise rather than complex and outmoded.
As is our custom, over the next several days the microscope will be on ways and means to ascertain and evaluate what options there are to
determine better systems especially where the lives, health and safety of our workforce is at stake.
We cant afford to cut corners, therefore we must simplify our systems so they are streamlined, clear and concise which will benefit every sector
of the industry. Whilst internationally we are placed amongst those countries that have the highest standards in Health and Safety Performance
we must become even more conscious of refining and simplifying our systems to such a degree that we remain at the top and be in a position to
share our knowledge so that others may benefit.
On a national level we must work together lobbying for better legislation and also be open to and embrace the use of new technology,
keeping ahead of developments which will allow us to work more efficiently, safely and productively.
Another major issue we face is our ageing workforce. As many of our operators reach retirement age we face a shortage of the experienced
personnel necessary to teach those new to our industry, therefore training will be paramount.
We trust the depth and breadth of discussion and the information contained within the presentations delivered by our speakers will be of
direct benefit to you and provide many ideas that can be taken back to the workplace for implementation.
The Innovation Sessions are always of great interest as they provide a direct conduit for the delivery of better safety procedures. The final
10 making the short list are to be presented on Monday, with the winners announced at the Conference Dinner on Tuesday evening. The
Conference concludes with Journalist, Jenny Brockie once again being the facilitator as the topic Raising the bar to achieve Zero Harm what
will it really take, comes under close scrutiny.
With our industry forging ahead to new heights it is critical that we pay attention and spend more time and resources to ensure this growth
is not at the expense of the general health and safety of our mine workers. When it comes to profits there is no more valuable asset than our
workforce and we must all work towards keeping them safe.
We also anticipate significant interest in the Exhibition which will be open each day during the morning and afternoon breaks and after lunch. All
the participating organisations have a direct relevance to this industry and have been invited to demonstrate the latest in products and services.
Our committee members welcome the chance to meet you so please make yourself known to them and we encourage you to participate in all
the Social Activities making the most of the networking opportunities that are so important to an event such as this.
Greg Dalliston
Chairperson
Queensland Mining Industry Health and Safety Conference 2010
Conference Committee
Chairman Michael Roche Paul Harrison
Greg Dalliston Queensland Resources Simtars, DEEDI Conference Organiser
Council Marion Powell and Robert Seaman
CFMEU Mining and Energy Liz Sanderson
Division Stewart Bell Anglo American ACCLAIM
Mines and Energy, DEEDI Metallurgical Coal Special Events and Meeting Management
Secretary Roger Billingham Darren Brady
Grant Cook Mines and Energy, DEEDI Simtars, DEEDI All correspondence to be addressed to:
Queensland Resources Council Gavin Taylor Rob O Sullivan ACCLAIM
Mines and Energy, DEEDI Mines and Energy, DEEDI Special Events and Meeting Management
Hag Harrison Annika Van Aswegen 371 Bowen Terrace, New Farm Qld 4005 Australia
Australian Workers Union Queensland Resources Tel: 61 7 3254 0522 Fax: 61 7 3254 0406
Council Email: safeconf@acclaimsemm.com.au
3
www.qldminingsafety.org.au
Conference Venues
Townsville Entertainment and Convention Centre
All Plenary Sessions and three streams of Concurrent Sessions, the Trade Displays and Morning and Afternoon Breaks will be held in
this venue. The Conference Dinner will be in the Auditorium on Tuesday Evening.
Jupiters Townsville
All Lunches will be held in the Grand Marquee on the Lawn at Jupiters Townsville. The fourth stream of concurrent sessions will be
held in the Pavilion. The Informal Dinner and Charity Auction will be in the Grand Marquee on Monday evening.
The Rescue Station
This popular after hours gathering place will again be located in the Lobby Bar at Jupiters Townsville.
The Brewery
The Welcome Function will be held at The Brewery in the old Post Office Building, 252 Flinders Mall.
B - AUDITORIUM
Business Sessions
G
Conference Dinner
Concurrent
G - Concurrent Sessions
Sessions
AUDITORIUM 1
G - Concurrent
Sessions
C - FOYER C - FOYER
Trade Displays A - REGISTRATION Trade Displays
& Breaks DESK & Breaks
GRAND MARQUEE
ENTRANCE
D - FORECOURT
PAVILION Trade Displays
& Breaks
Conference Compendium
Proudly Sponsored by Down Under Training TUESDAY CONCURRENT SESSIONS
Upon arrival each delegate will be provided with a Conference Compendium.
CONFERENCE PROCEEDINGS STUDENT HOST PROGRAM

The following proceedings will be available post Conference on the The Program is designed to promote health and safety within the mining
Website at www.qldminingsafety.org.au industry by giving students who are studying relevant courses exposure
Power Point presentations provided by Keynote Speakers to the industry via the medium of the Conference.
Power Point presentations provided by Concurrent Session Presenters Students come from the Queensland Resources Council Graduate Program
Papers provided by Concurrent Session Presenters and Minerals Industry Safety & Health Centre.
PowerPoint presentations from the Innovation Sessions Program proudly Sponsored by
Minerals Industry Safety & Health Centre
Innovation Finalists Submissions
Conference proceedings proudly Sponsored by
Anglo American Metallurgical Coal
PAVILION
4
Conference Information
Registration
The Registration Desk will be located in the Foyer of the
Opening times: 2.00pm 6.00pm Sunday
7.30am 6.00pm Monday and Tuesday
7.30am 1.30pm Wednesday
General
Dress code Name badges
Welcome Function - Smart Casual Proudly sponsored by Simtars, DEEDI
Business Sessions - Smart Casual Name badges will be provided at Registration.
Informal Dinner - Dressy Casual It is essential they be worn at all times to allow
Conference Dinner - Lounge Suit for Men and entry to Conference Sessions and all Social Functions.
Cocktail Attire for Ladies
Should replacement badges be required, please contact the
Acclaim staff at the Registration Desk.
Luggage Storage Wednesday
An area has been set aside in the Palm Room at TECC for Rescue Station - Lobby Bar Jupiters Townsville
the storage of luggage on Wednesday morning. Luggage is
stored at owners risk. Opening times are after Business Sessions each day and
following the Social Functions.
Beverages will be available at discounted prices courtesy of
Jupiters Townsville.
Coach Transfers - Complimentary Service

Airport Transfers
Sunday - The Coach service will meet all main flights into Townsville airport and transfer delegates to the
Conference Hotels.
Monday - This service will operate again on Monday morning picking delegates up at the airport and transferring
them to their hotel or Townsville Entertainment & Convention Centre.
Wednesday - The Coach service will be available to transfer delegates from the Townsville Entertainment &
Convention Centre to the Airport at the conclusion of the Conference.
Daily Coach Shuttle Service
Business Sessions
Sunday afternoon - This service will collect delegates from designated points close to the Conference
Hotels and transfer them to the Townsville Entertainment & Convention Centre in time for Registration and the
commencement of the Conference.
Monday, Tuesday and Wednesday - This service will operate each morning and Monday and Tuesday
afternoons between designated points close to the Conference Hotels and Townsville Entertainment & Convention Centre.
Social Functions
Sunday evening - Coaches will be ready at the close of the Opening Session to transfer all delegates to the
Welcome Reception at The Brewery and return them to their accommodation at the end of the Function.
Monday and Tuesday evenings - Coaches will be ready at the close of the Business sessions to transfer all
delegates to a designated point close to their accommodation. Coaches will return to transfer delegates to the
Social event that evening and then provide a return transfer to their accommodation at the end of the Function.

Coach Transfers proudly Sponsored by GCG health safety & hygiene
www.qldminingsafety.org.au 5
Conference Program
Sunday 22nd August
2.00pm 6.00pm REGISTRATION Townsville Entertainment and Convention Centre Foyer
4.30pm CONFERENCE OPENING
Master of Ceremonies Darren Isenberg
Welcome to Country
WELCOME
Greg Dalliston, Chairperson, Queensland Mining Industry Health and Safety Conference 2010
Hon Craig Wallace MP, Minister for Main Roads and Member for Thuringowa
5.00pm 6.00pm KEYNOTE PRESENTATION - Proudly Sponsored by ADT Security

Vision and Courage Leading in Complexity
Major General (Retd) Jim Molan, AO DSC
6.30pm WELCOME FUNCTION
The Brewery - Proudly Sponsored by Peabody Energy Australia
10.00pm to late THE RESCUE STATION Lobby Bar, Jupiters Townsville
Monday 23rd August

7.30am - 6.00pm REGISTRATION Townsville Entertainment and Convention Centre Foyer
9.00am 10.30am KEYNOTE PRESENTATIONS - Proudly Sponsored by Thiess
The Couch and the Longwall: The Marriage Between Psychology and Safety in the Mining Industry
Ali Dale, Principal Psychologist, Sentis
Tackling the Challenges in Site Risk Management
Jim Joy, Professor and Director, Minerals Industry Safety and Health Centre (MISHC)
10.30am 11.00am MORNING BREAK AND DISPLAYS - Proudly Sponsored by Macarthur Coal Ltd
11.00am 12.30pm KEYNOTE PRESENTATIONS - Proudly Sponsored by BMA Coal

From Health and Safety to Healthy and Safe: Making the Abstract Real!
Eddie Morland, Chief Executive, Health and Safety Laboratory (HSL), Derbyshire, UK
100 Years of Mines Safety and Health Research in the USA
Michael A Trevits, Senior Research Physical Scientist, Mining Science & Technology, National Institute for
Occupational Safety and Health, Office of Mine Safety and Health Research, Pittsburgh, USA
12.30pm 1.30pm LUNCH AND DISPLAYS - Proudly Sponsored by Southern Engineering Services Pty Ltd
1.30pm 3.00pm INNOVATION PRESENTATIONS - Proudly Sponsored by Coal Services Health & Safety Trust
Tyre Deflation Station
Xstrata Copper Ernest Henry Mine: Bill Robertson, Loch Bennett (Klinge & Co)
Coal Hauler Load Profiler & Sealing System
Jellinbah Mining: Rod Wilson, Robbie Bond
Windrow Delineator
MMG Century: Rod Dugmore
Wheel Chock Lowering Project
BMA Goonyella Riverside Mine: Steve Burns, Andy Langtree, Brian Mann
Pneumatic Controlled Deflector Plate
Sedgman Ltd at Rio Tinto Coal Blair Athol Mine Site: Damian Lloyd, Anthony Looker, Simon Cassidy
3.00pm 3.30pm AFTERNOON BREAK AND DISPLAYS - Proudly Sponsored by Xstrata Zinc & Copper North Queensland Operations
3.30pm 5.00pm INNOVATION PRESENTATIONS - Proudly Sponsored by Coal Services Health & Safety Trust
Geotechnical Hazard Maps
Poitrel Mine BMA Poitrel Mine: Peter Brooks, Yosef Setiyawan, Jason Owers & Chris Currier
Belt Lifting & Roller Replacement Tool
Kestrel Mine, Rio Tinto: Maehe Austin and Peter OBrien
Innovations continues...
6
Keynote
Vision and Courage Leading in Complexity
Presenter: Major General (Retd) Jim Molan, AO DSC
Keynote
The Couch and the Longwall: The Marriage Between Psychology
and Safety in the Mining Industry
Presenter: Ali Dale, Principal Psychologist, Sentis
8 www.qldminingsafety.org.au
Keynote
Tackling the Challenges in Site Risk Management
Presenter: Jim Joy, Professor and Director, Minerals Industry Safety and Health Centre (MISHC)
Keynote
From Health and Safety to Healthy and Safe: Making the Abstract Real!
Presenter: Eddie Morland, Chief Executive, Health and Safety Laboratory (HSL), Derbyshire, UK
Keynote
100 Years of Mines Safety and Health Research in the USA
Presenter: Michael A Trevits, Senior Research Physical Scientist, Mining Science & Technology,
National Institute for Occupational Safety and Health, Office of Mine Safety and Health Research,
Pittsburgh, USA
Conference Program
Innovations continues...
Bullgrip
Anglo American Metallurgical Coal Moranbah North Management: David Helsham, Katie Harrold
24H Grader Over Speed Control System Project
BMA Goonyella Riverside Mine: Steve Burns, Kial Hansen
Cathode Nodule Catcher
Xstrata Copper Copper Refinery: Noel Kimlin
5.00pm 6.30pm THE RESCUE STATION Lobby Bar, Jupiters Townsville

6.30pm 7.00pm PRE DINNER DRINKS The Grand Marquee, Jupiters Townsville
7.00pm
INFORMAL DINNER & CHARITY AUCTION IN AID OF MATER FOUNDATION PROSTATE RESEARCH
Proudly Sponsored by uvex Safety Australia Pty Ltd
The Grand Marquee, Jupiters Townsville
ENTERTAINMENT - Danny McMaster aka HIS MCMASTERS VOICE

Tuesday 24th August

7.30am - 6.00pm REGISTRATION Townsville Entertainment and Convention Centre Foyer
9.00am 10.30am KEYNOTE PRESENTATIONS - Proudly Sponsored by Xstrata Coal

So You Want to Keep Your People Alive? Coal Services, Training Real People, In Real Hazards...Without Risk!
Ron Land, Chairman/Executive Director, Coal Services Pty Limited
The National Mine Safety Framework: The Journey Toward a Nationally Consistent Approach to Mine Safety!
Michael Alder, Manager, Coal Industry and Mine Safety, Australian Government Department of Resources, Energy and Tourism
10.30am 11.00am MORNING BREAK AND DISPLAYS - Proudly Sponsored by Wesfarmers Curragh
11.00am 12.30pm CONCURRENT PAPERS

Auditorium 1 Magnetic Room Palm Room Jupiters Pavilion
HEALTH / COMMUNICATIONS EQUIPMENT Safety Accountability FATIGUE / HEALTH
Proudly Sponsored by Proudly Sponsored by Proudly Sponsored by Proudly Sponsored by
MICOMM Xstrata Zinc & Copper Nth Qld Vale Rio Tinto Coal Australia
Operations
Chairman Bob Fulker, Asset Leader, Chairman Michael Rosengren, Chairman Chris Coombes, General Chairman Rory Gordon, General
BHP Billiton, Cannington General Manager Australian Mining, Manager Coal, Vale Manager, HSE, Rio Tinto Coal Australia
Thiess Pty Ltd
Effective Health Communication Safe Systems Approach for Mining A1 Risk Management at Grasstree The Work Ability Index
in the Mining Industry Road Safety David Carey, General Manager, Gerard Tiernan, Manager,
Hugh Shannon, Associate Lecturer, Damir Vagaja, Manager, Mining & Underground Operations, Grasstree Health Surveillance, Safety and
Institute of Health & Biomedical Resources, Safe Systems, ARRB Mine, Anglo American Metallurgical Health, Mines and Energy, DEEDI
Innovation, Faculty of Health, Group Ltd Coal Trudy Tilbury, Senior Principal
Queensland University of Technology Ergonomist/Principal Human Factors
Improving the Operational Safety Understanding your Obligations
Advisor, Mines and Energy, DEEDI
Complicated Manual Handling of Road Going Heavy Vehicles in Mark Parcell, Principal Consultant,
Simple Prevention Mining Operations The Safety Managers Fatigue and Safety in Mining
Kevin Conlon, Director, KINNECT, Ken Johnsen, Chief Executive Officer, Roger Kahler, Director and Principal
A Positive Approach to
Adam Austin, Health, Safety & Advanced Braking Technology Ltd Consultant, The InterSafe Group Pty
Accountability: Understanding the
Training Superintendent, Newlands Ltd
Road Safety Audits on Mining Nature and Role of Accountability in
Northern Underground Supporting Health and Safety Simplifying the Complexity of
Operations
Simple Solutions: Communicating Damir Vagaja, Manager, Mining & Clinton Strahan, PhD Student Polysomnography - Understanding
Vibration Information to Workers Resources, Safe Systems, ARRB Peter Smith, Professor of the Objective Measurement of a
in Toolbox Talks Group Ltd Organisational Systems and Acting Sleep Disorder
Trudy Tilbury, Senior Principal Dean of Engineering and the Built Darren OBrien, Clinical Services
Ergonomist/Principal Human Factors Environment, Central Queensland Manager, Respiratory & Sleep
Advisor, Mines and Energy, DEEDI University Specialists
Concurrent Papers continues...
12
Keynote
So You Want to Keep Your People Alive? Coal Services, Training Real
People, In Real Hazards...Without Risk!
Presenter: Ron Land, Chairman/Executive Director, Coal Services Pty Limited
Keynote
The National Mine Safety Framework: The Journey Toward a
Nationally Consistent Approach to Mine Safety!
Presenter: Michael Alder, Manager, Coal Industry and Mine Safety, Australian Government
Department of Resources, Energy and Tourism
Notes
Conference Program
12.30pm 1.30pm LUNCH AND DISPLAYS - Proudly Sponsored by Downer EDI Mining
1.30pm 3.00pm CONCURRENT PAPERS

