HRD - SOM - LNR - TRM - 013 - National Certificate Mining Operations NQF 2 - Development

PLATINUM
NATIONAL CERTIFICATE MINING OPERATIONS NQF 2 -

DEVELOPMENT
1 Foreword
This manual has been revised with the following in mind:
To provide Mining Trainees with the most up to date Development Practices that are commonly applicable to
all underground operations. (It does contain certain generalizations that are not applicable to all sites).
Learners to ensure they familiarise themselves with the respective Mines standards and procedures
To be a valuable source of reference during all phases of training. It must be studied over and over again as
the Learner progresses onwards to Contract Development, and gains deeper insight into the hard, but never
boring Mining Industry.
During this Development training the Learner is expected to master the skills of each category of the
Development workforce and is expected to gain the knowledge of the Developer both technically and in
managing a workforce, as well as the legal requirements to enable him to pass his blasting certificate.
During contract work the Learner must gain hands on experience of production and being directly
responsible for the safety of all persons working under him in preparation to become a safety and production
orientated person.
Always bear in mind that with Mining (just as in all facets of life), the more effort you put into it, the greater
your personal rewards will be.
The National Certificate in Mining Operations Development manual serves as Supporting Learning
Material for the theory of the following Unit Standards:
119567 Perform basic life support and first aid procedures
OcM-G010 Demonstrate an understanding of sexuality and sexually transmitted infections including
HIV/AIDS
MnH-G580 Demonstrate an understanding of typical basic underground hard rock mining services,
process and layouts
MnH-G576 Extinguish a fire by means of portable fire extinguisher
OcS-F001 Conduct a preliminary incident investigation into workplace health, safety and environmental
incidents
MnH-G811 Conduct continuous hazard identification and risk assessment within a workplace
MnH-G501 Follow basic health and safety practices underground
MnH-G538 Make safe a workplace by means of barring
MnH-G555 Install and remove pipes and accessories
ANGLO AMERICAN PLATINUM
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REF NO: HRD_SOM_LNR_TRM_013 DATE OF IMPLEMENTATION: 26 September 2012
VERSION NO: 1.0 LAST REVISION DATE: 26 September 2012
OcS-F008 Control workplace hazardous substances

RoC-G047 Demonstrate a basic understanding of the causes of FOG
RoC-G032 Acquire an appreciation for the role of rock engineering in the mining process
MnH-G712 Install a blocking barricade
MnH-G702 Support an underground working place by means of temporary support units
MnH-G539 Load a battery onto and remove it from a locomotive
MnH-G571 Transport explosives and accessories by means of rolling stock
MnH-G711 Operate a locomotive underground
MnH-G540 Re-rail a track bound unit
MnH-G713 Transport rock, material and equipment by means of rolling stock
MnH-G509 Remove broken rock by means of a track-bound mechanical loader
MnH-G525 Drill holes underground by means of a hand-held rock drill
MnH-G705 Support an underground working place by means of anchors placed into drilled holes
MnH-G569 Construct and install platform
MnH-G714 Time a blasting round or circuit on a face where conventional fuses are used
MnH-G716 Time a blasting round or circuit on a face where shock tubes are used
MnH-G570 Measure, plot and interpret area measurements within an underground workplace
244419 Assemble Oxy-acetylene equipment
MnH-G558 Install and remove ventilation columns and accessories
EnM-G522 Lift and move a load using mechanical lifting equipment
EnM-G008 Replace an in-line fan in an underground environment
MnH-G508 Extend tracks by means of jump-sets and sliding rails
MnH-G548 Install a rail turn-out in an underground workplace
MnH-G547 Install a set of rails in an underground workplace
MnH-G565 Install a stope box front and chute
MnH-G566 Construct an underground ladder-way
MnH-G589 Analyse and solve problems

MnH-G579 Plan, organise, lead and control activities
Note to HRD Officer*** Give Learners all the handout books, workbooks and study Manuals
Study Guide
Workbook
Basic Book
2 Development Introduction and Terminology
OBJECTIVE
A.) To familiarise the trainee with development layouts, terms and gain an understanding of the methods
used.
B.) To enable the trainee to become a safe and productive mining orientated person.
National Certificate Mining Operations NQF Level 2 - Development Page 2 of 276
This document is maintained on an online electronic filing system.
The printed version should be compared to the online version as it may be outdated.
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RESOURCES
A: STUDY
1) Training Module
2) Mines Safety and Health Act
3) Development standards
4) Development Support Code of Practice
B: CONSULT WITH
1) Operational staff at shafts
2) HRD Officers
DEVELOPMENT INTRODUCTION:
The term development refers to tunnels made underground for the following reasons:
1. To expose the ore body so that it can be sampled and the mineral content of the ore determined,
2. To divide the ore body into blocks of ground, which if payable, are then available for stoping,
3. Development provides travelling ways for workmen, Tramming and transport ways for ore and
material, passages for ventilation currents, water ways to the main settlers and pumping stations and
openings in which electrical cables and compressed air and water columns are placed from the
shafts to the Workplaces.
DEVELOPMENT TERMS
1. DEVELOPMENT
Development is any tunnelling operation that has for its objectives either exploration or exploitation
or both.
2. IN STOPE DEVELOPMENT / RE - DEVELOPMENT

In Stope development is development which forms an integral part of stoping operations usually to
negotiate Geological anomalies such as pot-holes.
3. FOLLOW-ON-DEVELOPMENT
Is development which follows behind stoping operations usually in highly stressed ground.
4. BREAK AWAY
Is the creation of another development end in a different direction to the original.

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5. BULL NOSE
Is created by the breaking away of one lateral end from the other thus leaving a triangular shape on
one side of the excavations.
6. CROSSCUTS
Crosscuts are tunnels developed at right angles to the strike of the ore-body, to intersect the reef.
7. HAULAGES
Any tunnel through which transporting of men, materials and rock takes place by means of railbound
equipment.
8. STRIKE
Strike is the direction of a horizontal line drawn on the plane of the reef. (The Line that joins two
points that is on the same elevation)
9. DIP
The dip of a reef body is the inclination of its plane from the horizontal.
The line of the true or major dip is at right angles to the strike. (The shortest Line that joins two points
on different elevations)
10. DIRECTION
Direction is given by means of direction pegs in the hanging wall by the survey department. These
pegs are installed in pairs, approximately 4m apart, with one having a number (FLP and BLP)
11. GRADE
Elevation is given by means of grade pegs on the sidewall by the survey department. Two pegs are
installed in the opposite sidewalls in line with each other and a further two pegs are installed
approximately 4m in front of them for flat ends, or by means of grade chains for inclined ends.
12. MULTI BLAST

Blasting more than once in 24 hours with re-entry periods.
13. PRIMARY DEVELOPMENT

Primary development is the initial development carried out in any portion of a mining area.
14. SECONDARY DEVELOPMENT

Secondary Development is development carried out within the area already developed by primary
development.

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15. RE-ENTRY
After blasting. A period (Re-Entry period) to allow time for harmful dust and fumes to be cleared.
16. OFF SETS

Are pre-determined distances, at right angles, at intervals from a given survey line, curves and
breakaways are developed from offsets.
17. SAFETY PILLAR
Means every portion of an ore body purposely not mined, either for the protection of the surface or
objects thereon, or protection of underground workings.
18. FOOTWALL DRIVES

Are developed in the footwall, at a pre-determined distance below the reef.
19. TIME BLAST

Blasting once in 24 hours at a time set by the manager.
3 Definitions
BANKSMAN
Means a person stationed at the shaft top, who shall be the holder of an onsetters certificate, appointed by
the manager to supervise the loading and uploading of persons in the cage, or other means of conveyance
and to give the necessary signals.
CHAIRLIFT
Means any appliance or combination of appliances used or intended to be used for the conveyance of
persons and material by means of a chair or other carrier suspended from an endless hauling rope or with
chairs or carries running in or on a rope or rail circuit and provided with a traction rope or chain.
METALLIFEROUS MINE
Means and includes any mine other than a coal mine or a diamond mine
MISFIRED HOLE
Means a shot hole or part of a shot hole in which any explosive or any portion thereof has failed to explode.
ONSETTER
Means a person who shall be the holder of an onsetters certificate, appointed by the Manager to have
charge of a cage, skip or other means of conveyance underground in which persons are being raised or
lowered and to give the necessary signals.

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RAISE
Means a tunnel having an inclination above the horizontal in the direction of working of more than 5 degrees
and not included under the definition of Shaft
SCHEDULED MINE
Means a gold mine where more than 1 000 persons are employed underground at any time or any other
mine declared as such by the Government Mining Engineer: Provided that the Government Mining Engineer
declare such a mine not to be a scheduled mine by virtue of the district in which it is situated, by giving notice
in writing to the Manager.
SELF-PROPELLED MOBILE MACHINE

Means a machine or vehicle designed or adapted principally to travel on wheels or crawler tracks, driven by
a motor or engine, which is used for conveying persons or for conveying or lifting material or for conveying,
cutting, breaking, drilling, winning, loading or removing mineral or overburden in or at a mine or works and
used or intended to be used in connection with operations at and pertaining to a mine or works and shall
include any trailer used with such self-propelled mobile machine.
SHAFT
Means any tunnel having a cross sectional dimension of 3,7 meters or over and:
a. Having an inclination to the horizontal of 15 degrees or over, or
b. Having an inclination to the horizontal of less than 15 degrees but more than 10 degrees where the
speed of traction may exceed two meters per second (2m/s).
SHOT HOLE
Means any drill hole charged with or intended to be charged with explosives
SOCKET
Means any shot hole, or part of any shot hole, known not to be a misfired hole, which remains after having
been charged with explosives and blasted or which, for any other reason, may be suspected of having
contained explosives at any time and included any shot hole, or part of any shot hole, from which all
explosives have been extracted in accordance with the procedure prescribed by these Legal requirements
STEEPLY INCLINED
In connection with shafts or other underground excavations means an inclination to the horizontal of more
than 35 degrees
MHSA
Mines Health and Safety Act

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VENTILATION DISTRICT
Means such a part of mine as has an independent intake commencing from a main intake air-course and an
independent return air-way terminating at a main return air-course
WINDING PLANT
Means any hoist or other appliance for the conveyance of persons, material or mineral by means of a cage,
skip or other means of conveyance in any shaft or winze where the driving machinery can normally be
operated manually from the motor or engine room, but shall not include any lifting machine, endless rope
haulage and scraper winch installation.
WINZE
Means any tunnel having an inclination below the horizontal in the direction of working of more than 5
degrees and not included in the definition of Shaft
FLAMMABLE GAS WARNING DEVICE

Means a device designed to give a clearly audible or a clearly visible warning, or both a clearly audible and a
clearly visible warning, would it be placed in an atmosphere containing more than parts per hundred by
volume of flammable gas than allowed.
4 Underground waiting places
Question 1
What is the purpose of a waiting place?
Answer 1
For the use of all persons, prior to entering their working places, to prevent such person from proceeding to
their workings until they have been instructed to do so by the appointed responsible competent person, who
is responsible for the safety of their working places when they enter them?
Question 2
Who is responsible for providing waiting places underground?
Answer 2
The manager is to provide or cause to be provided such waiting places, as may be necessary underground.
Question 3
What check does the manager have that the waiting place procedure is being strictly adhered to?
Answer 3
The manager shall satisfy himself by reports from the Shift Supervisor that the procedure is strictly observed.
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Question 4
What and at what intervals must the Shift Supervisor report on waiting place procedures to the Manager?
Answer 4
By doing an early shift once per week, and recording the procedure in his logbook.
Question 5
What is the procedure to be followed on finding an unauthorized person beyond the waiting place barrier?
Answer 5
To be reported to the Shift Supervisor without delay.
Question 6
In what conditions should a waiting place be kept?
Answer 6
Waiting places must be kept safe, clean and disinfected.
Question 7
List 4 factors to be considered when deciding on the position of a waiting place.
Answer 7
1. Situated with due regard to position of latrines.
2. Where practicable NOT in main haulages (tramming danger).
3. Situated in a safe and well-ventilated zone (not in pillars, above or below remnants. (In through
ventilation).
4. Close to workings as possible.
Question 8
List 6 requirements of a waiting place.
Answer 8
1. Waiting place notices (conspicuously displayed).
2. Adequate seating accommodation.
3. Waiting place barrier.
4. Appointed guard and substitute. (if applicable)
5. Initial examination tools.
6. Lockable ticket box.

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Question 9
List the responsibilities of a Shift Supervisor regarding waiting places in his section.
Answer 9
1. Equip waiting place at selected position.
2. Report daily on condition of waiting place in logbook.
3. Check that procedures are carried out during early shift.
4. Ensure waiting place procedures are carried out and comply with legal and mine procedures.
Question 10
What important information must be posted up on the plan board?
Answer 10
1. The Stope plan (s).
2. Service department reports.
3. Escape route.
4. Productivity bulletins or notices
5. Safety Representative Name and Number
6. Special Instructions where applicable
7. Critical Standards
Question 11
What information must be posted up on the General notice board?
Answer 11
1. Name of appointed responsible competent person, Shift Supervisor and Mine Overseer / Manager.
2. Section number.
3. Working place name.
4. Contract number.
5. Present call.
6. Guard and substitute number. (if applicable)
7. Previous m2 achieved.
8. Emergency telephone numbers.
9. Team leader number. (if applicable)
10. Hand and Substitute number. (if applicable)
Question 12
Who is responsible to ensure that the waiting place procedures are adhered to and when?