LEADERSHIP / INVESTIGATION TECHNICAL HEALTH & HYGIENE TECHNICAL
Downer EDI Mining Vale Gemini Medical Services Transfield Services Australia
Chairman Neil Reynoldson, Chairman Marc Kirsten, Chairman Stephen Smyth, Chairman Rowan Munro, GMO/SSE,
Macarthur Coal Mine Manager, Newlands Coal District President, CFMEU Ensham Resources
The Art of Investigations and Fluid Power: Using MDG 41 to Education as a Path to a Healthy State Wide Audit of Underground
Accidents Promote Hose Safety Workforce and Early Detection of Coal Mine Gas Monitoring Systems
Peter Peachey, Director and Principal Rosa Burns, Senior Training Advisor, Health Problems Darren Brady, Manager OHECC
Consultant MMG Minerals and Metals Group Tammy Farrell, Managing Director, Tim Watson, Inspector of Mines,
Martin Kortlucke, Engineer and Century Core Health Consulting Pty Ltd Mines and Energy, DEEDI
Failure Analyst, Scientific & Toby Ford, Chief Executive Officer,
Risk - Cost - Benefit (RCB) Selection Assessing Work Tasks of Tyre
Engineering Consultants Pty Ltd Ford Health
of Optimum Early Warning Service Personnel
Ian Cooper, General Manager,
Risk Leadership - Focusing the Technologies Michael McDonald, Senior Lecturer,
Jellinbah Mine
Attention Where it Counts Gul Kizil, Research Fellow, Minerals School of Human Movement,
Marc McLaren, General Manager Industry Safety and Health Centre Increasing the Health Profile within Queensland University of Technology
Safety4Life and Organisational OH&S Framework
Knowledge Elicitation Solutions ISOLgate/TYREgate/COLLISIONgate
Consultancy Tony Parker AM, Professor, Institute
for Improving Performance and - a Suite of Global Risk Management
of Health & Biomedical Innovation,
Hitler and Gandhi were Both Efficiency Decision Support Portals
Faculty of Health, Queensland
Courageous Leaders Sue Leveritt, EMESRT Coordinator, Gul Kizil, Research Fellow, Minerals
University of Technology
Lincoln Eldridge, Managing Director, Minerals Industry Safety and Health Industry Safety and Health Centre
SAFEmap Australasia Centre Applying Risk Based Principals to Tilman Rasche, Inspector of Mines,
Managing a Pre Employment Mines and Energy, DEEDI
Medical Process
Mark Cassidy, Director, 4cRisk
Mark Jacobs, Health Services
Superintendent, Leighton Mining
3.00pm 3.30pm AFTERNOON BREAK AND DISPLAYS
3.30pm 5.00pm CONCURRENT PAPERS

LEGAL LOCATION & PROXIMITY SYSTEMS QUEENSLAND MINING INSPECTORATE TRAINING
Sparke Helmore Lawyers SICK Pty Ltd ABSC Group List Premier Learning
Chairman Matthew Smith, Partner, Chairman Alan Miskin, Chairman Rodney Bridges, Chairman Sean Cross,
Sparke Helmore Lawyers General Manager, Health & Safety, Executive General Manager SSE, Manager Health & Safety Systems,
Peabody Energy Australia Wesfarmers Curragh Pty Ltd Ensham Resources
Understanding Your Safety The Application of Laser Sensing Simtars New Mobile Gas Laboratory Lots of Training - How Much
Responsibilities Technology to Proximity Detection in for Emergency Response Learning?
Cameron Dean, Partner, the Mining Industry Darren Brady, Manager OHECC, John Sleigh, Inspector of Mines,
McCullough Robertson - Lawyers Nicky Guenther, National Technical Mines and Energy, DEEDI Safety and Health Mackay, Mines
& Sales Manager, Auto Detection & and Energy, DEEDI
Bullies are Bad Business Complex Managing Hazardous Materials in
Ranging Systems, SICK Pty Ltd
Problem/Simple Solutions Queensland Mines Zero Harm Starts with Proper
Hedy Cray, Partner An Overview of Mine Communications Carolyn Topping, Health Safety and Interactive Education
Shae McCartney, Senior Associate, and Tracking Systems in the United Environmental Scientist, Simtars, Johann DeBeer, Executive Chairman,
Workplace Relations, Employment and States DEEDI List Premier Education
Safety, Clayton Utz Michael A Trevits, Senior Research
Physical Scientist, Mining Science The Health Improvement and The Best Evidence of Competence
Fair Hearings in the Coroners Court & Technology, National Institute for Awareness Committee Deb Jones, Mining Industry Skills
Matthew Smith, Partner, Occupational Safety and Health, Fritz Djukic, Senior Principal Centre Inc.
Sparke Helmore Lawyers Office of Mine Safety and Health Hygienist, Simtars, DEEDI
Research, Pittsburgh, USA
Proximity Detection Systems in
Underground Mines
Denis Kent, Business Development
Manager, Mine Site Technologies Pty
Limited
Concurrent Papers continues...
16
Notes
Conference Program
6.30pm - 7.15pm PRE DINNER DRINKS Townsville Entertainment and Convention Centre Forecourt
7.30pm CONFERENCE DINNER AND INNOVATION AWARDS - Proudly Sponsored by Leighton Contractors Pty Ltd
Address by the Honourable Stephen Robertson, Minister for Natural Resources, Mines and Energy and Minister for Trade

ENTERTAINMENT presenting David De Vito
Wednesday 25th August

7.30am - 1.30pm REGISTRATION Townsville Entertainment and Convention Centre
9.00am 10.30am FACILITATED SESSION - Proudly Sponsored by Workplace Solutions
Safety Management Systems (SMS) What Makes an Effective SMS?
Queensland Mines Inspectorate Presentation of Results of SMS Working Group
Gavin Taylor, Chief Inspector of Coal, Mines and Energy, DEEDI
10.30am 11.00am MORNING BREAK AND DISPLAYS - Proudly Sponsored by Australian Workers Union
11.00am 12.15pm FACILITATED SESSION CONTINUED - Proudly Sponsored by Workplace Solutions

Raising the Bar to Achieve Zero Harm - what will it really take?
A panel of key stakeholders from Unions (AWU and CFMEU), Mining Organisations and Government will debate the
question What Makes an Effective Safety Management System
Facilitator: Jenny Brockie, Journalist and Broadcaster
12.15pm 12.30pm FORMAL CLOSE OF CONFERENCE

Closing address by Stewart Bell, Spokesperson, Queensland Mining Industry Health and Safety Conference 2010
12.30pm 1.30pm FAREWELL LUNCH
The presenters, topics and times are correct at the time of publishing and in the event of unforeseen circumstances, the Conference Committee reserves the right to alter or delete items from this program.
Master of Ceremonies
Darren Isenberg
Darren has spent the past 15 years making people feel happy at corporate events, whether through his insightful and humorous
MCing, his tailor-made team-building activities, his captivating corporate training or by keeping his distance. He has worked
all over Australia and the Asia/Pacific Region for industries all the way from finance to steel and is experienced in television and
radio, owning one of each. He is also extremely polite and modest and would like to thank you for reading about him but
wishes he had more interesting things to include in this paragraph.
Facilitator
Jenny Brockie
Jenny Brockie is one of Australias most experienced and respected broadcasters and television documentary makers. She
currently hosts INSIGHT on SBS TV, where she facilitates a lively discussion each week involving more than 50 people.
Jenny has won many prestigious awards, including two United Nations Association Media Peace Prizes for her work on INSIGHT.
18
Keynote
Safety Management Systems (SMS) What Makes an Effective SMS?
Raising the Bar to Achieve Zero Harm - what will it really take?
Facilitator: Jenny Brockie, Journalist and Broadcaster
Notes
Presenters
Michael Alder
Michaels current role involves heading up the secretariat supporting the implementation of the National Mine Safety
Framework and policy advisory responsibilities for coal industry development, investment, trade and infrastructure issues. He
is also a co-chair of the Coal Mine Health and Safety Steering Committee and a member of the Coal Mining Taskforce of the
Asia Pacific Partnership on Clean Energy and Development.
In a public service career spanning more than 30 years, Michael has held management positions covering a wide range of
policy and program issues, including, primary and secondary industry, trade, infrastructure, agriculture, environment and immigration issues. He
has led industry delegations and represented Australia at numerous international fora. He has also been a member of numerous government and
industry advisory committees and sat on the board of government corporations. He holds degrees in economics and history.
Ali Dale
Dr. Ali Dale is the Principal Psychologist for Sentis, a global team of psychologists and safety professionals who specialise in
enhancing safety performance through the psychologically based Zero Incident Process: ZIP. In doing so, Ali has consulted to
resources based clients around the world including Australia, Singapore, Europe, North & South America, Canada, Africa, and
New Zealand. With a Masters Degree and PhD in Clinical and Health Psychology, Ali focuses on the application of the latest
research and cutting edge psychology to improving safety performance in the resources industry.
Jim Joy
Professor Jim Joy has been the Director of the Minerals Industry Safety and Health Centre (MISHC) since start-up in 1998. MISHC
is in the Sustainable Minerals Institute at the University of Queensland. For over 20 years he has worked on mining industry risk
management projects. He is an internationally-recognised facilitator, technical expert, presenter and trainer. Jim has had company
advisory roles for BHP Billiton, WMC, and Xstrata. He is currently the Anglo American Chair of Risk Management which includes
helping develop their global HSE risk management initiatives.
Ron Land
Ron was appointed inaugural Chairman of Coal Services Pty Limited and its constituent divisions, Coal Mines Insurance Pty Ltd
and NSW Mines Rescue Service, commencing 1 January 2002. He was formerly a Board Member of the Joint Coal Board, from
February 1998. He entered the coal industry in 1974 and became Secretary of the Miners Federation in 1985.
He holds a Third Class Certificate of Competency under the Coal Mines Regulation Act, the Centenary of Federation Medal and
was awarded the Royal Humane Society Award for Bravery in 1981. Simultaneous to being Secretary of the Miners Federation,
he was Trustee and then Chairman of the $5 billion industry Superannuation Scheme from 1985 to 2002. He was named Superannuation
Trustee of the Year by the Australian Superannuation Funds Association in 1994. Ron has direct responsibility for New Property and Capital
Works Development and Virtual Reality Commercialisation for Coal Services Pty Limited. His commitment, drive and vision to see world class
virtual reality training facilities across the coal mining industry has been instrumental in changing the mine training culture across NSW with the
facilitation and implementation of such innovative technology.
Major General (Retd) Jim Molan, AO DSC

Retiring from the Australian Army in 2008 after 40 years, Jim Molan served in command and staff appointments in operations,
training, staff and military diplomacy. In 2004, Jim deployed for a year to Iraq as the Coalitions chief of operations, during
a period of continuous and intense combat. On behalf of the commanding general, he controlled all operations of all forces
across all of Iraq, including the security of Iraqs oil, electricity and rail infrastructure, a story told in his double best selling book
Running the War in Iraq.
Eddie Morland
Eddie is Chief Executive of the UK Health and Safety Laboratory (HSL) and a member of HSEs Senior Management Team. HSL
employs 400 staff across a wide range of science and engineering disciplines. Eddies career spans 30 years of developing and
deploying science and engineering know how to improve safe operational performance and enable innovation. Starting as a
research scientist in Nuclear Power, he has managed technical projects and people across a wide range of industries in both the
public and private sectors. He is a Fellow of both the Institute of Physics and the Royal Society of Medicine.
Michael A. Trevits
Michael is a Senior Research Scientist at the National Institute for Occupational Safety and Health (NIOSH), Office of Mine
Safety and Health Research. He has been conducting mining research for 36 years (originally for the U.S. Bureau of Mines
and now NIOSH). Michael is currently working to identify new health and safety technologies that may be beneficial to the
mining industry. He has conducted research on remote mine fire control and suppression, methane control, mining-induced
subsidence and use of ground penetrating radar to delineate ground control problems. He has authored 130 publications and
has been granted one patent.
Charity Auction - In aid of the MATER FOUNDATION
Every day, eight Australian men die of prostate cancer.
Prostate cancer is the most common cancer in Australian men and the second
biggest cause of cancer deaths in males. It claims almost 3,000 lives a yeararound
the same number as breast cancer. Today, there are more than 61,000 men fighting
prostate cancer in Australia and another 19,000 will be diagnosed this year. Many of
these men are watching the research at the Mater with eager interest.
Current screening methods are by no means perfect and treatment is invasive with side effects that most men
dont like to think about. There is an urgent need for better treatments, and ultimately a cure. At the Mater
Medical Research Institute the search for both is underway.
The Mater continues to treat hundreds of prostate cancer patients throughout regional Queensland with a
commitment to exceptional care. The cell research undertaken in this area enables these discoveries to move
from the lab to clinical application and trial at the hospital for men facing this diagnosis.
Vital funds received from companies and individuals ensure that this research continues to have significant
outcomes that are positive and provide hope for patients facing a journey of prostate cancer. For more than
100 years the Mater has been committed to providing compassionate health care to all Queenslanders with an
emphasis on the founding values of the Sisters of Mercy of dignity, mercy, care, commitment and quality.
The Mater Foundation is a leading philanthropic organisation that funds life changing healthcare and medical
research. Donations to the Foundation help purchase life-saving medical equipment improve patient care and
ensure our world-renowned research team continues to find better ways to diagnose, treat and ultimately cure
life-threatening diseases.
There is no question that this is a worthy cause; with lots of great auction items for you to bid on make sure
you bring your wallets as this condition is close to home for many of us in the Mining Industry.
Master Auctioneer, Phil Black will be in charge once again.
QRC/WIMARQ networking function - Coral Sea Room

Jupiters Townsville
Monday 23rd August 5.00pm - 6.30pm
The Queensland Resources Council is proud to host a Women in Mining and Resources Queensland
(WIMARQ) event on Monday 23 August.
The special guest speaker at this years networking event will be QRC 2010 Resources Awards for Women co-winner Jennifer
Mackenzie. Jennifer is an entertaining speaker and will share her career experiences and provide insights into climbing the
corporate ladder.
The event will be held in the Coral Sea Room at Jupiters Townsville from 5pm to 6.30pm.
The WIMARQ events have become well known for providing entertaining networking opportunities for women in the resources sector
throughout Queensland. Men are also encouraged to attend.
The event is free, but places are limited so its advised to book early. Drinks and fingerfood will be provided along with an exciting
guest speaker.
To book go to: http://www.qrc.org.au/02_cal/index.asp and follow the prompts.