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Answer 12
The appointed responsible competent person will ensure that the waiting place procedures are adhered to
on a daily basis.
IDENTIFIED HAZARDS PERTAINING PERFORMINIG OF WAITING PLACE PROCEDURES
HAZARDS POSSIBLE RESULTS CONTROLS
At the waiting place, check if Unauthorized entry if no guard in Visually check the condition of the
the barrier is closed and a place. waiting place and if drinking water
guard in place. available.
Check if all identification cards Unaccounted Team member in Check cards against ontel print-
were collected. Lock away the case of emergency. out. Leave a guard at the waiting
cards. place to collect cards from late
comers.
Check the early entry token Unauthorized entry into blasted or Refer Reg. 8.8.1, 8.8.2 and 8.1.1
card and instruct the Team dangerous areas may cause and concessions
Leader which panels he may serious accidents.
examine.
Select the 5 members of your Smoking when testing for Ensure Team members wear
early examination team and methane may cause explosions protective clothing and PPE is
check them for contraband. available.
Exercise:
HRD Officer to take Learners to a fully equipped waiting Place and facilitate all the requirements for a
waiting place and notice boards
Composition of a Development Team and their individual functions of each Team member
HRD Officer to Facilitate each occupation in a Development team and describe to the understanding of all
Learners the role and expected delivery (Performance) of each member per shift in order to achieve set
targets
Rock drill Operator

To be able to safely drill 26 holes in a flat development end (inclusive of pilot holes and support holes,
installation of support)
Effective time will reduce from 4 hours to 3 hours
Blasting Assistant
To be able to safely transport explosive & charging up & time all different timing methods
Loco Operator
To be able to safely operate a loco / pulling ore and tip / transport material / transport explosives

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Loader Driver
To be able to safely clean at least one flat ends per shift
PTV (Pipes, Tracks and Ventilation)

To be able to safely extend two ventilation pipes ( air & water pipes) & construct drains/ length of 9m rails
5 Emergency Preparedness and Refuge Bays
Question 1
What is the purpose of refuge chambers?
Answer 1
Refuge chambers are established in strategic places underground, close to workings. It affords refuge to
persons who might be endangered by smoke or gas (caused by underground fires or blasting), which has
contaminated the fresh air, and the persons are unable to retreat quickly and safely to fresh air.
Question 2
What is to be considered when deciding on the position and size of refuge chambers?
Answer 2
1. They must be established to be within the reach and adequate in size, to accommodate all persons on
the level or in the area which the refuge chamber serves.
2. When determining the size, a figure of 0,6m 2 per person is allowed.
Question 3
Which excavations are used as refuge chambers?
Answer 3
A disused lateral development end or a holed end, solidly sealed, not more than 30 metres from the
entrance.
Question 4
How is the entrance to refuge bays constructed?
Answer 4
The entrance is bricked off with an opening for a door.
Question 5
On what principle does the door of the refuge chamber work?

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Answer 5
It is constructed of flexible material, which hangs over the opening of the door inside the refuge chamber.
When opening the compressed air a high pressure is created inside this seals the door against the sides of
the opening.
Solid doors are also extensively used
Question 6
How will persons find the refuge chamber in dense smoke?
Answer 6
1. There is a remotely audible hooter outside the chamber with a bell wire control inside the chamber for
signalling at intervals, should persons be in a dense smoke and unable to find the entrance.
2. An amber flashing light is also installed to assist persons allocating such a refuge chamber.
Question 7
What is installed inside a refuge chamber? (Requirements)
Answer 7
1. There are compressed air and water valves inside the chamber.
2. Compressed air column 50 mm diameters. Noise reduction installed to back of chamber.
3. Potable, wholesome drinking water must be available.
4. First aid station consisting of length of a first aid box, stretcher and blankets.
5. Internal telephone where possible.
6. Adequate number of benches provided.
7. Drain for water to be led out of chamber.
8. Portable toilets (Male/Female).
9. The necessary notices as required by the standard.
Question 8
Which 5 notices are displayed at the first aid station in a refuge chamber?
Answer 8
Notices for the treatment of:
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1. Gassing.
2. Drowning.
3. Electric shock.
4. Heat stroke.
5. Heat Exhaustion.
Question 9
What is done to ensure that all persons know the location of refuge chambers underground?
Answer 9
All refuge chambers underground are pointed out to all persons by their responsible supervisors, and
relevant notices to the refuge bay are displayed. All refuge chambers must be marked on the plan at the plan
board.
Question 10
When must persons proceed to the refuge chamber?
Answer 10
When it is impossible to gain access to the fresh intake air side, all persons must proceed to the refuge
chamber in their area as soon as possible.
Question 11
What is the responsibility of the first person on his arrival at the refuge chamber?
Answer 11
He must open the compressed air valve at once and blow the air-hooter intermittently.
Question 12
When may persons leave the refuge chamber?
Answer 12
Under no circumstances must any person attempt or allow any person to leave the refuge chamber until
contact has been made by rescue teams or on instruction from a senior supervisor.
Question 13
How do supervisors ensure that persons are conversant with emergency procedures at all times?
Answer 13
Supervisors must check by questioning persons underground at regular intervals, to ensure that all persons
know and understand the procedure.
1. Regular drills must be conducted.
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Question 14
Give a sketch of a typical refuge bay.
Answer 14

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IDENTIFIED HAZARDS PERTAINING THE REFUGE CHAMBER REQUIREMENTS
HAZARDS POSSIBLE RESULT CONTROL

Do regular checks on Refuge
Chamber equipment:
Refuge chambers must be Excessive distance from working Refer Reg. 24.20.2.2
constructed in an unused x/cut places
within easy reach of the
working places.
It must be identified with a Bad identification Identify properly.
blue flashing light and a
symbolic sign placed at the
entrance to the x/cut.
Check if all the equipment is Refuge-Bay not fit for purpose Refuge-Bay checklist
available in the Refuge
Chamber for your section.
A solid wall at back with old Exposure to poisonous gasses Ensure proper sealing
ore passes blocked off and
sealed.
Compressed air for ventilation Lack of fresh air. No valve on branch pipe from
(50mm pipe with valve) 2m haulage column.
from rear wall, with by-pass
containing an orifice plate with
8mm diameter hole.
Brick seal with 1.4m x Leaking air seal Ensure proper fitting and sealing
0.9m steel door opening door.
at entrance to chamber door.
Must make a good seal.
Adequate seating Fatigue Provide seating while waiting for
arrangements. rescue
2 Sanitary buckets Hygiene Provide sanitation
12mm pipe for drinking water Thirst. Provide drinking water
and water available.
First aid canister fully Emergency treatment Check if fully equipped.
equipped
Telephone, instructions on No communication to surface Ensure communication means is
what to do whilst in chamber in working order.
(English, Afrikaans, Fanakalo)
Instructions for treatment of Ignorance of emergency treatment Provide posters with instructions.
Heatstroke, gassing and
electric shock.
A photo of a rescue team Unknown image. Show Team members who will
member. come to rescue them.
Exercise
HRD Officer to take Learners to the refuge-Bay and facilitate all the requirements and to ensure full
understanding of the refuge-Bay procedure, by conducting all the physical exercises required in case of an
emergency

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6 Dust
**Note to Learners - Prepare for the Dust examination as per study guide
Question 1
In what condition must service water be maintained underground to ensure the health of persons?
Answer 1
Clear, odourless and chlorinated.
Question 2
What is the maximum distance that pipes may be from the face?
Answer 2
According to the Mine Standard per specific shafts, usually less than 20m.
Question 3
What length of hose is required for watering down?
Answer 3
Sufficient length of hose shall be provided and used to bring water to every place where it may be required
for dust allaying purposes.
Question 4
Why is a water hose not left lying in a working place with the water running?
Answer 4
No person shall negligently cause or permit water supplied from any service pipe for dust allaying or drinking
purposes to run to waste.
It can cause mud rushes or flooding.
Question 5
How is dust prevented from being caused by drilling and mechanical cleaning?
Answer 5
Every machine for ripping, picking, cutting, drilling or loading rock, coal or other mineral shall be fitted with a
means, or means shall be provided, either for applying water effectively to prevent dust being created by the
operation of such machine, or for effectively trapping such dust by some suitable apparatus.

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Question 6
What are the requirements regarding dust allaying in main travelling ways?
Answer 6
The floor of every main travelling road, shall be kept damp or otherwise treated to prevent the escape of dust
into the air.
Question 7
What must be done before work of any kind liable to create dust may commence?
Answer 7
No person shall perform or cause or permit to be performed work of any kind liable to create dust unless the
floor, roof, sides and other surfaces where the work is to be performed and any broken rock, coal or other
mineral which is being moved or discharged, are effectively wetted, and kept damp so as to prevent as far as
practically possible the escape of harmful dust into the air.
Question 8
What is dust?
Answer 8
Dust is finely divided solid matter.
Question 9
What is the unit in which dust particle sizes are measured?
Answer 9
A micron
Question 10
What is a micron?
Answer 10
A micron is 1 mm or 0,001mm
1000
Question 11
When is dust visible?
Answer 11
When it is 50 microns in size and bigger.
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Question 12
When is dust dangerous?
Answer 12
When it is 7 microns in size and smaller.
Question 13
What effect has dust on a person?
Answer 13
It causes a lung disease called phthisis. It coats the bronchiole so that they cannot absorb oxygen from the
air.
Silicon dust from the quartzite in gold mines causes silicosis.
Coal dust from coal mines cause anthracosis.
Dust from asbestos mines cause asbestosis.
Question 14
What are the twelve sources of dust underground?
Answer 14
1. Blasting
2. Drilling
3. Blowing over in sinking shafts.
4. Lashing
5. Scraping
6. Mechanical loading
7. Tipping
8. Loading at loading boxes
9. Blowing out drill holes
10. Barring
11. Sweeping
12. Blowing out electrical motors.
Question 15
Which instruments are used to sample dust in mine air?
Answer 15
The konimeter and gravimetric sampler.
Question 16
What is the objective of dust sampling?
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Answer 16
Dust sampling is done to:
Detect unhealthy conditions
Detect causes of unhealthy conditions
Indicate dust control measures
Determine effectiveness of dust allaying methods
Provide records to determine trends
Comply with the MHSA
Gather information for research purposes.
Question 17
What are the five fundamental methods used to protect persons against the inhalation of dust?
Answer 17
1. Removing persons
2. Allaying at source
3. Diluting dust
4. Filtration
5. Using respirators
Question 18
How are persons removed to protect them against dust?
Answer 18
Mines have laid down blasting and re-entry times. This allows persons to be out of the working place
before they become contaminated by dust.
Whenever abnormally high concentrations of dust contaminate a working place, the person in charge
withdraws persons and takes appropriate action to prevent them being exposed.
Question 19
What are the methods of allying dust at its source?
Answer 19
Oil and other binding agents are used on the footwall of tunnels
Apply water effectively
Observe water application equipment e.g. water tube in machine, tip sprays, water blasts, blowpipes
etc.
Prevent substandard use of compressed air (e.g. blowing out of holes, blowing over footwall etc.)

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Question 20
How do you dilute airborne dust particles underground?
Answer 20
Dust is diluted underground by providing effective ventilation.
Learners to write Dust examination
7 Gases
Gases Encountered in Mines
** Note to Learners - Prepare for Gases examination as per the Study Guide
MAIN GASES AND VAPOURS DOUND IN UNDERGROUND MINES AND IN SURFACE WORKS
OEL-
CHEMICAL SOURCES AND METHODS OF
GAS CHARACTER SG TWA
COMPOSITION OCCURRENCE DETECTION
ppm
Simple asphyxiant. Compressed gas for
Detector
Acetylene C2H2 Explosive Limits 0.9 welding and cutting of
Tubes.
2.5% to 82% metals.
Poisonous irritant.
Burns eyes, nose
throat and lungs. Explosives based on
NMAM 6015
Explosive Limits ammonia, ammonia 25
0.5 Solid sorbent
Ammonia NH3 15% to 28%. used as refrigerant STEL
9 tube. Detector
Immediately (leakage), additive to 35
Tubes.
Dangerous to Life refining process.
or Health (IDLH)
300ppm
Colourless
Arsenic in acid
disagreeable garlic
solutions used in NMAM 6001
odour, highly
refining processes Solid sorbent
Arsine AsH3 poisonous. (250 2.7 0.05
(platinum). By-product tube. Detector
ppm is instantly
from chemical Tubes.
lethal)
processes.
IDLH 3 ppm
Asphyxiant, High Slow oxidation of
percentages are organic matter,
NMAM 6603
usually associated breathing, fires and
Carbon 5000 Gas sampling
CO2 with oxygen 1.5 explosions, operation
Dioxide C30 000 bag. Detector
deficiency. Causes of diesel locos. Occurs
Tubes.
headaches. in poorly ventilated
IDLH 40 000 ppm work places
NMAM 6604
Poisonous. Fires, explosions, Portable direct
Carbon Explosive Limits 0.9 blasting operations, 30 reading CO
CO
Monoxide 12.5% to 74.2%. 7 exhaust gases from C100 Monitor.
IDLH 1200 ppm diesel locos. Detector
Tubes.