Further inquiries contact Caroline Morrissey at carolinem@qrc.org.au
Social Program
We invite you to attend all the Social Activities during the Conference. These special events offer a rare and invaluable
opportunity for you to catch up with friends and colleagues and make new contacts within the industry.
DELEGATES TICKETS TO ALL LUNCHES AND SOCIAL FUNCTIONS ARE INCLUDED IN ALL FULL REGISTRATIONS.
ADDITIONAL TICKETS FOR PARTNERS AND GUESTS ARE AVAILABLE FOR PURCHASE FROM THE CONFERENCE ORGANISER
AT THE REGISTRATION DESK.
Sunday 22nd August

6.30pm WELCOME FUNCTION The Brewery, 252 Flinders Street, Townsville
Proudly Sponsored by Peabody Energy Australia
The Welcome Function is an event that we consider to be one of the most important at this Conference, setting the tone for
the next three days. A mouth watering menu featuring fresh seafood and The Brewerys famous boutique beers will be served
in a casual atmosphere allowing you to start your networking with fellow delegates.
COACH TRANSFERS
At the conclusion of the first business session, Coaches will be waiting outside TECC to transfer delegates to The Brewery.
Additional Partner and Guest Tickets $65.00 per person
MONday 23rd August

12.30pm LUNCH The Grand Marquee Jupiters Townsville
Proudly Sponsored by Southern Engineering Services Pty Ltd
7.00pm INFORMAL DINNER AND CHARITY AUCTION The Grand Marquee, Jupiters Townsville
Proudly Sponsored by uvex Safety Australia Pty Ltd
The Mater Foundation Prostate Cancer Research have been chosen as the beneficiary of this years Auction.
Master auctioneer Phil Black will entertain whilst encouraging you to bid for some great auction items.
SPECIAL ENTERTAINMENT Presenting Danny McMaster aka HIS MCMASTERS VOICE
Performing for your entertainment this evening will be Danny McMaster, Danny is recognised not only here in Australia but
around the world as one of the great comedy impressionists! His mum wanted him to grow up to be somebody. He grew
up to be..everybody!
TUESday 24th August

12.30pm LUNCH The Grand Marquee at Jupiters Townsville
Proudly Sponsored by Downer EDI
7.00pm CONFERENCE DINNER & INNOVATION AWARDS Townsville Entertainment & Convention Centre
Proudly Sponsored by Leighton Contractors Pty Ltd
Address by the Honourable Stephen Robertson, Minister for Natural Resources, Mines and Energy and Minister for Trade
The Conference Dinner which includes the Innovations Awards Presentation is always a feature of this event. This evening
presents the perfect opportunity to enjoy dinner with friends and colleagues within the mining industry.
SPECIAL ENTERTAINMENT Presenting David DeVito

Recently returned from Las Vegas, David has an amazing repertoire from rock to the classics with lots of audience interaction;
you will be amazed at the range and versatility of his performance. Accompanied by Tarsha they will be a special highlight
in the evenings proceedings.
WEDNESday 25th August

12.30pm LUNCH The Grand Marquee at Jupiters Townsville
Notes
Concurrent Sessions
Program at a glance
TUESDAY 11.00am 12.30pm

HEALTH / COMMUNICATIONS EQUIPMENT Safety Accountability FATIGUE / HEALTH
Effective Health Communication Safe Systems Approach for Mining A1 Risk Management at Grasstree The Work Ability Index
in the Mining Industry Road Safety
Fatigue and Safety in Mining
Understanding your Obligations
Complicated Manual Handling Improving the Operational Safety
Simple Prevention of Road Going Heavy Vehicles in Simplifying the Complexity of
A Positive Approach to Polysomnography - Understanding
Mining Operations
Simple Solutions: Communicating Accountability: Understanding the the Objective Measurement of a
Vibration Information to Workers Road Safety Audits on Mining Nature and Role of Accountability in Sleep Disorder
in Toolbox Talks Operations Supporting Health and Safety
TUESDAY 1.30pm 3.00pm

LEADERSHIP / INVESTIGATION TECHNICAL HEALTH & HYGIENE TECHNICAL
The Art of Investigations and Fluid Power: Using MDG 41 to Education as a Path to a Healthy State Wide Audit of Underground
Accidents Promote Hose Safety Workforce and Early Detection of Coal Mine Gas Monitoring Systems
Health Problems
Risk Leadership - Focusing the
Risk - Cost - Benefit (RCB) Selection Assessing Work Tasks of Tyre
Attention Where it Counts
of Optimum Early Warning Increasing the Health Profile within Service Personnel
Technologies OH&S Framework
Hitler and Gandhi were Both
ISOLgate/TYREgate/COLLISIONgate
Courageous Leaders Knowledge Elicitation Solutions
- a Suite of Global Risk Management
for Improving Performance and Applying Risk Based Principals to
Decision Support Portals
Efficiency Managing a Pre Employment
Medical Process
TUESDAY 3.30pm 5.00pm

LEGAL LOCATION & PROXIMITY SYSTEMS QUEENSLAND MINING INSPECTORATE TRAINING
Understanding Your Safety The Application of Laser Sensing Simtars New Mobile Gas Laboratory Lots of Training - How Much
Responsibilities Technology to Proximity Detection in for Emergency Response Learning?
the Mining Industry
Bullies are Bad Business Complex Managing Hazardous Materials in
Zero Harm Starts with Proper
Problem/Simple Solutions An Overview of Mine Communications Queensland Mines
Interactive Education
and Tracking Systems in the United
Fair Hearings in the Coroners Court States The Health Improvement and
The Best Evidence of Competence
Awareness Committee
Proximity Detection Systems in
Underground Mines
Responsibility: The Conference Committee for the Queensland Mining Industry Health and Safety Conference 2010 and Acclaim Special Events and Meeting
Management accept no liability or responsibility for death, or illness of, or injury to, or for loss of or damage to any property belonging to, or financial loss by, any person
attending the Conference, any person accompanying such person or any third parties, whatever the cause, nor do they accept liability or responsibility, whether it be
financial or otherwise, for any operators in association with the Conference. Signature on the Registration Form and receipt of confirmation issued by the Conference
Organiser shall be deemed as consent to the above conditions.
Paper Abstract Auditorium 1
Effective Health Communication in the Mining Industry

Presenter: Hugh Shannon
Authors: Hugh Shannon
Tony Parker
Historically, Occupational Health and Safety (OHS) has primarily presented as attempts to create a safer work environment for
employees. This essential focus can be complemented by a more comprehensive approach to OHS that also supports the design
and delivery of proactive health promotion programs. The collective health status of employees in workplace settings impacts upon
industry in terms of productivity and economic expenditure. A healthy workforce has the capacity to generate a range of positive
outcomes and employers that value and support workplace health promotion initiatives send important messages to their personnel
and the wider community.
Establishing a healthy workforce requires health education methods that effectively communicate information and support positive
and lasting effects on health related knowledge, attitudes, values and behaviour. Recent neuroscience research has provided a strong
scientific base for understanding how humans respond to new information. Past experience, current motivation and perceived
relevance are all influential factors which are especially important for adult learners.
This presentation will highlight a framework for evaluating the impact of health promotion and communication strategies in a
workplace setting. Potential barriers to effective health communication in complex and challenging work environments such as the
mining industry will be discussed.
Complicated Manual Handling Simple Prevention

Presenters: Kevin Conlon
Adam Austin
Authors: Kevin Conlon
Adam Austin
Does manual handling training have a valid and lasting impact on the rate of musculoskeletal injuries and the resulting duration
of rehabilitation? Traditional interventions have been based around PowerPoint driven theory presentations, with little evidence
indicating a return on investment. The Newlands Northern Underground STIPs (Soft Tissue Injury Prevention) program was structured
in stages that allowed for engagement and understanding of the challenges faced underground prior to actual interventions being
delivered. Stage 2 incorporated practical application of theory, confidential one on ones, goal setting and follow ups.
The outcome at two months post stage 2 reveals significant reduction in lost days, restricted days, number of injuries, LTIFR, TRIFR
and DISR. We believe this is a direct result of worker engagement and program personalisation. During follow ups workers commonly
reported there is more communication when were completing tasks, talking about the techniques were using and most people are
thinking about what they are doing and looking at their body movements a lot more.
Simple Solutions: Communicating Vibration Information to Workers in Toolbox Talks

Presenter: Trudy Tilbury
Author: Trudy Tilbury
Whole body vibration is a health hazard that is usually complex and difficult to understand. Workers and other safety and health
personnel on site need this complex information explained, and workers focused on what is important to reduce their immediate
exposure.
Background
The Health Improvement and Awareness Committee identified whole body vibration as one of the key hazards in mining. As part of
consultation with industry and unions it was apparent that there was a lack of knowledge on what the key components of a whole
body vibration measurement and management program needed communicating to workers.
Findings
A number of sessions with workers in both underground and open cut sites showed that presenting the information in toolbox talks
and with supporting information, such as handouts and checklists, helps to focus the resources on controlling vibration sources.
Workers felt they had more understanding of the key issues, and what they could do about whole body vibration. Everyone on site
also realised the role they had to play and how systems needed to be communicated on site.
Future plans
A number of information sheets and worker handouts will be available on the DEEDI website, along with a toolbox talk presentation for
Open Cut Coal and Underground Coal. This will include the ability for sites to discuss their own results and their own management plans.
Paper Abstract Magnetic Room
Safe Systems Approach for Mining Road Safety

Presenter: Damir Vagaja
Author: Damir Vagaja
Historically, road safety efforts around the world have focused on educating and influencing road users to adopt appropriate
behaviour while using a road network. Past gains have been significant, but securing further improvements has become increasingly
harder to achieve. This has led to a fundamental change in thinking, and the development of multi-disciplinary, systematic approach
to road safety.
The Safe Systems approach acknowledges that road users make mistakes but should not pay with their life for an innocent
mistake. This in turn necessitates an in-depth understanding of the systems four key components: users, vehicles, speeds and road
environments. Improvements must be well targeted and be complementary.
The system is gradually being rolled out on public road networks throughout Australia. The mining industry, however, is an example
where Safe Systems has been in place for some time now as mining organisations have direct control of all the four systems
cornerstones.
Resulting from experience obtained during numerous road safety projects on mining operations across Australia, this paper will
synthetise the industrys adherence to Safe Systems and will provide directions for developing an action plan, on either an industry-
wide or organisational level, with the ultimate aim of minimising traffic related hazards on mines.
Improving the Operational Safety of Road Going Heavy Vehicles

in Mining Operations
Presenter: Ken Johnsen
Author: Ken Johnsen
A case study on the development, testing and in-field implementation of fail safe auxiliary braking system for heavy rigid vehicles,
that covers:
* Identifying and addressing the needs from numerous incident reports including fatalities
* Reviewing a consortium-based approach involving key industry stakeholders
* A two-stage project - initial feasibility followed by prototype development
* Prototype release and testing followed by in-field trials
* Production release and roll out to customers
* Example of applications, risk assessment and industry take up
Road Safety Audits on Mining Operations

Presenter: Damir Vagaja
Author: Damir Vagaja
Road safety auditing is a formalised safety assessment that should be carried out during the design, construction or post-construction
(existing) phases of a project by experienced professionals who are independent of the designer or asset owner. It should be
considered as an intrinsic component of project development and a critical element of an effective and robust traffic management
framework.
Road safety auditing has been used on public road networks for a number of years and is recognised as an effective way of reducing
road trauma. In recent years it has been successfully applied in improving safety at numerous mining operations across Australia.
The aim of road safety auditing is to identify existing or potential road safety issues and suggest design solutions or procedural
improvements to address the issues. This paper will detail the process and application of road safety audits to the specific
requirements of the mining industry.
Issues addressed during audits include:

Interaction between light vehicles, heavy vehicles, and pedestrians
Speed management
Road design and layout including intersections and other areas of traffic conflict
Signage, delineation and lighting
Parking arrangements
Evaluation of the existing land transportation management systems, i.e. documentation and processes.
Paper Abstract Palm Room
A1 Risk Management at Grasstree

Presenter: David Carey
Author: David Carey
The Problem
Despite the ability to control technical hazards and having employed a workforce at least the equal of any other in the industry
Grasstree had consistently failed to achieve the levels of safety performance which its peers were during 2008 and 2009.
The Solution
Anglo American developed a four tiered Safety Risk Management System within which the A1 program is the level aimed for all
employees. This knowledge, built around the SLAM (Stop, Look, Asses, Manage) process, allows workforce at the coalface to make
better decisions at the time when decisions need to be made.
The Process
From October 09 a weekly A1 training session has occurred such that more than 90% of the workforce has now trained. Each session,
which takes some 6 7 hours to complete is facilitated by two of the mine management team and deals with real examples of mine
safety to build on the knowledge contained within the course.
The Results
Since the commencement of the course Grasstree employees have remained LTI free whilst TRC frequency rate for employees has
dropped to 35% of levels incurred in 2008.
Conclusion
When people are given the knowledge necessary to make the right decisions all of the time then their safety outcomes will
significantly improve. During these sessions facilitated by the sites senior management team a common belief in safety achievement
can be developed and the use of local examples develops a passion to apply this new knowledge.
Understanding Your Obligations

Presenter: Mark Parcell
Author: Mark Parcell
All mine workers, coal mine workers, other persons and persons generally at a mine have an obligation to comply with the
Queensland mining safety and health Acts and the procedures that are part of the safety and health management system for the
mine. This obligation also includes a requirement to comply with the relevant Regulations. Despite these obligations, it is very difficult
to comply with something that you have little or no understanding of.
The legislation is the cornerstone of mine safety and health. Many have touted the Queensland mining legislation, however, its value
and effectiveness is dramatically reduced when people dont understand or fail to fulfill their obligations.
The Safety Managers developed a coal mining safety and health legislation workshop several years ago to assist persons to
understand the legislation and their obligations. The workshops provide an explanation of the legislation and include practical
exercises to assist persons to navigate through and gain an understanding of the legislative requirements. Whilst many SSEs have
used the workshops to prepare for the SSE legislation exam, they have used the knowledge from the workshops to improve safety
and health in the workplace.
A Positive Approach to Accountability: Understanding the Nature and Role of

Accountability in Supporting Health and Safety
Presenters: Clinton Strahan
Peter Smith
Authors: Clinton Strahan
Peter Smith
Accountability can be a provocative word that typically elicits mixed reactions. In a negative sense accountability is often associated
with punishment, blame, and an authoritarian focus on rules and formal disciplinary procedures. This view is neither accurate nor
helpful.
Our research has taken a positive understanding of employee accountability: accountability as an expression of a mature
employment relationship which, in research across a number of Queensland mining operations, is linked to employee health & safety.
The take home message from the research is very clear. Accountability is not about punishment or blame, though consequences for
not performing are important. Accountability is primarily driven by absolute clarity about expectations and the provision of feedback
and rewards that function to guide employees in meeting those expectations.
Moreover, the results show that employees who report feeling accountable at work also report that they experience lower levels of
work-related stress and depression; plan to get adequate sleep before night shifts; adopt preventative strategies to cope with fatigue;
tend to take responsibility for their own safety; and are more positive about the safety culture of their organisation.
This paper highlights the potential health and safety benefits of taking a mature approach to accountability as demonstrated by the
results from our recent research and suggests how best to foster greater accountability in the workplace.
Paper Abstract Jupiters Pavillion
The Work Ability Index

Presenters: Gerard Tiernan
Trudy Tilbury
Authors: Gerard Tiernan
Stewart Bell
Trudy Tilbury
The 2007 Cliff and Parker Review of the Queensland Mines and Quarries Annual Safety Performance and Health Report
recommended the use of a modified version of the Work Ability Index (WAI) for the Queensland mining industry.
The Work Ability Index provides a measure of health status, using factors such as the number of medical conditions. Though it is
used in conjunction with medical examinations it does not go into the medical detail of conditions. It measures the workers own
perception of work ability and this qualitative measure has been shown to be well correlated with more objective measures derived
from medical examinations. It is therefore reliant on people being comfortable enough to provide the information honestly and in
the surety that it will not be used to penalise them. The Work Ability Index measures are of value in designing the most appropriate
interventions to maintain work ability and to provide useful information on changes in work ability over time at the individual and
group level.
Data from a Work Ability Index survey can be used to evaluate the efficacy of interventions at the work organisational, work
environment and individual worker level.
The Mines Inspectorate would like to see the Work Ability Index used in the Queensland mining industry. Used properly it is a tool
that will allow people to work longer and to stay healthy well into retirement. What we do not want is an industry where people are
forced to retire early through injury or illness or an industry that, when it is finished with its workers, leaves them sick and debilitated
throughout retirement. The Work Ability Index has the potential to ensure we do not do this and that we have an industry where
workers stay healthy during their working lives and well into retirement.
This paper will detail how the Work Ability Index could be applied in the Queensland mining industry and the potential benefits.
Fatigue and Safety in Mining