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NMAM 6011
Poisonous. Causes
Pre-filter and
intense irritation of
Water purification 0.5 filter. Detector
Chlorine Cl eyes, nose and 2.5
plants. STEL 1 Tubes.
throat.
Leak detection
IDLH 10 ppm
kits.
NMAM 2541
Nearly colourless
Sorbent tube.
gas with a pungent
Diesel exhaust fumes Direct reading
Formaldehy suffocating odour. 1.0 1
HCHO include a range of monitor.
de Explosive limits 4 STEL 1
aldehydes. Detector
7.0% to 73%
Tubes.
IDLH 20 ppm
Trade name for
NMAM 1003
various Methane
Sorbent tube.
halides. Phosgene
Freon - - Refrigeration plants. - Detector
gas formed when
Tubes.
exposed to flames
or welding arcs.
Non-Toxic.
Explosive limits 4%
Laboratory
to 75% Battery charging
analysis.
High 0.0 stations. Sometimes
Hydrogen H2 C 1.4% Detector
concentrations can 7 associated with
Tubes.
be associated with Methane.
an oxygen
deficiency.
Poisonous irritant.
Affects the eyes,
NMAM 7903
nose throat and Burning of PVC
Solid Sorbent
Hydrogen skin. Severe 1.2 products. Ignition of
HCL C5 tube. Detector
Chloride exposures result in 7 platinum salts used in
Tubes.
pulmonary refining processes.
oedema.
IDLH 50 ppm.
NMAM 6010
Solid Sorbent
Poisonous. Can be tube. NMAM
Hydrogen
absorbed through 7904 Filter
Cyanide ( Gold recovery using
the skin. Explosive 0.9 plus
also known HCN cyanide process. C 10 Sk
limits 5.6% to 4 bubbler(aeros
as prussic Burning of plastics.
40.0%. ol gas).
acid gas)
IDLH 50 ppm. MDHS 56/2
Filter plus
bubbler
NMAM 6009
Solid Sorbent
tube. MDHS
Poisonous. Can be
16/2 Diffusive
Mercury absorbed through 0.025m
Hg - Gold smelting. badge or
Vapour the skin. g/m3
pumped
IDLH 10mg/m3
sorbent tube
Detector
Tubes.

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Non-Toxic.
Explosive limits 5%
to 15%. Water fissures, dykes
0.5 Methanometer
Methane CH4 High and faults, blowers C 1.4%
5 s & GDI
concentrations can and coal strata.
be associated with
oxygen deficiency.
NO 25
1.0 Blasting operations, NMAM 6014
NO Poisonous. STEL
4 exhaust gases from Sorbent tubes
Oxides of NO2 IDLH (NO) 100 35
1.6 diesel locos, arc (NO & NO2).
Nitrogen N2O4 ppm. NO2 3
3.2 welding and burning of Detector
N2O3 IDLH (NO2) 20 ppm. STEL 5
1.3 explosives. tubes.
Necessary to life.
Deficiency caused
Not less NMAM 6601
by oxidation of
O2 1.1 than Portable direct
Oxygen timber and pyrites, Constituent of air.
19% reading
fires and
oxygen meter.
explosions, causes
asphyxia.
NMAM 6004
Poisonous irritant.
2.2 2 Filter and
Sulphur SO2 Burns throat, eyes,
6 Smelting operations. STEL 5 treated filter.
Dioxide nose and lungs.
Detector
IDLH 100 ppm .
tubes.
Poisonous irritant.
Can be corrosive to
1 mg/
all tissues with
m3 NMAM 7904
which it comes in
Chemical processes Solid Sorbent
Sulphuric H2SO2 contact. Affects -
using sulphuric acid. STEL tube.
Acid Mist eyes, nose, throat
Pickling processes. 3mg/m3 Detector
and skin.
tubes.
Colourless oily
liquid..
IDLH 15mg/m3 .
Sk = Danger of cutaneous absorption. NMAM = NIOSH Manual of Analytical Methods MDHS = Methods for the
determination of Hazardous Substances (HSE, UK)
Their Properties and Means of Detection
Question 1
Name 6 most common dangerous gases encountered underground in mines.
Answer 1
1. Carbon Dioxide (CO2)
2. Carbon Monoxide (CO)
3. Oxides of Nitrogen (NO and NO2 NOx)
4. Methane (CH4)
5. Hydrogen (H2)
6. Sulfurated Hydrogen (H2S)
Note: The density of gasses is relative to normal air.

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7.1 Oxygen (O2)
Question 1
What are the properties of oxygen?
Answer 1
1. Oxygen is one of the principal constituent elements in the atmosphere. It is the supporter of life and
combustion.
2. Non-poisonous
3. Colourless Tasteless Odourless
4. Slightly soluble in water
5. Slightly heaver than air, relative density (R.D) 1.1
6. It forms 20,9% by volume of normal air
Question 2
What danger is associated with oxygen?
Answer 2
If the oxygen content falls due to ineffective ventilation, underground fire, or displaced by other gases, then
unconsciousness and death can result.
Question 3
What are the physiological effects due to oxygen deficiency?
Answer 3
If the oxygen content of the air falls to:
17% breathing becomes deeper and faster
this symptom is followed by headache, dizziness, and bussing of the ears till oxygen content in the air
falls to 13%
If the oxygen content in the air falls to 10% men will become unconscious, then die due to asphyxia
Question 4
Where is a deficiency of oxygen likely to occur underground?
Answer 4
1. Where there is an underground fire.
2. After explosions
3. In old abandoned working areas where the oxygen has been consumed by the oxidation of minerals or
organic matter (e.g. timber)

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4. Ineffective ventilation
5. In working places where the oxygen has been displaced by other gases.
7.2 Carbon Monoxide (CO)
Question 1
How is carbon monoxide formed?
Answer 1
1. Blasting operations
2. Underground fires
3. Exhaust fumes of internal combustion engines
4. Methane explosions
Question 2
What are the properties of carbon monoxide?
Answer 2
1. Lighter than air (RD 0.97)
2. Colourless odourless tasteless
3. Very poisonous
4. Does not support combustion
5. A product of incomplete combustion
6. Slightly soluble in water.
Question 3
Name the effects on a human being.
Answer 3
CO is a deadly gas. The action on the body is cumulative, small percentages are readily absorbed and
retained until the blood becomes saturated. Carbon monoxide is absorbed by the haemoglobin (red blood
corpuscles) of the blood 300 times faster than oxygen and retained to form carboxyl-haemoglobin, thus
preventing oxygen fro reaching the tissue.
0,02% will produce slight symptoms of poisoning in 2 hours, 0,05% causes headache and discomfort in one
hour. 0,1% causes giddiness in 30 minutes, helplessness in one hour, and death in 2 hours.
Question 4
How do you test for this gas?

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Answer 4
1. A continuous monitor.
2. Colorimetric detector tubes (e.g. Drger)
Question 5
How would you prevent persons from being exposed to carbon monoxide?
Answer 5
1. Adequate ventilation
2. Barricading of unventilated areas
3. During underground fires get person on the fresh air side
4. Knowledge and use of compressed air in refuge bays in case of fires
5. Diesel motors to operate in well-ventilated areas only.
Question 6
Why is carbon monoxide a very dangerous gas?
Answer 6
It is a deadly gas giving no warning, as it is not detected by the human senses. The gas is absorbed and
retained by the blood, causing giddiness, helplessness and death.
Question 7
What amount of carbon monoxide is allowed by law?
Answer 7
The amount of carbon monoxide may not exceed 100 PPM of air by volume.
7.3 Carbon Dioxide (CO2)
Question 1
How is carbon dioxide formed?
Answer 1
1. Blasting operations
2. Underground fires
3. Methane explosions
4. Slow oxidation of organic matter (timber) in unventilated or badly ventilated areas
5. Breathing of person
6. Exhaust fumes of internal combustion engines

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Question 2
What are the properties of carbon dioxide?
Answer 2
1. Heavier than air (RD 1.53)
2. Soluble in water
3. Colourless odourless slight acid taste
4. Product of complete combustion
5. Does not support combustion
6. Not a poisonous gas.
Question 3
Name the physiological effects
Answer 3
1. Not a poisonous gas
2. 3 - 4% will lead to laboured breathing
6% will produce palpitations and a throbbing headache
8 10% will produce unconsciousness, which may lead to death from asphyxia, but requires a
considerable period to evidence itself.
NB: The percentage absorbed may vary depending on a persons activities. A person climbing up a
raise is affected sooner than a person waking level due to the extra physical exertion causing
increased breathing.
Question 4
Why is CO2 called the Miners Friend
Answer 4
Because of the warning it gives. Although CO 2 is not toxic, its presence is usually associated with a
decrease in the oxygen content of the atmosphere leading to oxygen deficiency and asphyxiation.
By causing laboured breathing and headache it often gives warning of more dangerous gases associated
with it, or of oxygen deficiency.
Question 5
How will you test for this gas?
Answer 5
1. With a CO2 monitor
2. A detector tube will show the amount present.
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Question 6
Why is it compulsory that we use monitors?
Answer 6
Due to the danger of igniting methane that may have accumulated in the underground working place.
Question 7
When and where do you expect to find CO2?
Answer 7
1. Refer to question no. 2 for how, when and where it is formed and expected to be found.
2. This is a heavy gas, which will work its way down winzes, the lower sections of workings and the near
footwall areas of badly or unventilated areas.
Question 8
What precautions must be taken to prevent gassing?
Answer 8
2. Diesel motors to operate in well ventilated areas only
3. Unventilated areas to be barricaded off
4. Adhere to blasting schedule and the MHSA
Question 9
What amount of carbon dioxide does law allow?
Answer 9
The amount of carbon dioxide may not exceed 5000 PPM of air by volume.
Question 10
If CO2 is not a toxic gas, the concentration shall not exceed 5000PPM of air by volume in the workings of a
mine?
Answer 10
The reason for this is that CO2 is nearly always associated with other gases (particularly CO) or an oxygen
deficiency and probably implies that the general ventilation is inadequate.

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7.4 Nitrous Fumes
Question 1
How are oxides of nitrogen formed?
Answer 1
1. Burning and exploding of explosives
2. Exhaust fumes of diesel motors
Question 2
What are the properties of oxides of nitrogen?
Answer 2
1. Heavier than air (RD 1.6)
2. A poisonous gas
3. Very soluble in water
4. Reddish brown colour
5. Irritates the eyes, nose and throat
6. Smells like ammonia
7. Acid taste
Question 3
How would you clear this gas?
Answer 3
1. By watering down.
2. Clean, strong fresh ventilation
Question 4
Name the physiological effects
Answer 4
1. During the early stages it irritates the eyes, nose and throat. Headache, tightness and perhaps pain in
the chest and coughing. May not be severe and pass of altogether.
2. Unfortunately these fumes have a delay effect, which may not show itself until 2 8 hours later.
During this delay it may cause acute inflammation of the lungs, forming blisters, which eventually burst
and cause water logging of the lungs. When suspected that a person has been exposed to oxides of
nitrogen, such a person must be sent to hospital for 24 hours observation.

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Question 5
How would you test for this gas?
Answer 5
1. Human senses, as this is an irritating gas with a reddish brown colour.
2. A detector tube.
Question 6
How would you prevent persons from being exposed to this gas?
Answer 6
1. In development ends use water blast.
2. By applying sufficient water.
3. Observing re-entry period when blasting.
4. Observe safety precautions when blasting obstructions during the shift.
5. Strict adherence to blasting schedule.
6. Adequate ventilation and proper maintenance of loco smoke boxes.
Question 7
What amount of oxides of nitrogen does law allow?
Answer 7
The amount of nitrous fumes may not exceed 5 PPM of air by volume.
7.5 Hydrogen Sulphide (H2S)
Question 1
How is hydrogen sulphide formed?
Answer 1
1. The chemical reaction of acid water on sulphide ores.
2. Released when stagnant water is disturbed.
3. Also liberated as water fissures are encountered.
Question 2
What are the properties of Hydrogen Sulphide
Answer 2
1. Very poisonous and can cause sudden death.
2. Colourless tasteless in small concentration it smells like rotten eggs.
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3. Heavier than air (RD 1,18).

4. Very soluble in water but when the water is subsequently disturbed it escape into the air.
Question 3
How does Hydrogen Sulphide affect the human?
Answer 3
1. Affects the nervous system causing quick death, about the same as carbon monoxide.
2. If this gas is encountered the human senses can not be relied upon for too long a period because it
deadens the sense of smell.
Question 4
How will you test for Hydrogen Sulphide?
Answer 4
1. Smelling
2. Detector tube
Question 5
What precautions must be taken to prevent people being exposed to this gas?
Answer 5
2. Special precautions when approaching or holing into large quantities of stagnant water.
3. Precautions when drilling into fissures issuing water and also liberating hydrogen sulphide.
Question 6
What amount of Hydrogen Sulphide does law allow?
Answer 6
The amount of Hydrogen Sulphide shall not exceed 20 PPM of air by volume.
7.6 Hydrogen (H2)
Question 1
How is Hydrogen produced underground?
Answer 1
1. It is associated with Methane in fissures.
2. In underground battery charging stations, Hydrogen is liberated when accumulators are put on charge.
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Question 2
What are the properties of Hydrogen?
Answer 2
1. Non-poisonous.
2. Lighter than air relative density 0,07 (lightest gas known)
3. Colourless odourless tasteless.
4. It is readily combustible, but does not support combustion.
5. Explodes violently if air contains 4% - 75% H2.
Question 3
How would you test for Hydrogen?
Answer 3
1. Methanometer (flammable gas measuring instrument).
2. Detector tube (must follow procedure laid down by the Ventilation Department).
Question 4
How is the human affected by Hydrogen?
Answer 4
1. Non-poisonous.
2. Displaced oxygen (asphyxia).
3. Burns of varying degree, to fatal should an explosion occur.
Question 5
When and where would you expect to find Hydrogen?
Answer 5
1. In underground battery charging stations where accumulators are put on charge.
2. It is associated with methane in fissures.
Gassing
All cases of gassing be reported to the Manager, Mine Overseer, Manager, Shift Supervisor and DMR.
Procedure To Rescue and Revive Gassed Persons

1. Before making any attempt to rescue, see that the fans are working and compressed air is turned on
into the place where gassing has taken place.
2. Send word to nearest senior supervisor.

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3. Send for first aid box, stretchers, blankets and oxygen resuscitation apparatus if available.
4. Do not enter danger zone until it has been flushed out. In low concentration of Oxides of Nitrogen, a
wet cloth may be used as a mask.
5. Never attempt to enter danger zone alone, for you are liable to get gassed yourself. Form a team of at
least 4 persons team to hold hands. If fresh men are available rescuers must not enter danger zone
a second time.
6. Get gassed person as quickly as possible to nearest fresh air point. Keep them warm by extra
covering, and keep them dry. Special care must be given to persons poisoned by Carbon Monoxide
due to a possible recurrence of unconsciousness after partial recovery.
7. If a person has stopped breathing or is breathing irregularly and poorly, start artificial respiration at
once. Administer oxygen if available. Do not allow collapsed person to walk or exert himself. It may
result in heart failure.
8. All cases of gassing, however slight, should be sent to hospital for at least 24 hours observation.
Banksman / control room to be notified from underground to organise an ambulance.
7.7 Methane
Introduction
Methane is one of the most hazardous gases encountered in the underground workings of a mine. It is not
detectable by means of the human senses. When mixed with air it becomes extremely dangerous as it
forms a mixture that rages from burning to exploding and displacement of the oxygen in the air.
With knowledge, available equipment and precautions in practice, methane is not a threat, provided the laid
down procedures are complied with.
Question 1
How is methane formed and distributed through the geological system?
Answer 1
The decaying of timber and vegetable matter in the absence of oxygen produces methane. It is liberated
from coal seams and penetrates the workings through faults, fissures and dykes.
Question 2
What are the properties of methane?
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Answer 2
1. Lighter than air Relative Density of 0,55.
2. Colourless tasteless odourless.
3. Inflammable up to 5%.
4. Explodes between 5% and 15% - most sever 9,4%.
5. Above 15% displaces the oxygen.
6. A non-poisonous gas.
Question 3
What quantity of methane is allowed by the Mine Standards?
Answer 3
Nil % on a detection instrument e.g. Methanometer.
Question 4
How are humans affected by methane?
Answer 4
1. Severe burns or death should an explosion occur.
2. Suffocation if a large quantity displaces oxygen.
Question 5
Name the instruments used to test for the presence of methane.
Answer 5
1. Detector tube (Drger)
2. Flammable gas warning device
3. Flammable gas measuring instrument (on cap lamp)
4. Methanometer (approved)
Question 6
How is methane explosions prevented?
Answer 6
1. Adequate ventilation.
2. Regular testing.
Question 7
When is methane dangerous?

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Answer 7
When there is an accumulation.
Question 8
Can methane be detected by means of the human senses?
Answer 8
No. Unless it is bubbling through water or hissing from a hole or cracks.
Question 9
Where is methane expected to accumulate in a drive, raise or winze?
Answer 9
At the highest points of the excavation/s such as pockets in the hanging.
Question 10
What gas is expected when intersecting water or water and H 2S?
Answer 10
Expect to find methane. Methane is found by itself, with H2S and often with water.
Question 11
When and where is methane expected?
Answer 11
1. In stopped and unventilated ends.
2. During drilling or even after completion.
3. After a blast.
4. When drilling pilot holes.
5. If a place has been standing idle for more than 6 hours.
6. If water is encountered.
7. If a fault, dyke or fissure is intersected or exposed by a blast.
8. During and after a ventilation failure or weakening of the air flow.
9. After a strain burst or large rock fall.
10. Any hissing from cracks, holes or fissures.
11. Any bubbling through water.
12. If there is a smell of rotten eggs.
Question 12
What action is to be taken when working in an end and the ventilation STOPS?
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Answer 12
1. Stop all work.
2. Withdraw crew and try to re-start fan.
3. If unsuccessful withdraw the crew through ventilation.
4. Place guard.
5. Report to Shift Supervisor.
6. Send word to electrician.
Question 13
If indications are such that a thin layer of methane against the hanging my be present, what procedure is to
be followed to find out whether methane is present?
Answer 13
Take the instrument to the gas, not the gas to the instrument
Question 14
Where do workers await instruction while testing for methane is in progress?
Answer 14
At the waiting place which is in through ventilation except those directly necessary to assist with making safe
and testing.
Question 15
If a fan has stopped and when testing, methane is found at the fan or switches, describe the procedure to
test the fan.
Answer 15
1. Blow compressed air over the fan or switch with air hose.
2. Test for methane.
3. If no methane, switch on.
4. Allow fan to run for at least 30 minutes before initial examination is attempted.
Question 16
Under what ventilation conditions must test for the presence of methane be carried out?
Answer 16
Under normal ventilation conditions.
Question 17
To whom do you give special instructions in methane areas?
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Answer 17
To all normal employees and especially to the rock drill operators. They must immediately report any
bubbling or gas or loss of water in any hole.
Question 18
On returning to the face after a blast, an extensive slab of bad hanging is found that should be barred down.
Should a test for methane be carried out first, the hanging might come down, if the bad hanging is barred first
the pinch bar may cause sparks which may ignite any methane present and cause an explosion. How will
you deal with this situation?
Answer 18
First test for methane on the safe side of the slab. If no methane is present at this point, it is unlikely that
sparks will cause an explosion, bar down the slab, then continue with the rest.
Question 19
Detail the procedure to be followed when Methane is detected.
Answer 19
1. Stop all work.
2. Remove all persons to through ventilation.
3. Warn all persons working on return air side.
4. Open compressed air to the source of CH4.
5. Place guards until barricades are in place:
Erect barricades
Display notices
No entry
Methane
6. Notify the Shift Supervisor and Mine Overseer / Manager immediately.
7. The Shift Supervisor or Mine Overseer / Manager shall conduct a systematic examination of the area.
If the presence of methane is confirmed, he shall proceed to the shaft station and notify the Manager
and Ventilation Department.
Question 20
What gases can be detected with a GDI (Gas Detection Instrument)?
Answer 20
1. All flammable gases

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7.8 Pre-use Examination of the GDI (Gas Detection Instrument)
Question 1
Where does the miner obtain a GDI before going underground?
Answer 1
From the lamp room
Question 2
May the responsible appointed competent person take any GDI?
Answer 2
No, only the GDI allocated to him. Only if allocated GDI is out of order, he will be allocated a spare.
Question 3
What must be examined on the GDI before taking it underground?
Answer 3
Examine the:
1. Number (allocated number)
2. Green light ON (indicating it is switched on),
3. Casing not cracked.
4. Glass on the dial not cracked or damaged.
5. Red warning light not damaged.
6. Probe attached not blocked or damaged (if applicable to the instrument).
7. Plastic cap covering diffusion screen in order.
8. Diffusion screen not blocked or damaged.
9. All visible screws in position and secured.
10. Battery charged.
11. Pump operating if applicable to the instrument.
12. Needle on the dial indicate zero or a digital zero is displayed.
Question 4
What is examined on the carry case of the GDI?
Answer 4
1. Sling connectors not broken and fastened.
2. Covering lid not damaged.
3. Belt holder and clips no damaged.
4. Case not damaged, dirty or wet.
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Question 5
Explain how the calibration of the GDI is checked?
Answer 5
Perform a span gas check
Hold the instrument intake of the GDI in the jack until you can observe a steady reading on the dial.
Compare reading with the percentage GDI on the notice board. It must be the same (e.g. 1,4%)
If different, have GDI adjusted by the lamp attendant or ask for a spare GDI.
Question 6
What must the miner do after he has examined and tested his GDI?
Answer 6
Sign for the GDI in the book provided by the lamp room attendant.
Question 7
When is a span gas check done on a GDI?
Answer 7
Before the GDI is taken underground and at the end of the shift when the instrument is returned to the lamp
room.
Question 8
How often is a GDI examined?
Answer 8
Daily
Learner to write the Gasses Examination
8 Methane
8.1 Gas Detection Instrument
Question 1
Define a flammable gas-measuring instrument.

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Answer 1
A GDI is an instrument designed to determine the concentration of flammable gas present in the atmosphere
in parts per hundred by volume, and which complies with the South African Bureau of Standards
specifications.
Question 2
On what principle does a GDI work?
Answer 2
The air to be tested is drawn into the instrument through the wire gauze opening on top of the instrument.
The air mixture now enters a chamber which contains two (2) platinum resistors. One resistor is coated with
a catalyst which causes any flammable gas to oxidise. The second resistor is not coated and merely
compensates for the changes in temperature of air passing through the instrument.
Question 3
What checks must be done on the GDI before proceeding underground?
Answer 3
1. Check number on instrument whether allocated to you.
2. Check casing for dents.
3. Check for any loose screws.
4. Check if glass (digital displays) is okay.
5. Check if battery is charged.
6. Check if leather case and socket for installing charging stick when measuring high places is in order.
7. Test instrument at testing point to see if correctly calibrated.
8. If in order, sign for receiving it, and return it at the end of the shift.
Question 4
How do you test for methane in a development end with the GDI?
Answer 4
1. Depress and release the switch on the top right hand side of the instrument.
2. The display (ammeter) will register and settle on 0.0
3. The instrument is now on and will remain on for 50 60 seconds before automatically switching off.
4. Take readings while on on, and if high places are to be tested, an anemometer rod or charging stick is
required. Screw the rod in the steel fitting at the bottom of the leather case, or fit a charge stick, switch
on, wait for zero to stabilize, and then extend the rod to the hangingwall and observe reading.
5. If during a test, the display reads E.E., then more than 5% methane is present and extreme caution must
be exercised.
6. If, during a test, the display reads - -, then the Sensor is faulty, and needs to be replaced.
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7. If, during a test, the concentration exceeds 1,4% methane then the alarm light will flash.
8. If, during a test, the battery light is illuminated, and the display goes blank, the instrument cannot be
used as the battery is flat and needs re-charging.
Question 5
What is legally required at mines where GDI and Continuous Monitoring Devices are in use?
Answer 5
At every mine with underground workings the manager shall draw up and implement maintenance, training
and testing procedure so as to ensure that every GDI and Continuous Monitoring Device issued is in proper
working order and calibrated, and that the person to whom it is issued is trained in the correct use thereof.
A record shall be kept of each person to whom a GDI or Continuous Monitoring Device been issued, and
such instruments shall be returned at the end of each shift.
8.2 Testing for flammable gas in development ends
Question 1
Where must test for Methane be carried out in a force ventilation system?
Answer 1
2,0m in front of the intake side of the force column.
In the return air from the end, before it flows into through ventilation.
All high places
Faults
Fissures
Dykes
Diamond Drill Cubby
- During drilling
- If not sealed
At the face
- Sockets
- Remaining barrels of pilot holes
- At highest point
Question 2
Where must tests for Methane be carried out in an exhaust overlap ventilation system?

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Answer 2
2,0m in front of the booster column intake
In the overlap section at high places
2,0m in front of the exhaust column intake
High places
Faults
Fissures
Dykes
Diamond Drill Cubby
- During drilling
- If not sealed
At the face
- All sockets
- Remaining barrels of pilot holes
- At highest point.
Question 3
Where must tests for methane be carried out in a remote exhaust ventilation system?
Answer 3
Testing positions same as exhaust overlap system
Additional tests where low air velocities result.
Question 4 (Refer Fig 1B)

Indicate by means of a x the Methane testing positions in:
Exhaust overlap system
Force system
Remote exhaust system
Answer 4
(Refer Fig1B for testing positions).
8.3 Continuous monitoring device

Means an instrument designed to give a clearly audible or a clearly visible warning, or both, should it be
placed in an atmosphere containing more than one comma four parts per hundred by volume of flammable
gas, and which complies with the south African Bureau of Standards specifications.

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8.4 Gas detection instrument

Means an instrument designed to determine the concentration of flammable gas present in the atmosphere
in parts per hundred by volume, and which complies with the South African Bureau of Standards
specifications.
Without any reference:
Indicate by means of x the position where tests for the

presence of Methane are carried out in the 3 ventilation
systems, starting at the development Primary Barrier.

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8.5 Additional basics requirements regarding methane
Question 1
What is the purpose of a development primary Barrier?
Answer 1
To prevent unauthorised persons from taking any device that can cause or create a spark that could ignite
inflammable gas into the workings.
Question 2
Name the factors that determine the position of a development primary barrier?
Answer 2
In such a position that as many ends as possible can be controlled from it.
In fresh air.
Question 3
Describe the notices, equipment and construction layout of a development primary barrier.
Answer 3
3.1 A chain or 50mm pipe across the drive one meter above tracks.
3.2 Notices to be displayed on a second chain or 50mm pipe against the hanging:
Primary Barrier
Blasting No entry
Re-entry (Period as given by the Ventilation Department)
Waiting Place
3.3 Additional equipment:

Safe declaration book
Question 4
Who may authorize the use of a cutting torch past the Primary Barrier?
Answer 4
The Manager
Question 5
Under what conditions is the use of a cutting torch allowed past the primary barrier?