Presenter: Roger Kahler
Author: Roger Kahler
This paper addresses the contribution, or otherwise, of fatigue to personal damage on mining sites in Australia. It does not address
personal damage involving travel to work or off-site road accidents e.g. transport of equipment to and from sites. The story which
would be told with respect to fatigue and its contribution to traffic accidents in the public sector would be quite different to that
which will be suggested for the mining industry.
Fatigue is a much discussed subject, particularly in the last decade. It occupies a significant space in many mining conferences, Codes
of Practice, newsletters etc.
In addition, Government legislation places requirements on employees and employers with respect to fitness, duty of care etc. There
are Alerts issued which reinforce the fatigue issue. Essentially, there is a complex set of drivers which result in an organisations
available resources being strongly directed towards fatigue management. However, should the expectation of effective fatigue
management be one of a change in the pattern of personal damage? Perhaps effective fatigue management has longer term
implications for health and societal improvements?
However, this paper will suggest that effective fatigue management will not have any noticeable reduction in future occupational
safety (versus health). At best it will produce minimal gains.
Simplifying the Complexity of Polysomnography -

Understanding the Objective Measurement of a Sleep Disorder
Presenter: Darren OBrien
Author: Darren OBrien
Polysomnography (PSG or a Sleep Study) is the internationally recognised, gold standard, objective sleep test. Performed overnight,
polysomnography involves the continuous and simultaneous recording of multiple physiologic variables during sleep, that is,
electroencephalogram, electrooculogram, electromyogram, electrocardiogram, respiratory air flow, thoracic and diaphragmatic
respiratory movements, leg movements, pulse oximetry, transcutaneous carbon dioxide monitoring (where applicable) and other
electrophysiologic variables.
The presentation will address how polysomnography is used to quantify a sleep disorder and verify treatment efficacy from initial
equipment setup through data interpretation. Particular emphasis will be placed on the diagnosis and treatment of sleep disordered
breathing (obstructive sleep apnoea).
The Art of Investigations and Accidents

Presenters: Peter Peachey
Martin Kortlucke
Authors: Peter Peachey
Martin Kortlucke
There is always an easy solution to every human problem-neat, plausible and wrong
Henry Mencker
The human mind is a poor judge of hazard. With the aid of the rigour imposed by mathematical reasoning we are well able, by
statistical methods, to quantify risk for events that occur with high frequency. However events that occur at a low frequency are
insensitive to quantification and hence subject to the vagaries of our minds.
The human mind likes a strange idea as little as the body likes a strange protein and resists it with a similar energy
William Beveridge
Herein lies the strength & weakness of investigation. Knowledge can only be advanced by investigation but what if the investigation
is flawed? Almost by definition every accident is unique yet the basis of most human interaction is to form an instant judgment
followed by vigorous defence of a now entrenched position.
There exist a multitude of models purporting to guide the investigative process. In general these have at their core a perception that
investigation is amenable to step by step methods, that is, investigation can be bureaucratised.
This paper will explore: Bureaucratised investigations vs. the art of investigation & accidents
Risk Leadership Focusing the Attention Where it Counts

Presenter: Marc McLaren
Author: Marc McLaren
Much has been written about how an organisation can improve its safety performance by focusing on improved safety leadership
and organisations safety culture. The obvious question is what type of safety leadership really leads to sustainable culture change?
Recent academic and field research points to the importance of understanding risk and enabling others to better manage unforseen
hazards through attending to early warning signs.
Safety4Life is currently working with several large organisations, within and outside the mining sector, to enable safety leaders to
build an in depth understanding of where and how risk fits into the leadership equation.
The presentation will unpack the unique risk leadership factors for effectively gaining sustainable OH&S performance through an
Australian and New Zealand case study and will cover
Why an understanding of risk is mission critical
What type of risk are we talking about?
The relationship between risk and safety leadership
Key contributors to risk leadership risk awareness, risk mindfulness, risk tolerance and risk competency enablers
Measurable strategies for improving risk leadership
The presentation will engage participants through the use of interactive technology and a take away check list to be used back at the
workplace.
Hitler and Gandhi were Both Courageous Leaders

Presenter: Corrie Pitzer
Author: Corrie Pitzer
There are three challenges when it comes to safety leadership:
Firstly, a leader is not just somebody who has the courage to change things and to lead people to their visions, he or she must also
show the right values and inspire peoplewhat are the right values and how do you inspire people?
Secondly, safety leadership is very complex and often in direct contrast with our management systems or goals. For example,
leadership requires from us to allow people to experiment, to try new ways to do things, to make mistakes, and to be supported
when they do. But in safety, we cannot allow mistakes, or experiments. We want people to only follow the rules
Thirdly, safety is strongly linked with change, which is often resisted at all levels. What can we do to embrace change as an
organization, as individuals or in teams? This presentation will demonstrate interactively what happens in people when they are faced
with change and what should be done to lead it. The paper analyses mindless change and heartless change and puts forward a
model of transformational safety leadership.
Fluid Power: Using MDG 41 to Promote Hose Safety

Presenter: Rosa Burns
Author: Rosa Burns
The use of hydraulic hoses in the mining industry creates situations that are potentially very dangerous. Even a pinhole leak can cause
serious injury through high velocity fluid injection through the skin.
High standards of training and appropriate qualifications in fluid power systems have not been easy to access. There has been a
heavy reliance on in-house training often sourced from private organisations that supply hose components to the mining industry.
While this has been beneficial in the absence of more appropriate alternatives, it does not allow workers to gain an accredited
qualification that would be transferable across mining sites.
MDG41 Guidelines have been recognised as best practice in NSW as a means to attain the highest safety standard in the training of
the manufacture of hoses and use of fluid power. Up to date QLD has been rather slow to take up MDG41.
At MMG Century Mine we have designed a program that offers employees training that results in a nationally accredited certificate in
fluid power and meets the guidelines recommended by MDG41. This will result in a professionally qualified workforce for those using
hydraulic hoses; it will increase safety awareness and provide a detailed history of manufacture and repairs.
Risk Cost Benefit (RCB) Selection of Optimum Early Warning Technologies

l Heavy Equipment Collisions l Highwall / Lowwall Slope Failure l Gas Outburst l Surface Subsidence
Presenter: Dr G Kizil (MISHC)

Authors: Dr G Kizil (MISHC) Prof A Bye (CRC ORE) Prof J Joy (MISHC)

Potential solutions to both financial and personnel risk in the mining industry are delivered by technology and applied research.
These solutions are often expensive and both the risk improvement levels and financial benefit of the alternative solutions are poorly
quantified. How then does a mining company make reliable decisions to implement these expensive technologies?
A successful joint initiative, funded by the Australian Coal Association Research Program (ACARP), between Minerals Industry Safety
and Health Centre (MISHC) and the WH Bryan Mining and Geology Research Centre (BRC) has developed an innovative and unique
generic Risk-Cost-Benefit (RCB) Decision Support Tool known as RCBGEN (Risk-Cost-Benefit Generator), to determine the complex
risks, costs and benefits associated with safety interventions. The practical tool defines a methodology for identifying appropriate
technologies/controls, assessing whether an appropriate technology/control reduces that risk, considering and determining an
optimal group of technology/controls and calculating the net financial benefit associated with the appropriate technology/control.
The methodology utilises the Bow Tie Analysis (BTA) risk analysis technique, and Risk-Control-Effectiveness Model, known as
RCEMODEL (Kizil & Bye 2009).
Once the RCBGEN is configured for a specific application, then the RCBGEN enables assessment for different risks within the mine
and the selection of the appropriate group of control mechanisms required. The Risk-Control-Effectiveness Model, RCEMODEL,
investigates each technology/control including the reliability of the technology/control comprehensively by using quantitative data.
The RCBGEN has been applied to a range of key areas: 1.Heavy Equipment Collisions 2.Highwall / Lowwall Slope Failure 3.Gas Outburst &
4.Surface Subsidence.
The RCB Project received significant Australian mining industry support and, involved mine site visits (NSW and QLD), and several meetings
with key industry representatives over two year period.
A key message from the in depth study is that the RCBGEN has proven to be a valuable tool for selecting the optimum combination of
appropriate technologies to reduce risk.
The presentation will introduce the Risk-Cost-Benefit (RCB) Decision Support Tool, RCBGEN, and Risk-Control-Effectiveness Model,
RCEMODEL, and demonstrate their practical application by providing an overview of the four case studies conducted in each key
area. The project work for each case study involved a number of site visits, considerable amount of data gathering and, risk and
in-depth controls analysis. The comprehensive Heavy Equipment Collisions project gathered significant amount of Australian and
global mining industry mobile equipment related accident/incident data. Over 1,500 cases were reviewed that occurred during the
2004-2007 period. The project focussed on 364 heavy equipment collisions to conduct the RCB Analysis. In addition to the accident/
incident database, associated accident investigation reports were also gathered, thoroughly reviewed and analysed. The Collisions
project collated considerable amount of industry data in relation to proximity detection and fatigue detection technologies. The
selected controls were then assessed and evaluated to identify optimal group of controls which would assist with reducing level of
risk.
By combining risk analysis with cost benefit analysis, it was shown that the RCBGEN is able to assist with the decision making process
and provide an optimal solution for the selection of combination of controls required to achieve ALARA. High risk industries such as
petroleum, oil, chemical and gas industries utilise cost-benefit approaches. There are a lot of similarities between mining and these
high risk industries in relation to the risks that are faced on day to day operations.
In summary, the presentation will introduce the unique Risk-Cost-Benefit approach developed for the mining industry application
and explain how the RCBGEN can be adopted and used as a pro-active scenario analysis tool to examine various accident/incident
scenarios.
Knowledge Elicitation Solutions for Improving Performance and Efficiency

Presenter: Sue Leveritt
Authors: Sue Leveritt
Tim Horberry
Tristan Cooke
Despite advances in mechanisation and automation processes, mining remains a people intensive industry, a large proportion of who
are responsible for operating and maintaining mining equipment under conditions that challenge even the most experienced people.
Over time, tacit knowledge develops that helps operators and maintainers perform their jobs safely and effectively. Sharing of this tacit
knowledge is generally a hap hazard process, depending largely on the whim and will of individuals. Trainers, particularly field trainers or
mentors, rely on their personal experiences to help inexperienced trainees acquire new operational skills and skills for decision making in
exceptional circumstances. Access to a larger pool of experiences about decision making in risky situations has the potential to improve
performance through training, particularly for simulator training.
This paper will introduce the findings of an ACARP project to identify and trial two innovative knowledge elicitation methods to capture
risks related to mobile mining equipment. They draw on the knowledge and experience of the existing workforce to provide simple
solutions to operational and maintenance issues that could otherwise develop into major factors affecting both safety and production.
The results of the research are a better understanding of equipment/operator related risks and where improvements could be
implemented in incident investigation, communication, equipment design and training.
Education as a Path to a Healthy Workforce and Early Detection of Healthy Problems

Presenters: Tammy Farrell
Dr Toby Ford
Ian Cooper
Authors: Tammy Farrell
Dr Toby Ford
Ian Cooper
The combination of increased mechanization, a compressed working week, commute lifestyle and poor diet has had a dramatic
impact on the mining industry workforce with statistics suggesting that 70% of workers are either overweight or obese. There is an
opportunity for the mining industry to implement practical and positive strategies to address the problems of reduced health and
wellbeing in mineworkers.
Jellinbah Mine in partnership with Ford Health has run a health and wellbeing program for the past 21 years. In 2009 Jellinbah Mine
was the workplace finalist in the Healthy Queensland Awards for Central Queensland. As part of that award they are implementing
a project to improve the awareness and participation of all employees in health programs, in particular, working aged males. The
question why dont men participate in owning their health is being asked. This pilot study will assess the effectiveness of different
media approaches using video-byte presentations, verbal, interactive internet and written materials provided by Core Health and
IPOWOW.
Ford Health with Jellinbah is conducting pre and post topic evaluation to understand best practice so that this may be shared with
other employers in regional areas to improve health outcomes and utilization of the health system.
Increasing the Health Profile Within the OH&S Framework

Presenter: Tony Parker
Author: Tony Parker
The changing demographics of the mining workforce and the increasing demand for skilled workers increases the importance
of sustaining a healthy workforce now and for the future. Although health is strongly related to safety, the two areas are not well
integrated and the relationship is poorly understood. As such there is an important need to raise the profile of health within the
OH&S domain.
This presentation will discuss a framework for enhancing the profile of health within OH&S using examples from a collaborative 4-year
longitudinal program initiated in the mining industry. The program provides a holistic and whole of company approach to identifying
key factors which impact on the health of the workforce and opportunities for improvement of health surveillance systems and
interventions. The program provides evidence to illustrate the significance of organisational, environmental, training and individual
factors which impinge on health outcomes and potential barriers to successful implementation of health initiatives in the industry.
The program also highlights the need for new and innovative evidence based solutions to reduce the risk of illness and injury in the
workforce. Examples of current research initiatives, conducted in collaboration with industry, which address key health issues such as
musculoskeletal injury and overweight and obesity, will be used to demonstrate the important link between research and practice.
Applying Risk Based Principals to Managing a Pre Employment Medical Process

Presenters: Mark Cassidy
Mark Jacobs
Authors: Mark Cassidy
Mark Jacobs
If organisations are to become more sophisticated in understanding how health risk is imported into business operations, then
applying risk based philosophies into the pre employment medical model should be seen as a key step. Sickness absenteeism caused
by musculoskeletal disorders (MSDs) is a persistent and costly occupational health challenge. (Arnetz, Bergt B. MD, PhD et all).
According to the Australian Bureau of Statistics, sick leave and unapproved absences account for 36.9% of all leave taken. (ABS 2009)
The most recent survey of Australian businesses, Australian Workplace Industrial Relations Survey 1995 (AWIRS) conducted by the
Department of Workplace Relations and Small Business found that an average of 2.7% of the Australian workforce was absent on
unapproved leave on an average day. (ABS 2009)
Leighton Contractors (Mining Division) and 4cRisk Pty Ltd, a Brisbane based health risk management organisation are currently
redefining the Leighton Contractors (Mining Division) pre employment system of engaging workers utilising a risk based process
to ensure that a fit for purpose relationship exists between the individual applicant and the specific workplace role, as well as
identifying underlying health risk concerns for the potential employee which may be able to be managed or addressed prior to
joining the business.
Arnetz, Bengt B. MD, PhD; Sjgren, Berit; Rydhn, Berit; Meisel, Roland BA, 2009. Early Workplace Intervention for Employees with
Musculoskeletal-Related Absenteeism: A Prospective Controlled Intervention Study Australian Bureau of Statistics, Labour Market Survey, 2009.
State Wide Audit of Underground Coal Mine Gas Monitoring Systems

Presenters: Darren Brady
Tim Watson
Authors: Darren Brady
Tim Watson
Ram Bhattacharjee
Daniel Usher
Queensland underground coal mines have the best mine gas monitoring systems in the world. To ensure that these systems have
been applied appropriately and are correctly maintained, Queenslands Commissioner for Mine Safety and Health engaged Simtars to
assist the Mines Inspectorate undertake a state wide audit of all mine gas monitoring systems.
This paper outlines the scope of the audit and findings and trends to date.
Assessing Work Tasks of Tyre Service Personnel

Presenter: Michael McDonald
Authors: Michael McDonald
Tony Parker
Roy Kei
Job tasks that involve exposure to work related musculoskeletal disorder (WMSD) risk factors may impact both the risk of injury
and production downtime. Common WMSD risk factors associated with mining tasks include forceful exertions, awkward postures,
repetitive motion, jolting and jarring, forceful gripping, contact stress, and vibration.
In order to keep the operations and processes more cost-effective, the mining industry has become increasingly dependent on
material movement by rubber-tyred equipment. As such, much of the equipment and key components, have become physically
larger and require additional skills and activities to maintain. The introduction of larger equipment creates new challenges to tyre
service personnel during wheel maintenance.
This presentation will discuss the process adopted to examine the common work practices of tyre service personnel from an injury
risk perspective as part of a larger project concerned with M/S injury. The project provides an approach to identify key factors which
impact upon injury and opportunities for improvement in injury prevention strategies.
Discussion will highlight the importance of understanding the relationship between various factors which contribute to
musculoskeletal injury within the industry.
ISOLgate /TYREgate / COLLISIONgate

A Suite of Global Risk Management Decision Support Portals
Presenters: Guldidar V Kizil Tilman Rasche