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Answer 5
Permission granted in writing by the Manager
Developer to have tested for flammable gas in the immediate area with a GDI.
No drilling shall take place whilst such apparatus is in use.
Whilst such apparatus is in use, regular tests for CH4 must be done.
Question 6
Who declares a development end a methane area?
Answer 6
The Manager after being notified by the Ventilation Department, or a Mining Official
Question 7
When is a development end declared a methane area?
Answer 7
If flammable gas, sufficient in quantity to constitute a hazard, is encountered or is in the opinion of the
Manager likely to occur.
Question 8
What additional precautions will apply to such declared Methane Areas?
Answer 8
A DANGER METHANE notice to be added to the development Primary Barrier barrier.
A guard shall be appointed and stationed at the Primary Barrier during all working shifts. His duties
will be as follows:-
- Take charge of the entry of employees at the primary barrier.
- Hand the book provided, to all persons, who will sign the book to state that they have no
articles in their possession, which have been prohibited.
- Search all workmen for articles, which have been prohibited.
- Retain all prohibited articles in a special receptacle provided for that purpose.
- The Miner in charge will ensure that the guard is fully conversant with his duties.
Question 9
What instrument is used to test for methane in a declared methane area and supplied by whom?
Answer 9
Flammable Gas Measuring Instrument supplied by the Manager

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Question 10
List the additional testing positions in a declared methane area.
Answer 10
At all fans before starting them.
All electrical switchgear.
Each completed pilot hole.
All high spots in the hanging.
Entrance to stopes fed by the return air from the development end.
Question 11
What procedure is to be followed when a diamond drill hole has been drilled to its full depth?
Answer 11
All diamond drill holes must be sealed
Question 12
When must Diamond Drillers test for methane?
Answer 12
At the beginning of the shift.
Each time the rods are withdrawn
When water is intersected
If flammable gas is suspected for any reason.
Question 13
What qualifications are required by a person to test for flammable gas?
Answer 13
A Methane certificate of proficiency for a person appointed by the Manager and must be renewed annually.
Question 14
How must all stopped, abandoned or temporarily discontinued development ends be treated?
Answer 14
To be barricaded off in such a manner as to prevent inadvertent entry of unauthorised persons, and if
considered necessary by the person appointed, in consultation with the responsible Manger of the section,
such development end shall be continuously ventilated to prevent any accumulation of flammable gas. A
recognised No Entry sign shall be provided at each barricade.

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Question 15
By what means are charges ignited in development ends?
Answer 15
1. Centralised electronic blasting system where cotton wool Stay-a-Lites have been withdrawn.
Question 16
On a sketch below indicate the testing positions on the face of a development end.
Answer 11
Start approximately 65cm from the footwall. Work your way up to the hanging, taking 30 seconds for each
observation point.
Exercise
HRD Officer to Facilitate Flammable gas testing in a development section from the last point of through
Ventilation until all Learners is fully conversant with testing in a development section
HRD Officer to Facilitate Temperatures and Velocity Tests in a development section until all Learners is fully
conversant with testing in a development section
9 Shafts and travelling ways
9.1 Background on sinking shafts
HRD OFFICER TO ARRANGE A VISIT THROUGH TONY PRETORIUS Cell No 082 902 6859 TO THE
SINKING TRAINING FACILITY ON COMPLETION OF THIS MODULE

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Safety Devices in a Sinking Vertical Shaft

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9.2 Introduction to vertical shafts sinking
Question 1
In what position, relative to the reef, are vertical shafts sunk?
Answer 1
This depends on the shape of the shaft
Any shaft with a long shape (elliptical and rectangular) will be sunk with the long axis in the direction
of dip
Square shafts will have one axis in the direction of dip and the other one in the direction of strike
Circular shafts have no limiting factors to the relative position of the shaft
Question 2
Why are circular shafts preferred to other shapes?
Answer 2
Circular shapes are relatively self supporting
Since they are not positioned relative to the reef, stations can be broken away perpendicular to the
strike (in a x/cut position) which is advisable for ground control
Question 3
What are the advantages of vertical shafts?
Answer 3
Rapid sinking
Fast hoisting, up to 915 metres/minute
Larger capacity for some excavated area than inclined shafts
Comparatively cheap winding and maintenance
Rapid opening up of mines with reef dips above 70 or flat
Shortest possible distance to reach final required depth
Comparatively little resistance to ventilating airflow
Comparatively low power consumption for hoisting
Question 4
What are the disadvantages of vertical shafts?
Answer 4
Comparatively long tunnels to open ore reserves below 70 dips (not applicable to flat reefs)
Equipment in shaft relatively expensive

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Sinking costs per linear metre comparatively high

Shaft accidents mostly very serious and often fatal
Question 5
How is the site at which a shaft is to be sunk chosen?
Answer 5
In order to select the best possible site, geophysicists and geologists survey the area. Extensive use is
made of remote sensing, image processing and geophysical surveys to arrive at one or more possible sites.
A detailed study (exploration boreholes) is then made in conjunction with detailed surface mapping of the
area. This all helps to determine the short and long term effects of the local geological structure on both the
headgear excavation and pre-sinking concrete lining of the shaft.
Question 6
What methods are used to search for, and treat ground water during the planning and sinking of vertical
shafts?
Answer 6
a) TREATMENT OF GROUND WATER
Up to twenty holes are drilled around the shaft area, each allowed for grouting a standpipe. When
set, the cement is re-drilled to a predetermined depth ( 25mm). Pressure tests are carried out and
grouted when necessary. If ground is badly fractured in a water bearing area, a second set of holes
may be required in order to grout a second curtain for stabilising the shaft area.
b) PRE-CEMENTATION
One hole may be sufficient and is drilled 40 metres from the centre of the shat. Pre-cementation
holes proved to be valuable in the detection and sealing of water. It also allowed for cavities to be
filled with cement, thereby stabilizing the ground
c) COVER DRILLING
This is done from the shaft bottom to depths of 50m below bottom. Spiral patterns are drilled varying
from between 10 and 20 from the vertical plane with a spin of 40 . This pattern ensures that any
fissure will be intersected
In some cases, where no diamond drilling was done from surface, cover holes may be drilled from
surface. They are then cemented to consolidate the area before permanent sinking operations
commence

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Question 7
Name the cycle of events from site selection to production, as practised in mining through a vertical shaft
access
Answer 7
Select site and investigate (see question 5)
Treat ground water (see question 6)
Excavate surface and sub-banks using opencast methods, eg heavy earth moving equipment from
or pre constructed access ramp
Pre-sink to required depth using cranes and buckets
Install sinking stage. (It is not essential to install the whole stage at this point. For 0m pre-sink 4
decks can be installed
Construct buildings. Civil Engineering contractors start work on hoist room, compressor room
change houses, offices, workshops, stores, etc
Erect Headgear simultaneously with building construction
Install hoists and plumb-bob winches (sinking + stage hoists)
Start full scale sinking, normally on treble shift
Profile and develop stations, pump chambers, etc.
Develop ore pass systems (commonly raise-bored)
Equip shaft if it was not finally equipped with sinking. Strip temporary equipment and install
permanent working from top down on equipping stage. The service and rock winder must be
installed. This is normally the same winder used for sinking, once equipping is complete the man
winders replaces the stage winder
Develop and commission services i.e. pump & sump level; rock and belt level, spillage arrangements
Develop ore reserves. Normally in initial stages, full scale multi-blast development is done
Start full scale production

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TYPICAL DRILLING PATTERN (DIP) WHEN USING A MECHANICAL

DRILLING RIG

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BLASTING SEQUENCE AND TIMING OF HOLES

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Question 8
What survey information is required to fix the position of a vertical sinking shaft?
Answer 8
Plumb bobs hang down the shaft excavation from where the shaft is fixed
Question 9
Give a breakdown of deck functions of a stage, assuming a 6 deck stage with fixed desks
Answer 9
Deck 1 (Top deck) supports the cross-head stop blocks and acts as a cover for a person giving
signals
Deck 2 accommodates suspension sheaves and carries three baskets of cables ie lighting, blasting
and welding cables
Deck 3 carries a basket of trailing cable and hand winches (usually 8) for lowering shuttering. Also
used for erecting shuttering
Deck 4 is used during erection of shuttering and during concreting operations
Deck 5 is for setting the curb ring, bunton fixing ring (BFR), and for doing scribing
Deck 6 (bottom deck) incorporates air and water distribution manifolds and supports the lashing unit
(grab)
Question 10
How is the stage suspended and moved in the shaft?
Answer 10
The stage is operated by a double drum stage hoist, the rope from each drum being led down the shaft
under a pair of sheave wheels situated below the top deck of the stage, and back up the shaft to an anchor
point in the headgear. By this method the weight of the stage is carried on four ropes which can also act as
guides for kibble cross heads. Similarly, by additional doubling up of the ropes, the stage can be suspended
from six or eight ropes

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Section through the Stage

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Diagram showing the path of one of the two

Ropes between Hoist and Stage
Question 11
What is the purpose of a cross head as used in sinking shafts?
Answer 11
Cross heads are used as a guiding mechanism to guide the kibble between the rope-guides

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Figure showing Crosshead and Alarm device

Question 12
How are vertical shafts supported?
Answer 12
Concrete lining
Rock bolting as temporary support where required
Question 13
What rate of lashing can be expected with a cactus grab lashing gear?

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Answer 13
Grabs with a capacity of 350 tons/hour have been used. During the latter phase of cleaning this will drop
dramatically to 150 tons/hour
Four brackets are attached to the grab deck from which the stage is suspended by means of slings from
either eyebolts or goose-neck-hang-bolt drilled into the shaft lining above. Four pneumatic jacks are situated
on the lower deck which grips the side-wall, all of which together with four retractable rubber wheels running
against the lining at the top deck has proved sufficient to steady the stage during grab loading. In some
cases four additional jacks may be provided on the top or second deck. Where stages are suspended from
eight falls of rope, It is normally not necessary to suspend the stage from stabilising slings, and it is simply
braced to the sides by means of jacks.
Question 14
Describe the preparation of the bottom of the shaft before drilling may commence
Answer 14
After the final cleanup with shovels, the bottom is blown over using a fishtail blowpipe, designed and
approved for this purpose. The fines from blowing over are lashed into the kibble and sent out. The kibble
carrying the drilling equipment is sent down in tandem
The sinker makes a sketch of the bottom of the shaft, showing the position of all sockets and misfires, and
the position of the new holes to be drilled in relation to these.
All misfires and sockets are treated according to the requirements of the Legal requirements

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Question 15
How is a vertical, circular shaft marked off if it is to be drilled manually?
Answer 15
Four plumb bobs are hung around the perimeter of the shaft
The centre point is determined from the point where lines strung between these plumb wires will
cross
When boom rigs are used, the position of the rig legs are determined from 2 circles drawn around
the centre point (eg 1,2m and 1,4m radius)
Croppers are marked around the perimeter of the shaft by means of plumb wires hung down from
the shaft 500mm apart
Easers are marked in consecutive rings 1,2m inside each other with individual holes spaced
750mm apart. The outside ring of easers is marked 300mm inside the croppers
The inner two easer rings are spaced 500mm apart and 300mm from the cut which is 300mm
from the stab hole
Holes for the cut are 300mm apart and 500mm apart in the inside ring of easers
Vertical lines are marked on the circles around the perimeter of the shaft to assist with the lining up
of croppers

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Question 16
How is the round drilled?
Answer 16
Croppers are drilled on mark and line, 6 outwards
Cut holes as well as the first line of easers are drilled 6 to 10 inwards, depending on the strength of
the rock
The rest of the holes are all drilled on mark, vertically downwards
The stab hole is drilled vertically down in the centre of the shaft, and is 100mm 150mm in diameter
The sinker is present at all times, and points out the position and direction of each hole to the driller

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Question 17
How tonnage broken is calculated in a vertical sinking shaft?
Answer 17
The formula for calculating tons broken is:
Tons = volume x density of rock

And: Volume = area x advance
Density = mass per unit volume expressed in t/m
Average advance = a) 3,4 with drill rig
b) 2,5m with hand held machines
EXAMPLE
a) Assume advance a constant (3,0m)
b) Density dependant on rock type (2,75 t/m)
1. CIRCULAR
A circular shaft has a diameter of 10m. What is its area?
Area = r (r = diameter)
= d,14 x 5
= 78,5 m
FOR VOLUME
Volume = area x advance (assume 3,0m)
= 78,5 x 3
= 235,5 m
TONS
Tons = Volume x density of rock (assume 3,17)
= 235,5 x 3,17
= 746,5 tons
Exercise
HRD Officer to give few examples with Calculators for the Learners to master calculations Areas of cylinders,
squares, rectangles and triangles, Volumes in Cylinders and Cubes, Tons from ore passes and cubes
structures.
NOTE**** Learners to master all calculations

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9.3 Shafts and Travelling Ways Legal Requirements
Question 1
When may a person enter or leave a shaft conveyance?
Answer 1
Question 2
Who may ride on the top of a cage, skip or kibble?
Answer 2
Question 3
What is the blasting signal in a sinking shaft?
Answer 3
Question 4
How does the driver signal (reply)?
Answer 4
Question 5
When are you allowed to enter the conveyance at the bottom in a sinking shaft?
Answer 5
Question 6
How must buckets or skips be filled in shafts and winzes?

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Answer 6
Question 7
When lowering the kibble, does the driver lower direct from surface to the bottom?
Answer 7
Question 8
How will you secure projecting material being raised or lowered by kibble?
Answer 8
Question 9
What system of signalling arrangements are required in (1) shafts, (2) sinking shafts?
Answer 9
i.
ii.
Question 10
If you want to do any work or examination in a shaft, headgear or winding compartment, what procedure do
you adopt?
Answer 10
Question 11
When is it not necessary to stop winding operations when effecting repairs or conducting an examination in a
shaft or headgear?

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Answer 11
Question 12
How long must the driver wait before moving the kibble in a vertical sinking shaft after you have lighted up
and signalled one?
Answer 12
Question 13
What will you do if the driver does not pull away?
Answer 13
Question 14
How long will you wait before getting out of the kibble?
Answer 14
Question 15
The driver failed to move the kibble and you try to reach a place of safety (stage) by means of the chain
ladder, but you find the chain ladder damaged and out of reach, what would you do?
Answer 15
Question 16
How do you steady a kibble in a sinking vertical shaft?

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Answer 16
i.
ii.
iii.
iv.
Question 17
Where and for how long must a driver stop the kibble going down a vertical sinking shaft if men are there?
Answer 17
Question 18
Whey must the kibble stop 5 metres from the bottom of a sinking shaft?
Answer 18
Question 19
Name one of the most dangerous common practices in a sinking vertical shaft?
Answer 19
Question 20
What is the accident to shaft signal?
Answer 20
Question 21
Where must ladder ways be installed?

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Answer 21
Question 22
At what intervals must breaks and resting places be erected?
Answer 22
i.
ii.
Question 23
Are you allowed to use old wire rope as handrails?
Answer 23
Wire rope shall not be allowed for climbing purposes if it is:
i.
ii.
iii.
Question 24
How do you construct ladder ways in the underground workings of a mine?
Answer 24
Shall be:
i.
ii.
iii.
iv.
v.
Question 25
How far must the chain ladder be from the bottom?
Answer 25

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Question 26
How far is the protection platform (stage) from the bottom in:
a vertical shaft?
i.
incline shaft?
ii.
Answer 26
iii.
iv.
Question 27
What protection do you have in a sinking shaft from falling material?
Answer 27
Question 28
Does the protection platform (stage) cover the whole shaft?
Answer 28
Question 29
Under what conditions may tools and material be transported on the ladder way of an incline shaft or winze?
Answer 29
i.
ii.
Question 30
How far away from any vertical or steeply inclined excavation may timber, rocks, tools or other loose articles
be stored?
Answer 30

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Question 31
One of your workmen is without a hard hat in a sinking shaft, what will you do?
Answer 31
Question 32
What is the difference between a shaft and a winze? (See definitions)
Answer 32
i.
ii.
Question 33
Where is the presence of a certificated Miner or miner compulsory at all times when workmen are there?
Answer 33
Question 34
What extra precaution must be taken in a sinking shaft from surface?
Answer 34
Question 35
Where may holes be drilled in a vertical sinking shaft?
Answer 35
Question 36
How do you treat a misfire in a sinking shaft?

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Answer 36
Question 37
Name the safety devices in a sinking vertical shaft
Answer 37
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.
Question 38
How must projecting materials be secured when conveyed by a kibble?
Answer 38
1. Fastened to the winding rope of the conveyance, or
2. Fastened to the bow of the conveyance
Question 39
What signalling arrangements are required in:
1. Sinking shafts
2. Shafts
Answer 39
1. Locked bell and call bell
2. Locked bell and pull bell or (E-Cam)

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Question 40
What procedure must be followed when any work or examination in a shaft is to be done?
Answer 40
1. Warn the driver of the winding engine operating the conveyance in such compartment that such
examination or work is about to be undertaken
2. In the presence of the driver on duty at that time, enter such warning in the drivers logbook which
must be countersigned by the driver or by any driver relieving him
3. The entry shall be cancelled by the person in immediate charge of such repairs, examination or work
on completion thereof
Question 41
What procedure must be followed when a person in charge of examination or any work in a shaft cannot for
any reason enter the warning in the drivers logbook?
Answer 41
The entry shall be made by the driver on duty and he shall ensure that every other winding engine driver
operating conveyances in the shaft or headgear shall be warned in a similar manner
Question 42
Who must cancel the warning on completion of work or examination in the shaft in the abovementioned
condition?
Answer 42
By the person in immediate charge of such repairs, examination or work
Question 43
When is it not necessary to stop winding operations in a shaft while conducting an examination or doing
other work?
Answer 43
1. Where such persons are adequately protected from the conveyance, falling stoned and falling material
2. Where the winding operations are necessary for such person to effect the repairs, conduct the
examination or to do the other work
Question 44
When may a person enter or leave a shaft conveyance?
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Answer 44
Only when the appropriate signals between driver and Onsetter have been exchanged
Question 45
Who may ride on top of a cage, skip or kibble?
Answer 45
Only persons engaged in examining or repairing the shaft
Question 46
What is the blasting signal in a sinking shaft?
Answer 46
Five (5) knocks or rings
Question 47
How does the driver reply to a blasting signal?
Answer 47
By raising the lowering the conveyance approximately two (2) metres)
Question 48
What distance is the stage from the shaft bottom in:
1. Vertical shaft?
2. Inclined shaft?
Answer 48
1. Not more than 25 metres from the shaft bottom
2. Not more than 30 metres from the shaft bottom
Question 49
Does the protection platform (stage) cover the whole shaft?
Answer 49
Yes, except for sufficient (passage) space therein, for the kibble to pass through
Question 50
Why does the stage cover the whole shaft?

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Answer 50
To protect the persons working in the shaft bottom
Question 51
When may a conveyance be entered in the bottom of a sinking shaft?
Answer 51
1. Only when the conveyance has been raised or lowered, (as for blasting signal) or
2. When some other distinct signal has been received from the winding engine driver
Question 52
Up to what level must buckets or skips be filled in shafts and winzes
Answer 52
Not to be filled above the level of the brim
Question 53
Name one of the most dangerous practices in a sinking shaft
Answer 53
Overfilling of the kibble
Question 54
Where, and for how long must a driver stop the kibble going down a vertical sinking shaft?
Answer 54
The driver must stop at least five metres (5m) above the shaft bottom and shall only lower the kibble when
he receives the signal to do so, by the sinker
Question 55
What must be done to a kibble that swings around in the shaft bottom?
Answer 56
No bucket or other means of conveyance that can sway around shall be allowed to leave the top or bottom of
the shaft unless the workmen have steadied it.
Question 57
How do you steady a kibble in a sinking vertical shaft?

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Answer 57
1. Driver to pick up kibble on signal
2. Raise slightly and then to be stopped
3. Steady with steel hooks
4. Persons to stand on the safe side
Question 58
What is the accident to shaft signal?
Answer 58
One long ring on the call bell until all conveyances stop
Question 59
Where is the presence of a certificated Sinker compulsory at all times when workmen are there?
Answer 59
In any shaft being sunk or in any main development in any fiery mine
Question 60
What extra precautions must be taken in a sinking shaft from surface?
Answer 60
Precautions against lightning or during a thunderstorm. No person shall remain within an area where he may
be injured by the accidental detonation of explosives
Question 61
Where may holes be drilled in a vertical sinking shaft?
Answer 61
Only where the sinker has clearly marked or indicated the position and direction of the hole
Question 62
Where may holes be drilled if marking is impractical?
Answer 62
Only where the sinker has pointed out the exact position and direction of the hole
Question 63
Are people allowed to work underground without a hard hat?

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Answer 63
No person shall enter or remain in the underground workings of a mine unless he is wearing an approved
hard hat
Question 64
Where must ladder ways be installed?
Answer 64
Where the inclination from the horizontal is more than 20 (degrees)
Question 65
What does the Legal Requirements state regarding the use of wire ropes as handrails in travelling ways?
Answer 65
Wire ropes shall not be:
1. Kinked
2. Knotted
3. Contain broken or projecting material eg. (strands)
Question 66
How must ladder ways be constructed in the underground workings of a mine?
Answer 66
Ladder ways shall be:
1. of strong construction
2. securely fastened to the timbering or wall of the excavation
3. maintained in good repair
4. no ladder shall be constructed steeper than 80 (degrees)
5. no ladder shall be fixed in an overhanging position
6. ladders to cover manholes of resting places
Question 67
At what intervals must breaks and resting places be erected?
Answer 67
1. If the inclination is more than 15 (degrees) and less than 70 (degrees) ladders shall not be
continuous for more than 16 metres
2. If more than 70 (degrees) ladders shall not be continuous for more than 10 metres and ladders to
cover manholes

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Question 68
How far away from any vertical or steeply inclined excavation may timber or tools be stored?
Answer 68
At such a distance that nothing can accidentally fall down such excavations
Question 69
Where is it required to have effective devices to arrest vehicles that may run out of control?
Answer 69
On an inclined plane with a gradient exceeding 1:50
Question 70
Who must appoint the persons to operate the safety devices on an inclined plane?
Answer 70
The Shift Supervisor in charge, or the Manager. In an emergency the Sinker may make a temporary
appointment
Question 71
How far must ladder ways be from the bottom of the shaft during steeply inclined shaft and winze sinking
operations?
Answer 71
At such a distance from the bottom of the winze as is necessary to secure the ladder ways from damage
during blasting
Question 72
What is the maximum distance that the signalling device may be from the bottom of the winze during
sinking?
Answer 72
At a point not more than 40 metres from the bottom of the shaft
Question 73
What arrangements must be made if the signalling device is more than 15 metres from the bottom of a winze
during sinking operations?
Answer 73
Some efficient signalling arrangement from the bottom to the loading point
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Question 74
What must be done to sockets and misfires in a sinking shaft?
Answer 74
The sinker shall indicate on a sketch the position of every misfire and socket that has been pumped out
Question 75
What must be done to sketches indicating all misfires and sockets?
Answer 75
Every such sketch must be kept at the mine for at least seven (7) days
Question 76
Name the safety devices in a winze being used for transport purposes?
Answer 76
1. Stop block
2. Safety slings
3. Drag bar
4. Drop rails
5. Barricade at bottom of shaft
Question 77
Name the safety devices in a sinking shaft?
Answer 77
1. Banksman
2. Hardhat
3. Fences and gates
4. Trap doors
5. Guide ropes
6. Cross head
7. Protection platform (stage)
8. Slow speed through stage
9. Bright lights
10. Driver to stop 5 metres from bottom
11. Locked bell and pull bell system or (E-cam)
12. Chain ladder
13. Sinker always present in shaft bottom during sinking
14. Kibble not to be overfilled
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15. Kibble to be steadied before raising
CLEARANCES - GENERAL
CONTENTS
1. TRAVELLING WAY CLEARANCES

2. FOULING MARKS
3. T-SPRAGS
9.3.1 Travelling way clearances
Question 1
What is the side clearance required by the Legal requirements between vehicles and obstructions?
Answer 1
A clearance of 0,5 metre is required between the side of every moving vehicle and the sidewall, side support
or any construction
Question 2
How is the side clearance distance measured between vehicles and obstructions?
Answer 2
The distance is measured from the side of the vehicle to the sidewall eg. Dolley wheel of hopper
Question 3
By what means are restricted clearances indicated?
Answer 3
Restricted clearances are indicated by means of black and yellow zebra stripes
Question 4
What is the maximum continuous distance of restricted clearance allowed?
Answer 4
No more than 15 metres (Consult Mine Standard)
Question 5
What is to be provided for pedestrians (to be clear of rolling stock) where side clearance is restricted for
more than 15 metres?
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Answer 5
Refuge places are provided and clearly indicated by means of notices and signs
Question 6
What is the required clearance between two vehicles on a double line of tracks when using the insides of the
double lance of tracks as a travelling way
Answer 6
A clearance of a least 0,5 metres between the sides of any two vehicles passing each other
Question 7
What is the height required by the Legal requirements in main travelling roads of a mine?
Answer 7
A height of at least 1.8 metre
9.3.2 Fouling Marks
Question 1
Describe a fouling mark?
Answer 1
A fouling mark is a paint line across the hanging of the excavation and down the sidewalls
Question 2
What is the purpose of fouling marks?
Answer 2
To indicate stopping positions for rolling stock at intersections
Question 3
Where are fouling marks painted in?
Answer 3
Painted in 9 metres from the frog of the switch at all intersections
9.3.3 T-Sprags
Question 1
What is the purpose of T-Sprags?
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Answer 1
T-Sprags are installed to stop or derail runaway rolling stock
Question 2
Name three places where T-Sprags are installed
Answer 2
1. At Fouling marks
2. 3 metres on either side of ventilation doors
3. 3 metres from the frog of switch on either side of loop rails
Question 3
Explain how T-Sprags are installed to function effectively?
Answer 3
T-Sprags are connected by means of a one metre length of chain bolted onto the flange of the rail and
placed one metre from the bolted position to the updip side. When a runaway of rolling stock occurs the T-
Sprag skids for 2 metres before the chain takes up tension
Question 4
What colours are T-Sprags painted?
Answer 4
T-Sprags are painted according to mine standard colours eg. Black and yellow, red and white
Exercise
HRD Officer to take learners for a visit as pre-arranged at the Sinking Training Centre.
10 Supervision points and lay-outs
STATION TO WORKING PLACE

1. Safety (Refuge Chamber)
2. Station/Shaft
3. Services
4. Sleepers
5. Switches & Rail joints
6. Spillage
7. Sludge
8. Storage
9. Support
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10. Rolling stock

11. Sanitation
12. Sub-station & Workshops
13. Labour
14. Housekeeping
DEVELOPMENT SUPERVISION POINTS

1. Direction
2. Grade
3. Dimension
4. Support
5. Ventilation
6. Breaking.
7. Material & Equipment
8. Labour
Learners to ensure they know these supervision points by heart.
Exercise:
HRD Officer to demonstrate / facilitate the Supervision points Station to working place
Learners to practise daily
10.1 Safety
Always apply the four steps to Safety and Zero Harm to all activities. Development has its own
inherent dangers, as a result of most of the work being carried out in areas beyond through ventilation,
as well as working in steeply inclined areas such as box holes.
10.2 Direction
Direction is determined by:
a) Survey lines are established by the survey department for all development ends. To determine
direction, a piece of string is hung from two pegs one peg which is the base peg, whose exact
position and elevation has been calculated and plotted on a plan, plus a line peg (either a Back
Line Peg (BLP) or a Front Line Peg (FLP)) The direction is taken and marked with paint on the
hanging wall and face.