Authors: Guldidar V Kizil Tilman Rasche
The minerals industry has highlighted Energy Isolation as a critical area which requires greater awareness, understanding and control.
Cursory investigation has shown that there have been 32 fatalities related to accidental contact with electricity over the past twenty
years in the Queensland mining industry alone. There are many other non-electrical incidents from hydraulic, pneumatic, other stored
energy systems where less than adequate isolation played a major role in the accident causation.
To assist the mining industry in better prioritising its approach to Isolation, the joint MISHC/DEEDI ACARP (Australian Coal Association
Research Program) funded project has developed ISOLgate: Isolation Risk Management Decision Support Portal. ISOLgate
provides the industry and its stakeholders including equipment manufacturers and service providers, with
an objective up-to-date all in one analysis and summary of accidents and incidents related to isolation,
an overview of root and contributing causes (acts and conditions, design issues etc.) that must be addressed proactively to
improve safety energy isolation procedures, and application in the field,
recommendations and risk controls, and ISOLgate Checklists assisting with workplace auditing processes.
ISOLgate is modelled on the already proven TYREgate: Tyres and Rims Risk Management Decision Support Tool (http://www.
mirmgate.com/tyregate). TYREgate and ISOLgate utilises a unique and innovative search methodology which allows managers,
decision makers and other users with limited time to access dynamically generated, graphically displayed accident, incident and risk
management data in near real time, using a 3 Click approach:
What are my major risk factors? (Click 1)
Where can I find the causes of these factors? (Click 2)
Why did these specific accidents occur? (Click 3)
How can I mitigate the risks at my own operation? (TYREgate / ISOLgate Checklists)
ISOLgate was launched on May 3rd, 2010 and is publicly accessible at: http://www.mirmgate.com/isolgate. ISOLgate provides a
further first call portal for information and decision making support on this family of accidents and incidents.
This presentation will focus on introducing the online accessible ISOLgate risk management portal, its key features and benefits, and
downloadable ISOLgate Checklists. Main conclusions about isolation related incident and accident causation will be outlined.
Importantly, the presentation will demonstrate how ISOLgate can assist decision makers at all levels of the organisation, anywhere
in the world with the complex issue of isolation of energies. The presentation will also introduce the newly re-engineered TYREgate
portal and provide an update on TYREgate industry usage.
The TYREgate and ISOLgate research team has been awarded with a new ACARP funding to establish COLLISIONgate:
COLLISIONgate a Vehicle Interaction Causal Factors Database and Risk Management Decision Making Tool. The
presentation will provide an overview on this projects objectives and deliverables.
Understanding Your Safety Responsibilities

Presenter: Cameron Dean
Author: Cameron Dean
Mining safety and health prosecutions usually involve the prosecution of the mine operator entity and, on occasion, the SSE.
However, recent prosecutions demonstrate that the legislative power to prosecute goes further, including to individuals. Changes to
individual responsibilities will also occur if the national harmonisation of workplace health and safety laws becomes a reality.
Understanding the statutory obligations is critical as part of compliance and in achieving the goal of zero harm. In this paper,
Michael Moy analyses the obligations and recent developments to help simplify safety and health compliance requirements for mine
executives and workers.
Bullies are Bad Business - Complex Problem/ Simple Solutions

Presenters: Hedy Cray
Shae McCartney
Authors: Hedy Cray
Shae McCartney
That bullying is bad for business will be no surprise to members of the mining industry, or anyone in business for that matter. That
bullying directly costs employers a whopping $13 billion each year, may be unexpected.
The number or cost of bullying related complaints in the mining industry has not reduced despite safety reforms in the industry and
a change in what society considers acceptable behaviour stamping out a lot of the hazing type of bullying that previously occurred.
This stealthy, insidious and costly phenomenon manages to crawl under the radar and into every work environment.
While the causes of bullying are complex, the tools to manage this significant problem are, like all good tools, simple. The trick is in
their consistent application.
Join Hedy Cray, Partner and Shae McCartney, Senior Associate, to discuss recent developments with particular emphasis on:
How recent and proposed changes in legislation impact on obligations in relation to bullying and harassment;
What do recent cases mean to the mining industry;
Traps and pitfalls to avoid when conducting a bullying and harassment investigation; and
How to manage bullying and harassment in the workplace - without losing control.
Fair Hearings in the Coroners Court

Presenter: Matthew Smith
Authors: Matthew Smith
Coronial Inquests are becoming increasingly important for businesses and industries with the potential to directly and indirectly
impact on business operations. In addition to the heavy emotional burden created by the loss of a co-worker, the findings of a
Coroner can have a significant impact on whether the business and its employees will be prosecuted, how the business will be run in
the future, the businesses ability to tender for work and the ability of the business to resolve compensation claims.
This presentation will provide an overview of the modern role of the Coroners Court, how it operates and what is to be expected in
the Coroners Court. It will focus on two unique aspects of a coronial inquest, the inapplicability of the rules of evidence and the role
of Counsel Assisting. In considering these aspects the presenter will question what is fair and how a fair hearing can be achieved. It
will equip persons who can expect to be involved in an inquest, in some form, with a working understanding of inquisitorial process,
incident management strategies and minimising potential negative consequences from a Coronial Inquest.
The Application of Laser Sensing Technology to Proximity Detection in the Mining

Industry
Presenter: Nicky Guenther
Authors: Nicky Guenther
David Duncan
Sick Maihak
Paul Harrison
Andre de Kock

Sick Maihak, better known to the mining industry as the supplier of mine gas monitoring hardware for underground coal mines, is a
technology leader in the application of laser scanning to indoor and outdoor applications.
Building on experience in the development of autonomous driving platforms and vehicle collision avoidance and lane guidance
systems based on laser scanning technology, Sick has developed a proximity detection system for the mining industry.
The system operates in real-time and is able to track up to 128 objects simultaneously, e.g. car, truck, pedestrian, motorbike, bike,
rocks, berm wall, etc. while automatically compensating for speed.
Sick has been conducting mining industry trials of the technology in partnership with Simtars.
This paper describes the technology, its development for the mining sector and the results of those trials.
An Overview of Mine Communications and Tracking Systems in the United States

Presenter: Michael A Trevits
Author: Thomas Novak
Recent mine disasters in the United States exposed various inadequacies and gaps in mine-safety technology. Congress responded
to these tragedies by enacting the Mine Improvement and New Emergency Response Act of 2006 (MINER Act), which resulted in the
most significant change to mine-safety laws in 30 years. To help meet the requirements of the MINER Act and to help eliminate future
tragedies, the National Institute for Occupational Safety and Health (NIOSH) initiated aggressive research programs for developing
new, and enhancing existing, mine-safety technologies.
A major research emphasis addressed the lack of post-accident communications, which surfaced as a critical deficiency in some
disasters. As a result, three communications approaches emerged as viable technologies enhanced leaky-feeder, wireless-mesh, and
medium-frequency systems. This presentation describes the operation, application, advantages, and disadvantages of each system, as
well as the challenges associated with underground wireless communications.
Proximity Detection Systems in Underground Mines

Presenter: Denis Kent
Authors: Denis Kent
Christian Fischer
Bill Schiffbauer
Proximity Detection or Collision Avoidance has been a key focus of the Queensland mining industry and authorities over the past
three years. The paper discusses the technology and experience in both hard rock and coal mines to provide a system that can
deliver an additional level of control to the risks associated with people-vehicle interactions underground.
The presentation will detail the initial implementation of Proximity Detection Systems in the hard rock mining environment. The
hard rock proximity system is based on two zones of detection required for large and relatively high speed vehicles. Information will
include:
- The principles of the underlying technology
- Installation learnings and effectiveness
- Change management methodology and issues
The initial trials of a Proximity System specifically developed for application around continuous miners and shuttle cars in coal mines
will be presented, covering:
- The technical challenge of providing precise control zones in the confined area around a continuous miner.
- The principles of the underlying technology, focussing on the alliance between Mine Site Technologies and Frederick
Mining Controls to avoid re-inventing the wheel.
- Trial results, particularly in relation to varying mining conditions and development layouts.
- Implementation plans.
Simtars New Mobile Gas Laboratory for Emergency Response

Presenter: Darren Brady
Authors: Paul Harrison
Darren Brady
Simtars has been working on replacing its original mobile gas laboratory for over a year. The result is arguably the best equipped
mobile gas analysis laboratory for mine emergency response in the world.
The design and manufacture of the original laboratory was tendered out to external consultants with several major changes made
to the system following deployment in the field and the realisation of areas requiring improvement. For the replacement laboratory
Simtars, armed with over ten years operational experience, took a more active role in the design and features of the current
laboratory.
Equipped with a state of the art twenty point tube bundle system and ultrafast gas chromatograph, this mobile laboratory replicates
the systems many of the underground coal mines in Queensland already have on site. The laboratory has its own dedicated on board
diesel generator, overcoming the most commonly experienced problem when arriving at a mine site; provision of power.
This paper outlines the features of the new laboratory, its capabilities and the philosophy behind the design and inclusions.
Managing Hazardous Materials in Queensland Mines

Presenter: Carolyn Topping
Author: Carolyn Topping
Hazardous substances, dangerous goods and combustible liquids present risks in many workplaces including mines. Numerous
incidents have occurred at mine sites due to the inappropriate use, storage and handling of these materials.
This paper describes some common problems identified in the management of these substances during audits conducted by
Simtars personnel. The paper will also look at ways mines can improve the management of hazardous materials to achieve regulatory
compliance and reduce risk.
The Health Improvement and Awareness Committee

Presenter: Fritz Djukic
Authors: Gerard Tiernan
Fritz Djukic
Joanne Garrad
Kevin Hedges
Trudy Tilbury
This paper provides industry with an update of the activities of the Queensland Mining Health Improvement and Awareness
Committee (HIAC) activities during the past year.
HIAC is a tripartite committee with representatives from the AWU, the CFMEU, the coal industry, the metalliferous industry, the
quarrying and cement industry, the Queensland Resources Council and the departments Safety and Health Division. It was
established in 2007 to assist industry anticipate, identify, evaluate and control health hazards in the mining environment. It aims to
enable the inspectorate, unions and industry to work in unison to provide a greater emphasis on worker health and the prevention of
illness and disease.
The committee developed a list of prioritised health hazards for the mining industry in Queensland. The list was prioritised using a
simple likelihood/consequences risk matrix and was based on a qualitative assessment of the entire Queensland mining industry as a
whole rather than considering individual sectors.
Following the identification of these as priority issues the committee has started to review and share control strategies to address
these hazards. In addition, Safety and Health has started to run seminars in conjunction with HIAC meetings.
The Committee has had presentations from experts on fatigue management, research into fatigue, risk management of
musculoskeletal disorders due to manual tasks in mining, UV radiation exposure, noise control and health management systems.
Lots of Training How Much Learning?

Presenter: John Sleigh
Author: John Sleigh
How effective is the training that is being given to mineworkers? Is the most pleasant memory of a training room leaving it?
How can we apply adult learning theory to mining training, so that the emphasis is on skills and knowledge rather than a record of
attendance?
How can we evaluate training effectiveness?
How can we maximise the value of experience, both our own and other peoples?
Are adult learners still a neglected species? How can we avoid this?
These questions were first posed by the gurus of adult learning: Donald Kirkpatrick, David Kolb and Malcolm Knowles. How can we
use their theories to make mining training more effective?
This is a how to session, filled with practical examples and useable techniques, applying accepted, proven theories.
The session is based on Johns 40 years experience in the mining industry, as a miner, a mine manager, a consultant and now an
inspector.
Zero Harm Starts with Proper Interactive Education

Presenter: Johann DeBeer
Author: Johann DeBeer
Health and safety in the mining industry is of paramount importance, given the dangers that exist in performing mining and
manufacturing work. Aside from the moral obligation towards workers to protect their health and safety, the mining legislation
places an obligation on all participants in the industry to prevent exposure to unacceptable levels of risk.
The legislation also outlines stringent requirements to ensure that workers are adequately skilled and trained in safety systems and
are inducted before they commence work on site. Zero-harm can only be achieved with proper interactive education and training.
The key focus in modern interactive education and training is using modern technology to train students effectively.
Key aspects of the training should be:
- Exposing students to real-life learning situations;
- Participation in the learning process;
- Improving focus and concentration;
- Changing attitudes towards health and safety issues;
- Guiding instructors with comprehensive and structured lessons;
- Incorporating practical sessions, evaluation and assessments;
It is therefore imperative that inductions and ongoing training be designed to limit the chances of incidents arising. In a worst case
scenario, such proper safety training programs and inductions may be called in aid when statutory or civil claims occur.
The Best Evidence of Competence

Presenter: Deb Jones
Author: Deb Jones
Can training truly be transportable?

Does practical assessment involve more than a checklist?
What does it really mean to assess someone as competent?
What is it that experienced people do automatically that differentiates them from inexperienced people?
The need for confidence in assessment practices continues to remain high on the agenda for safety and training professionals in our
industry. Initiatives such as the Transportability Scheme, which have emerged as potential solutions to these questions, have failed to
transcend these challenges why?
This session provides strategies for improving assessment quality and knowledge transfer through using the senses and a
kaleidoscope approach to verify competence.
Notes
Voting for Peoples Choice
Please cast your vote for the Peoples Choice Award and tear out for collection at the end of the Session.
Queensland Mining Industry Health and Safety Conference

22 - 25th August 2010
Innovations
Peoples Choice Award
Innovation Please tick only one box q
1. Tyre Deflation Station
Xstrata Copper Ernest Henry Mine
2. Coal Hauler Load Profiler & Sealing System

Jellinbah Mining
3. Windrow Delineator
MMG Century
4. Wheel Chock Lowering Project

BMA Goonyella Riverside Mine
5. Pneumatic Controlled Deflector Plate

Sedgman Coal Wash Plant - Rio Tinto Coal Australia - Blair Athol Mine
6. Geotechnical Hazard Maps

BHP Billiton Mitsubishi AlliancePoitrel Mine
7. Belt Lifting & Roller Replacement Tool

Kestrel Coal Rio Tinto Coal Australia
8. Bullgrip
Anglo American Metallurgical Coal Moranbah North Management
9. 24H Grader Over Speed Control System Project

10. Cathode Nodule Catcher

Xstrata Copper Copper Refinery
64
Innovations
Index
Tyre Deflation Station____________________________________________________Pg 66
Coal Hauler Load Profiler & Sealing System___________________________Pg 68

Jellinbah Mining
Windrow Delineator_______________________________________________Pg 70
MMG Century
Wheel Chock Lowering Project___________________________________________Pg 73

Pneumatic Controlled Deflector Plate________________________________Pg 76

Sedgman Coal Wash Plant - Rio Tinto Coal Australia - Blair Athol Mine
Geotechnical Hazard Maps__________________________________________Pg 79

Belt Lifting & Roller Replacement Tool________________________________Pg 83

Bullgrip_________________________________________________________Pg 86
24H Grader Over Speed Control System Project________________________Pg 91

Cathode Nodule Catcher___________________________________________Pg 92

Innovation Submissions 2010

This year 30 submissions were received for the Innovation Awards. With a view to providing a wider circulation throughout
the Industry, the Conference Committee has printed a separate publication which includes all the Innovations received for
the 2010 Awards.
Innovation
Tyre Deflation Station
The Problem or Initiative

Wheels and rims are required to be removed on a daily basis in several areas of EHM operations. When tyres are deflated, hazards such
as noise and flying objects are created due to the high pressure release of air.
Total cost of $ 206.10 for a significant improvement for the working environment.
Solution
Mobile trolley fitted with two large mufflersPhotos:
and a deflector.
Releasing air prior to Mobile Deflation Station
The air passes from the tyres through the air lines and into the mufflers, reducing noise considerably. The air is directed downwards
through the mufflers to the deflector which captures any loose particles, in turn preventing injury from such particles being released at
high pressure.
Benefits/Effects
Elimination of hazards associated with extreme noise and particles being released into the environment at high pressure.
Transferability
The tyre deflation station can be used in all work/maintenance areas when the deflation and removal of a tyre and rim is required.
Total cost of $ 206.10 for a significant improvement for the working environment. The Mobile Deflation Station
Approximate Cost
Photos:
Total cost of $ 206.10 for a significant improvement for the working environment.
Releasing air prior to Mobile Deflation Station
Releasing air with the Mobile Deflation Station
The Mobile Deflation Station.
Releasing air prior to Mobile

Deflation
Releasing air Station.
with the Mobile Deflation Station
Releasing air with the Mobile

Deflation Station.
Notes
Innovation
Coal Hauler Load Profiler & Sealing System
Jellinbah Mining
The Problem
The 180 tonne coal haulers used to transport coal from the mine to the train loadout over a distance of approximately 25 kilometers
presented a problem with coal dust and occasional pieces of coal being blown off of the trucks due to strong side winds during the
journey. The original equipment manufacturers for the coal hauler trailers were contacted to assist with providing covers for the open
trailers but could not provide a workable engineering solution. A mechanical engineering consultant was then engaged to review all
after-market solutions and this process also failed to find a workable solution.
From previous experience at another site with these coal haulers being loaded by a flood loading system with washed coal, a solution
started to form where the load could be profiled and flattened to reduce the affects of the side wind and the load could be sprayed
with a veneer to effectively trap fugitive coal particles.
The Solution
The solution was discussed with the coal haulage company and a consulting mechanical engineer was engaged to manage the
design and installation of a coal hauler load profiler and spray sealing system that was simple effective and reliable. A review of the risks
associated with the use of the load profiler and the sealing agent was carried out to ensure that the project could advance to the next
phase. A sealing agent was selected that would not present a health hazard to persons, would not corrode equipment and would not
affect the coal quality.
The sealing agent was trialed on a number of coal haulers and a comparative assessment made of the effectiveness of the agent
compared to no agent and using only water to spray the load. Site workshop personnel were involved in setting up and implementing
the spray sealing trial. The sealing agent proved to be the most effective in controlling dust emissions over the entire journey from the
mine to the train loadout facility.
The load profiler and spray systems were designed by a design engineering firm with sketches of the concept provided by site
personnel. The profiler and spray system was then constructed on site ready for testing. An operational risk assessment was conducted
involving the project personnel, coal loading operators, coal hauler operators and site maintenance personnel. The profiler was placed
into service prior to the spray system being available due to delays with the installation of the water line to the facility. They spray
system was then commissioned and implemented.
Benefits/Effects
The coal profiler was effective and even without the spray sealing provided a reduction in dust emissions and coal particles. The
introduction of the spray sealing has eliminated dust from the sealed load and also binds the larger particles to the top of the load. The
result has been very effective in reducing dust on the haul road as well as the incidents of windscreen and light damage to vehicles
from coal particles coming off of the load.
Dust sampling was carried out for a six month period prior to the implementation of the profiler and sealing system and these
measurements are being compared to sampling after the implementation of the system.
Transferability
The system design has been provided to a neighbouring mine and would be useful for other operations utilizing these types of coal
haulers. The system is simple but very effective and provides an effective barrier as well as the removal of loose coal that can cause
damage to equipment.
Notes
Innovation
Windrow Delineator
MMG Century
Problem or Initiative
A number of safety measures are in place to ensure that operators of heavy machinery at MMG Century can drive safely within the
mines open-cut pit at night. One of these measures is the erection of reflective pickets at 50 metre intervals on windrows along in-pit
roads so that operators can clearly see road boundaries at night.
Haul truck, and other heavy machinery operators, often drive as close to the left hand side of the in-pit ramps as they can, hugging the
windrows. This practices leads to a build up of dirt and rock along windrows on the left of the road, often covering the reflective pickets.
Extensive damage is also caused to tyres as a result of operators hugging the windrows while driving. This is because the rock and dirt
built up along the left hand side of the road causes cuts and abrasions to the tyre itself. This hazard was identified during discussions
regarding safety in the pit and during a review of the causes of tyre damage and deterioration on site.
While regular inspections are carried out on in-pit roads, there may be periods where the reflective pickets are covered by dirt and rock
on particular sections of road. The reflective pickets need to be erected manually, meaning that a person has to drive a light vehicle
along in-pit roads and have the vehicle stopped for a period of time while they climb up the windrow and hammer in the covered
reflective pickets. While all safety procedures are followed during this process, there are inherent risks involved in personnel climbing
the uneven and slippery surfaces of windrows to install the reflective pickets and the light vehicle being in close proximity to moving
heavy vehicles.
The Solution
A solution was required that ensured that operators could clearly see the side of in-pit roads, and therefore, reduce their tendency to
hug the left side of the road.
Discussions occurred during the audit of safety activities in the pit and a review was conducted into the causes of tyre damage and
deterioration. During these discussions, it was determined that the best way to ensure that operators could clearly see the edge of the
in-pit roads was to develop a device that attached to the windrows, but could not be covered by moved rock or dirt falling from the
trucks. The team discussed a number of different options that could be used. It was decided that a device with two adjustable arms
that could be removed and replaced with different types of arms suitable to each application could be used. The device is known as
the Windrow Delineator.
The team then developed a prototype based on this design. The prototype was tested after a review by Centurys Safety and Health
team to ensure that it was safe for us to use. The device was designed to be made entirely from PVC pipe and in such a way that it rests
on the top of the windrow and hugs the sides (Figure One).
The key difference with this new style of windrow delineator is that is does not need to be hammered into the ground and is light
enough to be thrown over the windrow from the side alleviating the need to climb up uneven and slippery surfaces. The device is
also large enough to provide excellent visibility for vehicle and mobile equipment operators. One of the most important features of the
Windrow Delineator is that due to its design, it can be used on all windrows, regardless of size or shape.
The device has been successfully tested in a small area of the pit. However, due to the number of the Windrow Delineators required,
the device has not yet been rolled out along all in-pit roads.
Benefits and Effects

The purpose of the Windrow Delineator was to provide an effective means for illuminating the edge and centre of in-pit roads at night.
As the Windrow Delineator attaches firmly to the windrow itself, it cannot be moved or covered by rock or dirt moved by the trucks.
This means that the device is always visible to operators and unlike with the reflective pickets, does not need to regularly inspected or
re-erected.
As a result of its design, the Windrow Delineator:

l Improves safety by clearly illuminating the edge and centre of in-pit roads.
l Reduces the potential for light and heavy vehicle interactions by reducing the need for inspection, maintenance and
replacement of reflective devices along in-pit roads.
l Reduces the time taken to install/remove the delineator because of simple throw-on windrow design
l Eliminates the risk of injury arising from personnel climb upon windrows to fix the reflective pickets in place.
Innovation
Transferability
In-pit safety is a priority at any mine site, and the design of the Windrow Delineator means that can be easily used at other operations.
Key design elements that aid transferability within the industry include:
l Adjustable arms and different angle connections mean that the device can be erected to all windrows, no matter what size
or shape.
l The use of lightweight materials to build the device means that it can be easily erected.
l The windrow delineator could also be utilised on ROM pads for delineating the edges of stock piles.
The design of device also means that it could be easily applied outside the mining industry, for example during road works.
The Windrow Delineator
Notes
Innovation
Wheel Chock Lowering Project

Goonyella Riverside Mine has a total of 44 trucks which operate 7 days a week around the clock. Wheel chocks are used whenever the
vehicle is required to be parked up such as for break down, maintenance etc. Chocks could be used once in a shift or multiple times
in each shift depending on the days events. Employees have reported that they experience difficulty in removing chocks from the
vehicles as not only were they required to lift a substantial weight high above shoulder height but then lowering them to the ground
also proved difficult as they are cumbersome and awkward to handle. There had been a number of employees present to the site
Occupational Therapists to report injuries and strains as a result of performing this task which saw the necessity for a safety initiative to
improve the ergonomic issues involved in performing the task of removing the chocks and minimizing the risk of injury.
The Solution
HSEC made a request to Brian Mann from the Maintenance department to review the system in place, to identify the issues which
impacted on the health and safety of operators who had to unload the chocks. This request was made as a direct result of injuries being
reported. Brian Mann, in consultation with Occupational Therapists, was able to assess the need for a device that would assist in the
removal of the chocks whilst not putting the operators at any risk of harm. Observations of how the task was performed identified the
main issues to be risk of harm by reaching to lift (chock) weight of 14 kilograms from above shoulder height and when removing the
chock often dropping it onto the floor which could have hit shins or feet causing injury.
A device was designed to enable the chocks to be lowered to an accessible height to allow operators to remove the chocks safely
without having to reach above shoulder height thus eliminating the risk of injuries to back, shoulders and neck. Also, as the chocks
were at a good height when lowered the risk of dropping was also eliminated. A trial of the device on one truck provided valuable
feed-back from operators of the success of the device thus providing the opportunity to install the chock lowering device on to other
vehicles.
The device was designed from its inception by mine employee Brian Mann and then fabricated on site before being fitted in the
workshop. The operation and safety control systems were designed by the Mobile Maintenance project team, the device operates
using the main air supply, this allows for total control by the operator in all conditions. The system also incorporates safety load check
valves in case of air supply failure preventing the chocks from uncontrolled lowering. Control unit has been designed and positioned
for ease of operation and by giving the operator full vision eliminates all risks of third party interaction.
By using the chocks and also watching others using them, it was decided that a similar system could be designed which would
eliminate associated risks. A design was drawn which was then taken to site engineers who reviewed the design and provided
feedback. The company Parker was resourced to manufacture the RAM and fittings. Worked with mobile maintenance to ensure the
design was effective and avoided any hidden dangers.
Benefits/Effects
Installation of the chock lowering device has actively promoted the health and well being of Goonyella Riverside Mine operators.
Investigations were initiated as a direct result of operators reporting to the Occupational Therapists due to ergonomic issues they were
experiencing with the task. After consultation with operators, HSEC Manager and Occupational Therapists, Brian Mann was able to draft
the original design which was then fabricated and installed. All operators who have had the opportunity to utilise this equipment have
given outstanding feedback to its practicality and functionality. Operators have enquired as to when the remaining truck fleets will be
fitted with this device. This device has proven to be a win-win outcome for the company and employees in that risk of injury and harm
has been nullified.
The benefits of the device are minimizing the risk of harm to our people. With such a diverse workforce that is employed at Goonyella
Riverside Mine and across the other sites in the business this device reduces the risk of harm to all employees who have to perform the
task of removing chocks from the vehicle. This innovation is being presented to the truck manufacturers for their review as a design
improvement for future production. The cost of installing the device on the existing vehicles would be $6000 per unit.
After studying and watching the current chock being pulled down from the truck and also put back on the truck, the level of risk
associated was high and action was required. The hierarchy of controls was applied as per below:
l Elimination Remove the apparent hazards.
l Substitution Replaced existing chock with new design.
l Re-design Fabricate and fit the pneumatic chock design.
l Administration Introduce and trial the new process.
Innovation
Transferability
This device has been installed on one pre strip truck and is now going to be fitted to a production truck. HSEC site manager is putting
forward the device to the truck manufacturers with a recommendation for its implementation for future trucks to have installed. The
device is not expensive to implement as it uses existing air used for other components of the vehicle and once fabricated by the
workshop team is able to be installed on site.
Notes
Innovation
Pneumatic Controlled Deflector Plate
Sedgman Coal Wash Plant
Rio Tinto Coal Australia - Blair Athol Mine
The Problem
Sedgman operates a 300tph coal washing plant on the Blair Athol lease. Coal is pushed into a dump hopper and is conveyed to the
head chute. At times, material hangs up in the head chute causing down time in the plant, which affects productivity. Unscheduled
delays and breakdowns usually result in unplanned work which is known to cause most injuries in the workplace. Any improvements
to prevent or minimise unplanned losses will directly increase our probability of achieving zero harm.
When large lumps of coal became stuck in the head chute of the plant feed conveyor, operators were required to use a platform ladder
to access the top of the head chute. They then used a crow bar to assist in the removal of the wedged coal between the deflector plate
and the head drum of the conveyor. The deflector plate is used to direct the coal over the teeth of the crusher. This assists in spreading
the coal across the teeth to ensure even wear.
This practice had the potential to result in an injury to an employee due to the manual handling task and working in an awkward
position. It could have also lead to equipment damage if the crow bar was dropped into the crushers below, causing them to jam.
Solution
Using the Hierarchy of Controls, the highest level of control was chosen - elimination. This could be achieved by eliminating the need
for the operators to stand on a platform ladder leaning over the head chute to remove the blockage.
The solution proposed was to install pneumatic rams which were designed to move the deflector plate approximately 150mm away
from the head drum of the conveyor when activated. This allowed enough clearance between the deflector plate and the head drum
for any blockage to clear without intervention. The idea was developed by Anthony Looker and Simon Cassidy, Sedgman operator
maintainers. The implementation of the idea and the subsequent installation of the deflection plate was completed by Damian Lloyd,
Plant Manager.
The improvement won the Blair Athol 2009 HSE Innovation Award, and was submitted to the Sedgman Innovation Program for judging
across the Sedgman group. A project initialisation form was submitted for the improvement which was approved. The design team
met a couple of times to brainstorm the finer points of how the moving deflector plate was going to work. Once the team agreed, the
parts were ordered for the job. The fabrication took place in site during a shutdown and only took 12 hours to install. Once installed
the deflector plate worked successfully with no issues from start up.
Benefits
The installation of the moving deflector plate eliminated a number of manual handling tasks from our daily operation. These included:
the risk of injury due to pinch points; eye injury from using high water pressure to clear the blockage; back strain; and the risk of
slipping and falling off the ladder due to awkward position. These tasks had the potential to result in a lost time injury. Sedgmans
Wash Plant celebrated seven (7) years lost time injury free in 2010.
The total benefit was not fully realised until the site management team noticed a steep decline in the number of reported head chute
blockages. It has come to the stage where a blocked head is not even recorded in the SCADA (Sedgman computer control and
reporting system) as a delay. For an outlay of $8500 the deflector has already paid for itself due to eliminating of lost feed rate from
removing blockages and the associated flow on within the plant. One of the main benefits that the management team at Sedgman
have noticed is the positive response that the idea received from other crew members. In addition, there is a belief that management
will take on ideas and develop them, which instils confidence within the team to bring forward ideas and then act upon them as
quickly as possible.
Transferability
This simple, low cost modification provides protection for our work force from a potentially hazardous situation. Every plant across
the industry has troublesome chutes which present the same issues that we identified. For a small cost outlay, the risk of injury can be
eliminated.
Since the moving deflector plate has been installed, a number of improvements have been made which help
in the locking and unlocking of the deflector plate. This was done by installing two pneumatic cylinders to lock
the shafts in place which took the place to two manual locking clamps. Since the inception of this idea, Anthony
Looker has applied the same improvement process to another blocked chute problem within the plant.
Innovation
Figure 1: Large lumps of coal stuck
Figure 2: A crow bar being used to assist in th
coal in the head
between chute
the of theplate
deflector plant and
feedthe head d
conveyor
Figure 2: A crow bar being used to assist in the removal of the wedged
coal between the deflector plate and the head drum of the conveyor.
Figure 4: Deflector plate movable mounting arm.
Figure 1: Large lumps of coal stuck in the Figure 2: A crow bar being used to assist in the
head chute of the plant feed conveyor. removal of the wedged coal between the deflector
Figure 3:
plateAand
diagram
the head drumofofthe role of the
the conveyor. deflector
Figure
Figure 2: 3: A diagram
A crow bar of the role
being usedof the
to deflector
assist inplate
the removal of the wedged
coal between the deflector plate and the head drum of the conveyor.
Figure 4: Deflector plate movable mounting arm.

Figure 3: A diagram of the role of the deflector plate.
Figure 5: Locking arm and actuation arm for the deflector pl

Figure 3: A diagram of the role of the deflector plate
Figure 5: Locking arm and actuation arm for the

Figure 4: Deflector plate movable mounting arm. deflector plate.
Notes
Innovation
Geotechnical Hazard Maps
The Initiative
One of the greatest Principal Hazards within an open pit coal mine is working near slopes and crests. People working within the shell of
the pit or active benches are exposed to a variety of potential failures and geotechnical hazards that can lead to serious or fatal injuries.
Any method, innovation or control that can reduce the risk of injury or damage to personnel and equipment from this Principal Hazard
is worthy of the pursuit of solutions.
The Solutions
In a proactive effort to effectively manage and monitor this Principal Hazard, Poitrel Mine has developed Geotechnical Hazards Map
(GHM). These maps are simplistic tools that use colour coded ratings of green, orange and red to visually display the level of risk
associated with entering the pit shell and active benches near identified geotechnical hazards. The meanings of these colours are clear
and effective and are based upon the traffic light system. The GHM was initially created by Pete Brooks Senior Resource Geologist and
Technical Services Superintendent, Yosef Setiyawan at Poitrel using an extensive and complex technical data set gathered from grade
control drilling, observations, I Site scans, research and past knowledge. The GHM and associated processes were implemented in
November 2009 by Poitrels site contractor, Leighton Contractors Pty Ltd (LCPL).
The initial GHM were A0 in size and highlighted the colour coded risks on a contoured map. Operators indicated the maps were
extremely useful, however they stated they felt more confident in identifying their location if an aerial map was used. The team re-
developed the maps using aerial photography. Subsequent maps now also include bolded crib hut locations and bolded strip and
block number labels to assist in area identification.
The process of developing and maintaining the maps is complex, despite the simplicity of the final product. The GHM are maintained,
used and re-developed through a number of processes.
l Poitrel Mine requires all operational site personnel to be trained in geotechnical awareness, which covers information
relating to the GHM. All personnel are expected to be aware of all elements relating to the maps. In an effort to monitor this
knowledge, routine questions concerning the maps must be answered during Safety Area Observations.
l The colour zone controls used on the maps are outlined in Job Safety Analyses (JSA), which are developed by an Open Cut
Examiner, Mining Superintendent, geologist and or geotechnical engineer and approved by the Project Manager.
l All coal mine workers that are required to work near slopes and crests or in active bench areas must read the JSA and
understand the controls before commencing work. The JSA requires workers to utilise the GHM and understand the colour
codes stand-off zones, bund height requirements and placement of lighting plants and pumps in the area of work.
l At prestart meetings, the Open Cut Examiner or Supervisor reviews the maps with their team. This reinforces the usefulness
of the maps and refreshes their memories to implement controls that will effectively manage specific hazards.
l GHM are printed onsite weekly or as required and are displayed in areas where toolbox talks are regularly conducted by
Poitrel employees and Leighton Contractors.

l GHM are reviewed at least weekly by the geological team and circuit signage is updated to include geotechnical risk colour
coding.
l The ongoing maintenance and development of the maps is determined by data collected from the FY Grade Control drilling
programs and other site databases. These results are evaluated and inserted into future maps.
The GHM have the potential to effectively contribute to all controls outlined in the hierarchy of controls. Here are some
demonstrated examples of how the map has been successfully used as a high level control.
l EliminationGHM assisted operational workers in identifying a thrust fault plane day lighting within a highwall face that
was deemed high risk, and subsequently eliminated the risk by using a specific bench blast pattern 2 and 1/2 strips wide.
The highwall returned to a 70 degree batter allowing crews to cast blast in the next strip. The highwall changed from a red
zone into a green zone.
l SubstitutionThe maps assisted crews to identify an orange zone highwall with an established two metre high bund,
ten metres from the toe of the wall. The wall was subsequently upgraded to a red zone following new tension cracks
observed on the highwall bench. The updated map assisted crews to recognise that action needed to be taken, so the bund
height was increased to five metres. The highwall failed two weeks later, but was captured within the higher bund.
The estimated annual operation costs to continue utilising the GHM amounts to $300,000 per year.
Geotechnical failure is a Principal Hazard at Poitrel Mine and may result in multiple fatalities if not managed effectively. The GHM
provides us with a proactive tool to manage the potential for geotechnical failure. Before the implementation of the GHM, uncontrolled
movements (without bunds, rills, berms etc) were common. To date, there have been no uncontrolled failures in
our highwalls or lowwalls.
Innovation
Benefits/Effects
The GHM have proven to be a simple visual indicator for complex issues faced in open cut mining. Poitrel has identified that the
innovation is benefiting the mine in a variety of ways.
l Reduces risk of injury
l Reduces risk of damage to equipment and machinery
l Has encouraged better communication lines between the mine and contractors
l Demonstrated to reduce costs as innovation uses information collected in everyday operations
l Addresses high level Hierarchy of Controls
In addition to the above, this project has facilitated the awareness of all site personnel of current geotechnical hazards on site. The
information is now readily and visually available in an easy to read, simple format. The GHM initiative is effective, intuitive, and easily
transferred and communicated to the entire workforce.
Transferability
Poitrels GHM can be developed and used by any open pit mine facing hazards associated with slopes and crests.
Poitrel is committed to the safety of its personnel as well as the safety of the industry. The map represents a very significant safety
initiative with the potential to impact many sites and eliminate high risk high consequence hazards. For this reason, Poitrel Mine is
eager to share and communicate all knowledge and learnings associated with this project.
l BMA CEO Marcelo Bastos has indicated that the GHM is an effective and useful safety tool. He noted that they were extremely
relevant for use at BMA mine sites.

l The Regional Mines Inspector has openly recognised the value these maps have for the industry.
l Poitrels General Manager, David Chatto, has actively promoted this innovative map and method to all BMA
General Managers and has suggested that idea be rolled-out as a One BMA safety initiative. Subsequently, South Walker Creek Mine
has expressed an interest in the innovation and is in the process of conducting a site visit to view its effectiveness.
Poitrels GHM initiative has been presented at the BMA Central Queensland Geologists meeting and a paper on the development and
implementation of the project is proposed for the Bowen Basin Geologist Symposium in October 2010. This initiative has the potential
to be implemented in open cut mines and mines exposed to slopes and crests hazards across the industry.
Innovations
To date, Poitrel is not aware of any other mine or industry that has employed a similar process to address hazards associated with slopes
and crests. Innovative measures used to develop the GHM include:
l The use of Acoustic Televiewer tool (ATV) and Optical Televiewer tool (OTV) to gather data used to define status and colour coding
on map. These technologies had not previously been used in BMA mine operations, so trials and tests are still continuing to ensure
accuracy and consistency.
l The development of theoretical concepts and data gathering methodology devised and conducted by onsite personnel. This is
continuing.
l Regular reviews, updates and management of maps.
l Gathering feedback and initiating discussion on the usefulness and effectiveness of the maps.
l Proactively acquiring data to construct a structural model within the Geotechnical Module in Vulcan, which acts as a useful resource
to further develop and evaluate slopes and crests featured on the maps. This tool has significant advantages in short term mine
planning.
l Training all personnel in geotechnical awareness.
l Using specialised tools such as the I Site scanner and supplemented with Tech Services own Topcon survey equipment to
supplement databases with information.
Innovation
Image 1 - GHM Poitrel Mine Ramp 10 South showing potential wedge failure zone within the next two strips.
Image 2 - Colour coded

guidelines used for
Geotechnical Hazard Maps.
Notes
Innovation
Belt Lifting & Roller Replacement Tool
The Problem
After changing 30 rollers on the conveyor belt network on a maintenance day, two workers decided there must be a simpler and
safer way to change out the often failing return rollers. The environment in which these rollers are located is dark and often dusty or
under 200mm of water. The ground is uneven and the workspace minimal, due to the confines of the mine wall (known as the rib) and
conveyor belt.
At Kestrel Coal Mine there are in excess of 6000 return rollers in operation at any one time and at 18.4kg each roller, the task of
changing them was one surrounded by many safety hazards. The process in lifting them out is difficult and was done by the use of
cumbersome chain blocks and safety chains hung off the roof to support the belt off the roller. A co-worker has to get down on all
fours or lie on their side in the mud or dust to replace the old roller with a new one. It was with these issues in mind that Maehe Austin
and Peter OBrien set out to change the way in which the rollers were replaced. They sat down that day to formally discuss the need for
change and decided to meet again in two weeks after formulating a design to make the task easier and safer.
The Solution
Peter and Maehe referred to the hierarchy of control and concluded that the most suitable way to address the issue was to engineer a
tool specifically to change return rollers in an underground mine environment.
Throughout the next 18 months of trialling, testing and numerous prototypes, the original design evolved to include improvements
that allowed the tool to be even more efficient, user friendly but most importantly, safer. Also during this period, documents were
released to the workforce asking for feedback and suggestions. One of the improvements implemented was to add a set of rollers on
the head, allowing the tool to slide in and out from under the belt far more easily. Much of the process has been conducted onsite.
From the initial brainstorming, through the prototype stage and into the engineering phase, Kestrel Coal Mine has had full control
over the development of the tool. After having drawings engineered by Highlands Drafting. Emerald and the tool manufactured by
Integrated Metals Emerald for Kestrel, it is now used by infrastructure crews and outbye maintenance crews at Kestrel Mine.
The roller replacement tool has been designed to address one of the more common manual handling tasks within an underground
mining environment. With the addition of the rollers on the support bar, the operator only has to place and slide the roller into position
without having to slide under the belt supporting the weight of the roller to locate. This part also swivels and locks at 90deg for Non
walk side roller replacement.
As a result, the risk for injuries of a serious nature has been minimised, including but not limited to: line of fire, pinch points on hands
and arms, working at heights, back strains and sprains and eliminates the chance of falling debris from hanging chain blocks from the
roof.
Benefits / Effects
The benefits of this innovation are numerous but can be summarized into two categories.
A) Personnel / time efficiency; and

B) Safety Improvements / hazard minimisation.
Prior to this innovation, the task was a two man task. After isolating the belt, a worker would stand on top of the belt and screw two eye
nuts onto roof bolts. He would then be passed two one tonne chain blocks from his co-worker. After lowering the hooks onto safety
chains placed under the belt, both operators would lift the belt until it was off the roller sufficient enough to get the old roller out
and a new one in. This process alone could take up to 15 minutes per location and it was not uncommon to repeat it many times per
maintenance day.
By using the 7.5 kg roller replacement tool, the task can now be carried out by only one operator, which eases manning constraints. It
is completed in less than two minutes per roller, which is a significant time saving in situations where production is waiting to have the
belt back in operation to allow them to recommence coal output.
The safety benefits are numerous. There is no more carrying of chain blocks of lengthy distances on uneven ground. There is far less
opportunity of pinch points to hands and arms as there is no longer any need to be placing any part of the body where the eyes cant
see. There is no longer a need for an operator to get in under the belt and physically lift the heavy roller into position whilst being
forced to use very poor lifting techniques.
Innovation
Transferability
The design of this innovation incorporates a head attachment which can be adapted to suit different types of structure frames
presently found at Kestrel Mine and indeed other mines throughout the Bowen Basin and beyond.
The structures supporting conveyor belts vary in design across the mining industry. The versatility of this tool allows very easy
reengineering to fit most structure frames at other mine sites, be it in coal or hard rock.
The Innovation
The innovative features of this tool are:
l Light weight at only 7.5kg
l One person operation.
l Lessons loss of production time.
l Less labour intensive.
l Two men @ 10 minutes replaced by one man @ 2 minutes.
l Easy to use operation requiring no training.
l Removes the need for cumbersome lifting equipment.
l Improves body posture when manual handling the heavy roller.
l Negates the need to work under conveyor belt.
l Easily adapted to be used on other belt structure and at other mines.
l Multifunctional design.
l No maintenance required.
l The cost of tool manufactured to specification and hot dipped galvanised is $1860.00, a cost which could be recouped in
less than 2 shifts.
Old way
New way
Notes
Innovation
Bullgrip
The Problem or Initiative:

The Anglo Operational standard and MDG41 (MDG41 is a document which was created in response to an increasing number of
incidents involving high pressure fluid injection injuries on mine sites). In response to this, the NSW Department of Primary Industries
established a joint committee with involvement from the Mining Industry, Equipment Manufacturers, Repairers, and Suppliers of Fluid
Power components in order to formulate a bestpractice document, requires all high pressure hoses to be restrained in case of hose
failure or accidental uncoupling which could cause the hose assembly to whip violently due to sudden release of energy. This sudden
release of energy could make the whipping hose lethal and create a dangerous situation. In such situation, whip-restraints (also known
as whip checks, whip socks, or hose restraints) ensure safety from injury and property damage. Current practise within the mining
industry utilises metal whip-restraints. These whip-restraints are safety cables made of corrosion resistant, high strength steel which on
installation diverts strain on the coupling to the whip-restraints. Whip-restraints are used throughout the mining industries including:
longwall roof support hoses, air hoses, water blasting, drilling, steam, concrete, sandblasting or other high pressure applications.
The hose restraint principle has been widely adopted for a number of years, as a static in use system it performed its function without
At Moranbah
fail. The drawback with the system wasNorth, the
when the following
following hoses
occurred: Whenare restrained:
hoses needed to be replaced, the whip-restraint needed
to be removed from thefailed On theandpowered
hose routed ontoroof supports
the new hose, this in some cases did not occur resulting in a substandard
operational installation. DN20 Solenoid feed
l When the hoses were of a different configuration, i.e. had spiral wrap fitted making it extremely cumbersome to re-fit a whip-
DN25 Positive-set pressure feed
restraint.
DN50 System pressure feed
l When the whip-restraint became exposed to unusually high corrosive environments which tended to compromise the whip-
restraints integrity. All Mono-rail hoses

l Typically the strands of the metal whip-restraints begin to fail and can result in injury to personnel. Injuries can vary from cuts/
scratches to a deepThe cutSolution:

on the body requiring stitches which could then lead to possible tetanus illness and bacterial infection of the
wound; to broken bones of the limb to death.
Owing to the afore mentioned background of the steel type whip-restraints
l Increased manual handling in getting the whip-restraint to fit over the hose properly.
and the noted drawbacks, a conscious decision was made to actively pursue
At Moranbah North, the following hoses are restrained:
an alternative application for the operation.
l On the powered roof supports
Bullivants
DN20 Solenoid feed were approached to lend expertise and assist with finding an
alternative solution
DN25 Positive-set pressure feed to the metal whip-restraints currently in use at Moranbah
North Mine. Following the Change Management and risk assessment
DN50 System pressure feed
l All Mono-rail hoses
process, a Kevlar whip-restraint trial was undertaken. The trail included the
The Solution: use of the whip-restraints on powered roof support DN20 Solenoid feed,
Owing to the aforeDN25 Positive-set
mentioned background of pressure feed
the steel type and DN50
whip-restraints andSystem
the noted pressure
drawbacks, a feed hoses.
conscious The
decision was made
primary
to actively pursue an intention
alternative applicationofforthe trial wasBullivants
the operation. to eliminate personal
were approached injury,
to lend corrosion
expertise and assistand
with finding an
alternative solutionincreased manual handling.
to the metal whip-restraints currently in use at Moranbah North Mine. Following the Change Management and
risk assessment process, a Kevlar whip-restraint trial was undertaken. The trail included the use of the whip-restraints on powered roof
A Kevlar
support DN20 Solenoid whip-restraint
feed, DN25 is a feed
Positive-set pressure polyand
coated high pressure
DN50 System tensilefeed
rope comprised
hoses. The primary of a
intention of the trial
was to eliminate personal injury, corrosion and increased manual handling.
Parafil; which consist of a closely packed core of high strength synthetic
fibres
A Kevlar whip-restraint lying
is a poly parallel
coated to each
high tensile rope other. The
comprised of aParafil is encased
Parafil; which consist of ain tough
closely andcore
packed durable
of high strength
polymeric
synthetic fibres lying sheath.
parallel to each Each
other. The Kevlar
Parafil whip-restraint
is encased in tough and durablestartpolymeric
from approximately
sheath. Each Kevlar whip-restraint
$250.00,
starts from approximately and
$250.00 andincrease
increases inin value
value depending
depending on widthon andwidth and
length of length of the
the whiprestraint whip-
required. Various types
restraint required. Various types of the Kevlar whip-restraints are available
of the Kevlar whip-restraints are available including, single eyed and double eyed whip-restraints; 2ply, 3ply or 4ply whip-restraints. A
double eyed whip-restraint.
including, single eyed and double eyed whip-restraints; 2ply, 3ply or 4ply
whip-restraints.
A double eyed whip-restraint.
Other features of the Kevlar include:

UV resistant
Highly resistant to water
Excellent dimensional stability
Innovation The Kevlar (chemical name for Kevlar is poly(p-phenyleneterephtalami

itself a carbon based aramid. An aramid is a manufactured fibre related
Other features of the Kevlar include: chemical composition to the nylon family, yet its properties vary greatly

nylon. Aramids
Excellent dimensional
l UV resistant stability are prepared by condensation of a diamine and terapht
l Highly resistant to water acid, a carboxylic acid that contains a hexagonal benzene ring in its
molecules.
The Kevlar (chemical
l High tensile strength at low The isaramid
name for Kevlar
weight ring gives Kevlar thermal
poly(p-phenyleneterephtalamide)) is stability, while the par
itself a carbon based aramid. An aramid is a manufactured fibre related in
l High modulus (structuralstructure
rigidity) gives it high strength and modulus.

chemical composition to the nylon family, yet its properties vary greatly from
l nylon. Aramids
High chemical are prepared by condensation of a diamine and teraphthalic
resistance
l acid, a carboxylic
High toughness acid that contains a hexagonal benzene ring in its
(work-to-break)

molecules. The aramid ring gives Kevlar thermal stability, while the para
l High cut resistance
structure gives it high strength and modulus.
l Low elongation to break
l Low electrical conductivity
l Low thermal shrinkage

Chemical
Chemical structure
structure of
of Kevlar. Kevlar.
l Excellent dimensional stability
Chemical structure of Kevlar.
Benefits/Effects:
The Kevlar (chemical name for Kevlar is poly(p-phenyleneterephtalamide)) is itself a carbon based aramid. An aramid is a manufactured
fibre related in chemical composition to the nylon family, yet its properties vary greatly from nylon. Aramids are prepared by
Benefits/Effects:
condensation of a diamine and teraphthalic acid,Kevlar whip-restraints
a carboxylic arealight
acid that contains weight
hexagonal andring
benzene easier to manevour
in its molecules. on
The aramid and o
ring gives Kevlar thermal stability, while the para structure
Kevlar whip-restraints are light gives
weight it high strength
and easier to and modulus.
manevour on and off the
hoses; thus eliminating the extra manual handling from the metal whip-
hoses; thus eliminating the extra manual handling from the metal whip-
restraints. They do restraints. They do
not cause abrasions not cause
to personnel whilstabrasions
installing theto personnel whilst installing th
Benefits/Effects:
Kevlar whip-restraints are light weight and do
Kevlar
Kevlar whip-restraint
easier to
whip-restraint
onto the hose due to the onto
manevour on and
polymeric
off retardant;
the
the hoses; the
hose
coating.
thusfibres
due to
The Kevlar
eliminating the
the polymeric coating. The K
extra manual handling from
whip-restraints not corrode and are flame do not melt
the metal whip-restraints. They do not causeatwhip-restraints
but decompose abrasions
around 460 to personnel
o do not installing
C. Whenwhilst
corrode theand
Kevlarare
the Kevlar whip-restraints
flame retardant; the fibres do no
whip-restraint
break, the onto the hose due to the
o
polymeric coating. The Kevlar whip-restraints
polymeric but decompose
do not corrode
sheath ruptures, exposingandtheat around
are Parafil
flame retardant;460
rope inside. C. When
the Iffibres do notthe
personnel meltKevlar
brush whip-restraints
but decompose at around brea
460oC. When the Kevlar whip-restraints break,polymeric
against the exposed Parafil
the rope,
polymeric sheath ruptures,
they doruptures,
sheath not incur an exposing
injurythe
exposing the the
asParafil Parafil
Parafil
rope inside. Ifrope inside.
personnel brushIf personne
against the exposed Parafilrope
rope,isthey
not do
sharp
notunlike
incur the
an metal
injury aswhip-restraints,
the Parafil rope which
is not results
against the exposed Parafil rope, they do not incur an injury
sharp in an
unlike injury
the to
metal whip-restraints, whichas the Par
the person.
results in an injury to the person.
rope is not sharp unlike the metal whip-restraints, which results in an in
NATA testing was conducted NATA
priortesting
and post the
wastrial; person.
conducted
table prior andthe
1 illustrates post trial; The
results. tabletrail
1 illustrates
was conductedthe results.
over a period of 6 months; from
Thethe
these results it is evident that trail was whip-restraints
Kevlar conducted overdo a not
period
lossoftheir
6 months;
integrityfrom these
during results
their it is
time in use. No Kevlar whip-restraints
evident that the Kevlar whip-restraints do not loss their integrity during their
were replaced during the trial period. Table 1:NATA testing was conducted prior and post trial; table 1 illustrates
Prior to trail and post trail breaking results of Kevlar whip-restraints the r
time in use. No Kevlar whip-restraints were replaced during the trial period.
Table
The trail was conducted over a period of 6 months; from these results i
Table1:1:Prior
Priortototrail
trailand
and post
post trail breakingresults
trail breaking resultsofofKevlar
Kevlarwhip-restraints
whip-restraints
evident that the Kevlar whip-restraints do not loss their integrity during
Hose / Ply Prior to trial Post trial
time in use. NoParafil
Break Kevlar
Test (Kg) whip-restraints
Break Testwere
is currently used in antennae
(Kg) replaced during the trial per
and electrical industries are insulating
guys, catenaries and support systems; providing excellent insulating
1 inch / 2 ply 3307
properties and resistance to UV 4413degradation to ensure a long and essentially
2 inch / 3 plyTable1: Prior 5428
to trail and post trail breaking
maintenance free life. Parafil 5737
is now used inresults of Kevlar
urban transport system inwhip-restr
overhead conductors for supporting tram and trolley buses. Parafil is also
Transferability: Hose / Ply used in marine application forPrior to trial ship and yacht rigging, guard
buoy moorings, Post trial
Transferability:
rails and tow ropes. There
longwall chock hoses.
Break Test (Kg)
are potentials for a lace up style Break Test
whip-restraint for (K
Kevlar is currently used in1making bulletproof vests, belts for radial tires,
Kevlar is currently used in making bulletproof vests, beltsinch / 2 tires,
for radial ply cables, reinforced composites 3307for aircraft panels and boat 4413
cables, reinforced composites for aircraft panelsNorth
andisboat hulls, flame-
hulls, flameresistant garments, sports equipment such2as inch
golf / 3
club ply
Moranbah
shafts
resistant garments, sports equipment longwall and
such aschock shafts and 5428
looking
lightweight
golf club
hoses.
at fully
bicycles, integrating the Kevlar
and in asbestos
lightweight
whips onto in
replacement 5737
all of the
clutches and brakes. Parafilbicycles,
is currently
and used in antennae
in asbestos and electrical
replacement industries
in clutches andarebrakes.
insulating guys, catenaries and support systems;
providing excellent insulating properties and resistance to UV
Transferability:
degradation to ensure a long and essentially maintenance free
life. Parafil is now used in urban transport system in overhead
conductors for supporting tram and trolley buses. Kevlar isiscurrently
Parafil also used in making bulletproof vests, belts for radial tires
used in marine application for buoy moorings, cables,
ship and reinforced
yacht composites for aircraft panels and boat hulls, flame-
resistant
rigging, guard rails and tow ropes. There are potentials forgarments,
a sports equipment such as golf club shafts and light
lace up style whip-restraint for longwall chock hoses.
bicycles, and in asbestos replacement in clutches and brakes.
Moranbah North is looking at fully integrating the Kevlar whips
onto all of the longwall chock hoses.
A metal whip-restraint.A metal whip-restraint.
Notes
Innovation Entire strand on the metal whip-restraint failing, which can cause injury to
personnel.
Strand of the
Strand metal
of the metalwhip-restraints
whip-restraintsbroken which can
broken which cancause
cause injury
injury to to
Entire strand on the metal whip-restraint failing, personnel
Individual wire strands broken on metal whip-restraints - can cause injury to
personnel.
ntire strand on the metal whip-restraint failing, which can cause injury to
which can cause injury to personnel. personnel
personnel.
Strand of the metal whip-restraints broken which can cause injury to

personnel
Individual wire strands broken on metal whip-restraints - can cause injury to

Individual wire strands broken on metal whip- Metal whip-restraints in use on the monorail of
personnel
restraints - can cause injury to personnel. the longwall.
Metal whip-restraints in use on the monorail of the longwall
Single eye Kevlar whip-restraint

Single eye Kevlar whip-restraint.
Whip-restraints located on the longwall chock hoses. Single eye Kevlar whip-restraint
Whip-restraints located on the longwall chock hoses.
Whip-restraints located on the longwall chock hoses.
Metal whip-restraints in use on the monorail of the longwall
Kevlar whip-restraint at breaking point note the fibres are easily seen when
Single eye 2 ply Kevlar whip-restraint on a 1 inch hose Kevlar whip-restraint at breaking point note the fibres
the Kevlar whip-restraint is broken, nor do the fibres result in injury to
Single eye 2 ply Kevlar whip-restraint on a 1 inch hose are whip-restraint
Kevlar easily seen atwhen the point
breaking Kevlar whip-restraint
note
personnel is broken,
the fibres are easily seen when
Single eye 2 ply Kevlar whip-restraint on a 1 inch hose. the Kevlar
nor do thewhip-restraint
fibres resultis broken, norto
in injury dopersonnel.
the fibres result in injury to
personnel
Notes
Innovation
24H Grader Over Speed Control System Project

Issues re the safety aspects and brake system failures of the grader over speed necessitated investigations which led to the conclusion
that a modification needed to be implemented. The investigations found the brake system failure could be directly attributed to
operator influence thus supporting the need to find a solution that would eliminate this aspect of the grader operating capacity. Two
separate control units have been fitted to eliminate over speeds. One gives a visual and audible warning alerting the operator he
is approaching the limit, whilst the other disengages the inching pedal which eliminates the overriding of the system giving a true
operation condition.
The Solution
Due to the excessive brake system failures that were occurring there was a need to find the root cause. This identified there was a need
to eliminate operator influence to assist the diagnostics. Kial Hansen (Supervisor - Mobile Maintenance) and Steve Burns (Supervisor
Mobile Maintenance Projects) undertook the initial investigations to discover the cause of the problem and then through consultation
with Remote Control Technologies in Western Australia were able to come up with a solution that was not costly but very effective.
A risk assessment analysis was conducted to determine the associated risks with operating at higher speeds then the operating ranges
recommendations.
Benefits/Effects
Installation of the over speed control system aligns with the safety value in the company charter by showing an overriding
commitment to the health and safety of the operators. The project supported the value courage to lead change by identifying an
issue and addressing it whereby there was a strong need for acceptance and re-education of the personnel and supervisors to ensure
success. It showed the commitment of our people to drive towards being a high performance organisation.
Since the installation of the system, over speeds and brake failures have reduced. The availability of the equipment has increased as it is
not out of service for maintenance thus cutting down time in production.
Installation of unit costs $10,000 whereas cost of brakes would be $80,000 and engine damage in the region of $150,000 so financial
benefit of the system is substantial.
This system is simple to use as it doesnt impact the way in which the machine is operated. The operators of the machine need to be
aware and understand how it works and what measures need to be put in place should the alarm be activated.
Team understanding of machine function and working with RCT in Western Australia to ensure a designed system to achieve results.
To instill confidence in the device and gain operator acceptance was a challenge as we were changing operating habits of the drivers.
Supervisors were an integral part of coaching operators.
Maintenance of the unit and the testing regime and fostering an understanding of the operations was vital to the success of the
project. Ensuring that the device was simple to operate was a step towards user acceptance.
Transferability
All operations that use Caterpillar 24H Graders could have
the over speed control system installed. The system is able
to be installed in a short time frame thus not interfering with
operation. Goonyella Riverside Mine is currently in the process
of sharing this design with other BMA sites.
Innovation
Cathode Nodule Catcher

Cathodes are washed in the wash station of the Cathode Stripping Machine prior to being stripped. This process removes electrolyte
and wax remaining from the refining process and often causes nodules of copper to fall on the floor of the chamber. The wash station
is required to be cleaned of foreign materials, such as wax, scale and copper debris at the completion of the weekly stripping cycle to
prevent build up (Photo 1). Many of the tasks performed during the cleaning process involve manual handling activities in cramped
areas (Photo 2). Prior to the change, workers were first required to remove three false floor plates which weigh approximately 32kg
each, and then shovel up the tramp copper and wax from the floor into buckets. The buckets were then carried to the front of the wash
station to be emptied into bins. Approximately 250 kg was shovelled in total, taking up to an hour and a half. In addition to the manual
handling risks associated with the task, the internal area is still quite warm and humid due to the wash water temperature being
maintained at 85C, and only a window of time is available to complete the job.
Solution
A system has been installed that virtually cleans itself by gravity (Photo 4). The false floor plates have been removed and a nodule
catcher has been installed. This means that all the copper waste ends up in the nodule catcher (Photo 5), which is emptied bi-weekly
without any issues. The requirement to enter the wash station to remove wax build up has reduced due to an increase in temperature
and pressure in the system.
Benefits/Effects
This innovation has provided a cleaner system and has reduced the requirement to enter the wash station from weekly for up to an
hour and a half, to once every 2 months for approximately 5 minutes. The manual handling risks have therefore reduced significantly,
along with the risks associated with working in hot conditions.
Transferability
The system could be easily installed in other refineries, or the concept installed in processing plants
Photo 1 where similar cleaning and
maintenance issues exist.
Photo 3
Photo 1. Photo 2.
Photo 3 Photo 2 Photo 4
Photo 1
Photo 3. Photo 4. Photo 5. Photo 5

Photo 3 Photo 4
Notes
Notes

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Queensland Mining Industry

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CONFERENCE PROCEEDINGS STUDENT HOST PROGRAM

Coach Transfers - Complimentary Service

5.00pm 6.00pm KEYNOTE PRESENTATION - Proudly Sponsored by ADT Security

Monday 23rd August

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Tuesday 24th August

9.00am 10.30am KEYNOTE PRESENTATIONS - Proudly Sponsored by Xstrata Coal

11.00am 12.30pm CONCURRENT PAPERS

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1.30pm 3.00pm CONCURRENT PAPERS

3.00pm 3.30pm AFTERNOON BREAK AND DISPLAYS

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Wednesday 25th August

11.00am 12.15pm FACILITATED SESSION CONTINUED - Proudly Sponsored by Workplace Solutions

12.15pm 12.30pm FORMAL CLOSE OF CONFERENCE

Major General (Retd) Jim Molan, AO DSC

Master Auctioneer, Phil Black will be in charge once again.

QRC/WIMARQ networking function - Coral Sea Room

To book go to: http://www.qrc.org.au/02_cal/index.asp and follow the prompts.

Sunday 22nd August

MONday 23rd August

TUESday 24th August

SPECIAL ENTERTAINMENT Presenting David DeVito

WEDNESday 25th August

Auditorium 1 Magnetic Room Palm Room Jupiters Pavilion

TUESDAY 1.30pm 3.00pm

Auditorium 1 Magnetic Room Palm Room Jupiters Pavilion

TUESDAY 3.30pm 5.00pm

Effective Health Communication in the Mining Industry

Complicated Manual Handling Simple Prevention

Simple Solutions: Communicating Vibration Information to Workers in Toolbox Talks

Safe Systems Approach for Mining Road Safety

Improving the Operational Safety of Road Going Heavy Vehicles

Road Safety Audits on Mining Operations

Issues addressed during audits include:

A1 Risk Management at Grasstree

Understanding Your Obligations

A Positive Approach to Accountability: Understanding the Nature and Role of

The Work Ability Index

Fatigue and Safety in Mining

Simplifying the Complexity of Polysomnography -

The Art of Investigations and Accidents

Risk Leadership Focusing the Attention Where it Counts

Hitler and Gandhi were Both Courageous Leaders

There are three challenges when it comes to safety leadership:

Fluid Power: Using MDG 41 to Promote Hose Safety

Risk Cost Benefit (RCB) Selection of Optimum Early Warning Technologies

Presenter: Dr G Kizil (MISHC)

Knowledge Elicitation Solutions for Improving Performance and Efficiency

Education as a Path to a Healthy Workforce and Early Detection of Healthy Problems

Increasing the Health Profile Within the OH&S Framework

Applying Risk Based Principals to Managing a Pre Employment Medical Process

State Wide Audit of Underground Coal Mine Gas Monitoring Systems

Assessing Work Tasks of Tyre Service Personnel

ISOLgate /TYREgate / COLLISIONgate

Presenters: Guldidar V Kizil Tilman Rasche

Understanding Your Safety Responsibilities

Bullies are Bad Business - Complex Problem/ Simple Solutions

Fair Hearings in the Coroners Court