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a) To break away from a main development end, a direction can be given by means of a clino-rule, until
such new end has advanced far enough to install a survey peg to give the direction of the new end. The
direction is painted on hanging wall and on the face.
NOTE: Carry off sets from survey lines as instructed by the survey note.
b) In In Stope development, direction for strike gullies may also be given by means of a klino-rule,
measured from the direction of the original raise winze connection.

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Dip Plug
Peg
A.S.G.
Peg
Plug
5 Above Strike
EXAMPLE OF A SURVEY NOTE FOR THE ESTABLISHMENT OF LINES IN A

CROSSCUT
35/16 Crosscut
PEGS D3467 and a F.L.P. at 3,4m have been established in the above crosscut.
Carry lines as given. At peg D3467 + 21,7m turn at 25 LHS and carry lines centre x 1,5m LHS by 1,5m
RHS.
At TP + 4,0m call for new survey lines.

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DIMENSION
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A typical Main Development End.
The dimensions of development ends vary from mine to mine, however the method of marking is standard.
a.) Waste Development (usually done horizontally to expose the ore body).
1. From direction the line, measure required dimensions left and right of direction the line. The
direction line may be carried in the centre or, left or right side of the development end, according
to the survey note.
2. From the grade line (horizontal) measure required dimensions of end above and below the
grade line.
b.) Development on Reef

The dip of the reef determines the inclination of the excavation. Raises are up-dip and winzes down-
dip.
GRADE
Grade lines are used to determine the position of development ends in relation to the horizontal. The
purpose of grade in flat development is so that water can flow back to the shaft. The purpose of grade in box
holes is that ore can gravitate into hoppers below the reef plane.
NOTE: The developer must demonstrate to the trainee the method of taking grades in different ends.

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N.B.: The hanging wall of reef development must be the same as the hanging wall of the
Development when stoping starts, otherwise brows will be created.
(Top Reef Contact)

(Bottom Reef Contact)
Steeply Inclined Development

Height and width are obtained by measuring from a point on the face obtained by sighting through washers
on grade chains. To breakaway such ends, make use of a Klino-rule.

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10.3 Lay-Outs
TYPICAL SCATTERED LAYOUT

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TYPICAL PLAN OF LONGWALL DEVELOPMENT LAYOUT WITH

DEVELOPMENT FACE POSITIONS:
Survey Notes will be handled in much more detail in advance development basics. For the purpose
of Development Basics learners need to know direction and grade in order for construction
purposes, especially rails to be graded and on line.
Exercise
HRD Officer to take Learners to a development end and install all lines demonstrate to the Learners the
rails in relation to the grade and direction lines

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11 Development Ventilation and Ventilation Layouts
11.1 Ventilation
Question 1
Why is a mine ventilated?
Answer 1
1. To dilute and remove harmful dust, gases and heat.
2. To remove heat
3. To keep working conditions safe and healthy.
Question 2
How is fresh air supplied to the works and shafts?
Sketch and describe.
Answer 2
The quantity of air supplied at the working face of every development end, shall not be less than 150 cubic
decimetres per second for each square meter of the average cross sectional area of the excavation,
(Consult mine specific standard) as it may differ from mine to mine.
There are three basic methods of ventilating development ends:-

a) Force system
b) Exhaust system
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c) Force / Exhaust system
a. Force System:
The size of ventilation pipes depend on the size of the excavation to be ventilated and is determined
by the ventilation department.
b. Exhaust System:
The size of ventilation pipes depend on the size of the end, re-entry period (cleaning) of nitrous
fumes.
c. Force Exhaust System:

This method is most commonly used for high speed development under multi blast conditions. The
diameter of the exhaust column is larger than that of the force column.

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FAN SUSPENSION (Refer to Mine Standard)
Ventilation pipes must be suspended from eye bolts. Every third suspension must be from 10mm chains
with C inks, the other two with galvanised wire.

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RE CIRCULATING AIR
No fan shall be operated, or cause or permitted to be operated, if any re-circulation of ventilating air takes
place.
OVERLAP
To prevent ventilation from re-circulating in a force/exhaust system, the intake of the force column and the
intake of the exhaust column are spaced a distance apart, - this distance may vary from mine to mine
according to the laid down mine standard, but is usually min 9m and max 18m.
No one shall enter a blasted end until at least 30 minutes after charges have been set off, and then only if
the air is free from smoke, gas, fumes and dust.

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METHOD 1 OF VENTILATING A TWIN HAULAGE DEVELOPMENT
Not less than 10m

overlap
11kw x760mm
Fan
RAW
22kw x760mm 11kw x570mm

Fan Fan
Not more than 10m
overlap
Regulat
or
Not more than 10m
overlap
INTAKE AIR WAY

11kw x570mm
Fan
Not less than 10m
overlap
METHOD 2 OF VENTILATING A TWIN HAULAGE DEVELOPMENT
Not less than 10m

overlap
11kw x760mm
Fan
RAW
22kw x760mm 11kw x570mm

Fan Fan
Not more than 10m
overlap
Regulat
or
Not more than 10m
overlap
INTAKE AIR WAY

11kw x570mm
Fan
Not less than 10m
overlap

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11.2 Ventilation and Dust Allaying
Note to Learners ***
Study your study guides as Ventilation, Dust, gasses will be handled in detail during Stoping Basics,
which after you will write exams with a required pass rate start studying now!!
Question 1
Are persons allowed to work in harmful air?
Answer 1
Question 2
When only, may persons work in harmful air?
Answer 2
Question 3
When is air harmful?
Answer 3
Question 4
Are persons allowed to work in noxious fumes?
Answer 4
Question 5
When only, may persons work in noxious fumes?

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Answer 5
Question 6
For what purpose is a mine ventilated?
Answer 6
Question 7
What is the minimum quantity of fresh air required in any development end?
Answer 7
Question 8
Explain the term Time Blasted?
Answer 8
Question 9
Explain the term Multi-Blasting?
Answer 9
Question 10
When can a wetting apparatus be installed?
Answer 10

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Question 11
How long must the apparatus be in operation?
Answer 11
Question 12
Why is there a minimum and maximum distances for the overlap?
Answer 12
Question 13
How must dead ends be ventilated?
Answer 13
Question 14
What is the minimum pressure of water allowed underground, and how do you determine the minimum
pressure?
Answer 14
Question 15
How do you know if your workers have been acclimatised?
Answer 15
Question 16
How must ventilation doors be operated?
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Answer 16
Question 17
What is your responsibility when passing through a ventilation door?
Answer 17
Question 18
Are you allowed to adjust the regulator in a ventilation column?
Answer 18
Question 19
How far from the face must water pipes be?
Answer 19
Question 20
What pressure of water must be maintained at the working place?
Answer 20
Question 21
Are there legal requirements that prohibit the wastage of water?
Answer 21
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Question 22
What does the legal requirements on water wastage state?
Answer 22
Question 23
How is dust allayed at tips and transfer boxes?
Answer 23
Question 24
Are you allowed to wash hoppers on the tip?
Answer 24
Question 25
For what purposes are you not allowed using compressed air underground?
Answer 25
Question 26
By what means may you clean the footwall of any Development or development end or skip or truck
underground?
Answer 26
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Question 27
When only, may compressed air be used to blow out any hole or socket?
Answer 27
Question 28
Name the legal requirements applicable to the rock drills you use underground?
Answer 28
Question 29
What must be done with every mobile equipment that you are using during a shift?
Answer 29
Question 30
Who may operate a loco in the underground workings of a mine?
Answer 30
Question 31
When may persons re-enter after re-firing a misfire in a development end?
Answer 31
Question 32
What action do you take on completion of charging up and ready to connect up when:
1. The ventilation flow changes?
2. The fans in the development ends stop?
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Answer 32
Question 33
On entering a working place you smell smoke and fumes but cannot see anything will you remain?
Answer 33
Question 34
Workmen in a working place complain that they feel dizzy, what would you do?
Answer 34
Question 35
What precautions must be taken if flammable gas has been found during the preceding 24 hours and
charges must be fired?
Answer 35
Question 36
Detail the procedure when detecting gas underground
Answer 36
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Question 37
What are you required to do in any case of gassing?
Answer 37
Question 38
When may you re-enter after re-firing a misfire in a development end?
Answer 38
Question 39
What procedure would you adopt if a scraper is in operation in a raise ventilated by means of a force system
and methane is detected, both in the raise and in the winch chamber?
Answer 39
Question 40
What tests are required before charging up in a development end?
Answer 40
Question 41
When must you water down?
Answer 41
Question 42
How often do you water down during the shift?
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Answer 42
Question 43
What are the main preventatives of dust underground?
Answer 43
Question 44
Where may a water blast be used? .
Answer 44
Question 45
What action must be taken prior to any work being performed underground?
Answer 45
Question 46
For what purposes are you not allowed to use compressed air underground?
Answer 46
For the cleaning of:
i.
ii.
Question 47
By what means is a sinking shaft blown over?
Answer 47
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Question 48
You have almost completed your round there is only one side hole left and the air goes off, will you blast
the round?
Answer 48
Question 49
Where must atomizers or sprays be used?
Answer 49
Question 50
What action do you take on completion of charging up and ready to light up when (a) the ventilation flow
changes direction or (b) fans in development end stops?
Answer 50
Question 51
You complete the round too late for charging, the next day charge early and at blasting time find out the
Ventilation stops. What would you do?
Answer 51
Question 52
May 10mm pipes be used to supply water to working places?
Answer 52
Question 53
How far from the face must water pipes be?
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Answer 53
Question 54
What must the length of a water hose be?
Answer 54
Question 55
Do legal requirements exist pertaining to leaking water taps or taps not closed on completion of watering
down?
Answer 55
Question 56
What will you do if the axial hole of your drill steel is blocked?
Answer 56
Question 57
If your machine is fogging badly, what do you do?
Answer 57
Question 58
What is the minimum amount of ventilation required in a sinking shaft or any development end?
Answer 58
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Question 59
How must dead ends be ventilated?
Answer 59
11.3 Fire Prevention
Question 1
What is your duty after flame-cutting equipment were used underground?
Answer 1
Question 2
What is your first consideration when preparing to use a cutting torch underground?
Answer 2
Question 3
Name the possible causes of underground fires.
Answer 3
i.
ii.
iii.
iv.
v.
vi.
vii.
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Question 4
Why is it necessary to fire proof areas at Electrical equipment?
Answer 4
Question 5
What arrangements must be made about clearing oily cotton waste used for cleaning in the loco bay?
Answer 5
Question 6
Are you allowed to store inflammable material near a transformer?
Answer 6
Question 7
Are you allowed to smoke in a cage?
Answer 7
Exercise
HRD Officer to hand out different development Layouts and Learners to ventilate these ends with the
ventilation methods.
Exercise
HRD Officer to hand out FLIP chart papers with the sketch below and learners to ventilate these ends with
the ventilation methods
Draw in all Ventilation columns and Fans in the following sketch
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To
RAW
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12 Development Barring & Support
12.1 Barring
Bar down loose rocks

Water down the area to expose cracks and loose rocks
Identify the loose rock or friable area by visual examination and sounding the rock with a pinch bar
while always remaining within a safely supported area
Once a loose rock or friable area has been identified:

Warn and remove persons from the immediate area.
Take precautions to prevent inadvertent entry of persons.
Safeguard machinery and equipment that may be damaged by falling rocks during the barring
process.
Check existing support

Support must be solid and stable
Support must be according to mine requirements
Follow the golden rules of barring

Always have a buddy close by in a safe place to assist
Wash the area to expose cracks/geological features
Use correct length of pinch bar
Use only pinch bars fitted with gaskets and sharp at both ends
Is the area where you are standing safe?
Remove ALL personnel in the near vicinity behind and below the area to be barred
Is the escape way clear from obstruction
Are you standing on solid ground
Bar down from the up-dip side
Inspect behind for hidden joints
Pay special attention to areas within 5m of the face
Continuous barring to be done whilst drilling, when drilling is completed and before charging up
If the rock cannot come down with one pinch bar, use two pinch
Ensure that the escape route is safe

Bar from an up-dip position.
Always be in a position that the barred rock will fall away from you.
You can loose your balance and fall.
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Get a firm footing

Make sure you have a safe footing, never stand on piles of material or broken rock that feel or look
as though it might dislodge when you step on it.
Warn persons in the vicinity and make sure that they heard and understood your warning and ensure
that no other persons enter the area being examined and barred.
Support or barricade the hanging if unable to bar down

Rock which looks/sounds loose, or suspect in anyway and it was not possible to bar down, must be
barricaded off until such time as the support can be installed or it can be blasted down
Never leave such a rock unsupported or not barricaded off. Do not leave the area before you are
satisfied that it is supported or barricaded
On completion of the barring process and when you are sure that the area is safe and solid, follow
the specified requirements in declaring the area safe for persons to travel through or to work in.
Pinch bar
Physically examine the pinch bar to ensure that:
It is sharp at both ends and not chipped
It has a protection guard (gasket) fitted
Grip the pinch bar, firmly with both hands behind the protection guard
When sounding or barring rock:

Work from a safe, supported position
Stand on the up-dip side from the position of sounding or barring
Push the pinch bar in an upwards and forward direction
Insert the point of the pinch bar, properly into the crack before levering, hold the rear end alongside
your body
Never hesitate to release the pinch bar if it is struck by a rock
When using a pinch bar for moving or lifting purposes, always ensure that you use your legs and not
your back to lift or move the load
Water hose
Physically examine the water hose for the following:
It is of the correct size and length
It is not damaged or leaking
Working in confined areas

Working in confined areas means
Confined spaces are areas where the normal body posture cannot be maintained.
Work must be performed while bending or sitting down.
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The physical utilisation of tools and equipment are also restricted

Always wear personal protective equipment
Never throw material or equipment into confined spaces
Take care not to bump your head or body against the hanging wall
Working in steeply inclined excavations

Working in steeply inclined areas:
Working in steeply inclined areas means working in an area that has an inclination of 35 or more to
the horizontal.
Persons could loose their foothold or grip when working in steeply inclined areas and objects could
slide or fall down a steeply inclined area
Persons could slip and fall or be struck by sliding or falling objects.
Wear safety belts/harnesses where required
Make use of climbing chains, hand rails, additional support stulls, barricades or platforms to ensure
safe travelling through the inclined areas
Handling heavy material and equipment

Tools, material and equipment, if not handled correctly, could result in undesirable contact with
persons or other objects.
Make use of the correct tools and equipment
Never misuse the tools, material and equipment
Working in the proximity of moving machinery

Examine the area to be barred for moving machinery and equipment in the form of scrapers, scraper
ropes or rolling stock
Safeguard the area against moving machinery and equipment before commencing with the barring
process.
13 - STEPS TO SAFE BARRING (SHE 0024)
1. Always have a buddy close by in a safe place to assist

2. Wash the area to expose cracks/geological features
3. Use correct length of pinch bar
4. Use only pinch bars fitted with gaskets and sharp at both ends
5. Is the area where you are standing safe?
6. Remove ALL personnel in the near vicinity behind and below the area to be barred
7. Is the escape way clear from obstruction
8. Are you standing on solid ground
9. Bar down from the up-dip side
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10. Inspect behind for hidden joints

11. Pay special attention to areas within 5m of the face
12. Continuous barring to be done whilst drilling, when drilling is completed and before charging
up
13. If the rock cannot come down with one pinch bar, use two pinch
IDENTIFIED HAZARDS PERFORMING BARRING RELATED TASKS
HAZARD POSSIBLE RESULT CONTROL

Wear PPE when barring. Use a
1. Check that the pinch bar is the
gasket to prevent hand injury by
correct length, sharp at both ends, Sub-standard tools can cause
rocks sliding along the pinch bar. A
straight and equipped with a injury.
too short pinch bar can cause rocks
gasket.
to fall on you.
If the support is substandard in the
area to be barred, first install the
1.1. Check the support in the Sub-standard support may result in support required by the Support
surrounding area. a fall of ground Code of Practice.
Work from a safe supported area
and wear PPE.
Do not stand where falling rocks
2. Face down dip when barring Rolling rocks
can injure you.
3. Warn and remove all persons
Bystanders may be injured if Bystanders must be moved to a
away from the area where barring
barring causes a larger area to fall. safe supported area.
is to take place.
4. Ensure that you are standing on Loosing you balance when barring Do not stand on loose rock when
solid ground may cause injury barring
5. Check that a safe area to retreat
Sudden collapse of large piece of Ensure safe escape way is
into is available before starting to
hanging. available in emergency.
bar.
Sound hanging above your position
6.Bar down dip from a safe and Collapse of unchecked hanging
and stand near support (Use a
supported area may cause serious injury
1.8kg hammer to sound hanging)
7. Bar down dip for 2 meters, turn
Bad hanging not visible from up-dip Always check hanging behind for
around and check for hidden joints
may cause serious injury signs of danger.
or poor hanging wall conditions
Get assistance to bar if the rock
8.If one pinch bar is not enough to Failed attempts to bar down may
cannot be barred down by one
bar down the loose rock, use cause accidents later if not
person. Observe safety
another pinch bar(s) supported.
precautions and wear PPE.
9. If the suspect rock cannot be
barred down with 2 or more pinch Temporary support under loosened
Sudden collapse of loosened
bars, temporary support i.e. rock must be installed under direct
hanging may cause injury
mechanical props, must be installed supervision of a competent person.
underneath the rock
10. If the suspect rock is not
A barricaded-off area may only be
immediately attended to, the area Entry into danger area may cause
re-entered after a re-examination
must be barricaded off and all fatal injuries.
by a Certificated Miner.
access be prevented.
11. Temporary support is also
Temporary support must be
required where examination and Unsupported suspect rock could fall
positioned beneath the suspect
sounding of the hanging wall suddenly and may cause serious
rock and be supervised by a
reveals suspect rock which does injury
competent person.
not come down.
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Temporary support may only be

12. Permanent support must be Inadequate support may cause fall
removed after permanent support
installed to replace temporary of hanging with possible injury to
has been installed under the
support under suspect hanging persons.
supervision of a competent person.
13. The removal of temporary Must be done under supervision by

support jacks must be carried out Fall of hanging may cause injury. a competent person. Use a
remotely from a previously Falling jacks may strike persons 5.0meter release tool for stoping
examined safe position, using a releasing jacks when remote and 7.0 meter for development.
remote release tool of the correct release tool not used. Use the release tool to pull jacks to
length. a safe area.
Exercise
1) HRD Officer to take all Learners to a Development end/s for Practical barring
2) Learner need to prove verbal and physical competence to the satisfaction of the HRD Officer on the
steps to Barring, examination of a Pinch bar and Golden Rules of Barring
Note*** Learners to practise safe barring techniques daily when entering Development ends
13 Rock Engineering; Strata Control and Support
PRACTICAL STRATA CONTROL FOR MINING LEARNERS

To give knowledge and skills in strata control, identify sub standard conditions, understand basic rock
behaviour and hazards and to implement basic measures to address and control dangers in rock conditions,
in the workings underground.
What is Strata Control?

Strata control is the identification of hazardous rock conditions and having the knowledge to mine and
support the fractured ground around underground excavations to achieve safe conditions.
Learner Outcome & Evaluation

1. This manual is based on the following outcomes based unit standards.
a) Identify and deal with rock strata conditions pertaining to daily mining operations within an
underground working place MnH-G577
b) Demonstrate an understanding of the identification of and dealing with rock strata conditions MnH-G
578
2. To understand strata control, you must know, where, why, and how to control fractured ground and
methods that needs to be applied in and around underground excavations.
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3. This will be achieved through theoretical training and practical sessions underground to enhance the
learning process and to support comprehension.
4. Application of knowledge and skills will be evaluated through a proper test that will provide enough
evidence to determine understanding.
Need for this course

It was identified that there was a need to train Learners in the following:
1. To understand and to be able to identify different basic geological disturbances that may affect the
normal expected behaviour of the rock strata.
2. To identify sub standard conditions in terms of Strata Control.
3. To understand basic rock behaviour and hazards and create a clear understanding of non-compliance.
4. To implement basic measures to address and control dangers in rock conditions.
WHAT IS FOGM?
It is a Management System based on a holistic and comprehensive approach, taking in account all possible
factors with the aim at eliminating the Risk of Falls of ground.
FOGM is applicable to everybody working in the mine and delivering a service to the mine, such as planning,
training and service departments.
FOGM POLICY: NO ROCK WILL FALL UNCONTROLLED.

This means that we have to make sure that everybody working underground understands the basic
behaviour of rock; everybody can identify a hazardous condition and take the correct action to prevent an
uncontrolled fall of ground.
This course is aimed at educating people working in, or entering the underground environment about the
rock related dangers they could encounter and to ensure that everybody is equipped to adequately deal with
these conditions or refer the observed conditions to the correct authority for advice and remedial action.
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FUNCTIONS OF DIFFERENT LEVELS EMPLOYEES IN THE FOGM PROGRAM
TEAM
MINER TEAM
SUPERVISOR
FOGM 1
MACRO DESIGN
PILLARS
F OGM 2
MICRO DESIGN PRE PLANNING SHORT PRE WORK PLANNING
SUPPORT TERM PLAN WITH TEAM
MAKE SAFE FACE MAKE SAFE FACE

FOGM 3 IDENTIFY & MITIGATE PREP MARK OFF - PREP MARK OFF -
IMPLEMENTATION SUPPORT DRILL SUPPORT DRILL
LOCALISED RISK
MINDSET SUPPORT CHARGE - SUPPORT CHARGE -
BLAST CLEAN BLAST CLEAN -
FOGM 4 SUPPORT SAFE PERFORM SAFE AGREE TO SAFE

MONITORING DECLARATION DECLARATION WORKPLACE Monitor
AUDITS Monitor Rock Condition Monitor Rock Rock Conditions and
INVESTIGATIONS respond to local Conditions and Report Report Changes
changes - PTOs Changes
WAITING PLACE WAITING PLACE WAITING PLACE
FOGM 5 MEETING MEETING MEETING
REVIEW WORKPLACE ID WORKPLACE ID WORKPLACE ID
IMPLEMENTATION
GAPS REFER IF GAPS REFER IF GAPS REFER IF
CANT FIX CANT FIX CANT FIX
Always put SAFETY first and apply the following FOGM rules:
Never enter areas of unsupported ground.
Never drill without a safety net.
Do not enter restricted areas unless you have permission.
Always inspect, test and sound your work area and bar down according to your training.
Work does not start unless a safe declaration has been done.
All stopes must have bolting and netting, including ledging.
Gully nets have to be extended to the sidewalls and siding.
Up-dip and down-dip sidewalls in gullies have to be bolted.
Always know the issues identified in Rock Engineering and Geology reports.
Always know the support standard for your working areas.
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13.1 Module 1
1.1. CASUALTY STATISTICS ANALYSIS
Rock related accidents / incidents have not decreased sufficiently. A high percentage of these accidents /
incidents are related to Falls of Ground and poor strata control.
1.2. SAFETY
1. Definition
Safety is a state of mind by which employees are kept aware of the possibility of injuries at all times.
2. Results of injuries
a. Loss of life
b. Loss of shifts production loss
c. Additional costs pay out of compensation penalties
d. Morale of employees & families decreases
e. Financial loss
f. Medical costs increase
1.3. MAJOR CAUSES OF INJURIES IN SHALLOW MINES
a. Falls of ground
b. Material handling
c. Transport and Tramming
d. Rigging and scraping
e. Slipping & falling
f. Machinery
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1.4. MAIN CAUSES OF BAD GROUND CONDITIONS
a. Poor Mining Practices

These will be covered under drilling and blasting in Module 3. They include: Poor
Marking/Drilling/Charging/Timing Practices
b. Geological features in the area

A geological feature is defined as any plane of a geological origin, which may result in a weak plane
between rocks on either side of the plane.
Note: These planes do have little or no cohesion, which makes it very dangerous. Geological features
store stress, and with the additional mining stresses that we generate when mining towards or through them,
slippage on these planes result in falls of ground and seismicity.
1.5. DIFFERENT TYPES OF GEOLOGICAL FEATURES

Faults
Joints
Dykes
Sills
Parting Planes
Potholes
Domes
1.5.1. Faults
Definition
A Fault is a fracture or break in the rock where displacement (movement) has taken place.
Type of faults
a. Normal fault loss of ground
A NORMAL FAULT
FAULT
Weak Side
Reef Band
Loss Reef Band

Of
Ground
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b. Reverse fault gain of ground
A REVERSE FAULT
Fault
Plane
Reef Band
Weak
Side
Reef Band
Gain of Ground
Dangers associated with faults
The weak side of the fault is very dangerous because of mining under a wedge that can result in a
sudden collapse of the hanging wall and result in a possible injury or death to workers.
It is possible to mine into completely different type of ground, i.e. from Norite to Serpentinite. The
danger of this is one of the contributing factors towards bad ground conditions. Planes between
different rock types usually have little or no cohesive abilities.
Treatment of faults:
Identify
Demarcate/Mark
Treat- Bar; Support; Barricade
When in doubt stay out
Notify / Report / Declare safe in safe declaration book
Warn workers of the dangers involved
The following steps should be adhered to when intersecting a fault

1. Test for gasses
2. Water down to expose fault
3. Bar thoroughly.
4. Install temporary support both sides of the fault.
5. Install permanent support as per mine standard.
6. Mark the fault with yellow paint.
7. Report to Supervisor on first intersection of fault.
8. Increase the support density when mining through major faults or faulted ground.
9. Warn workers of the dangers involved
10. Monitor the feature for possible further movement
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1.5.2. Joints
Definition and description

Joints are planer, parallel, equidistantly spaced breaks (called joint sets) along which no visible
movement has taken place. Multiple joint sets cause the formation of blocky ground in the hanging wall
that may become unstable and cause falling or sliding out of these blocks on low cohesion contact planes.
Joint sets are mostly consistent and a set found in a stope panel will most likely continue in adjacent panels.
Joints are mostly associated with the cooling down process involved during the formation process of the rock
type. Joints are very dangerous, especially when dipping towards the face, as unsupported wedges may be
present between the face and the last row of support.
Joints can be frozen or in-filled. In-filled means that the planes contain an infilling of talc, Serpentines or
Calcite and tend to reduce the cohesion on these joints.
Prominent Joints are structures that continue for more than 5mm and:
With water coming out (dripping, flowing and or damp)
Can form an unstable block and brows
Joints opening up
Joints that shows signs of movement
Or that is deemed significant in that it may influence the stability of the immediate adjacent rock wall
and form the boundary of an obviously potentially unstable block. For example, a joint dipping at a
low angle, less than 60
Wedge Failure
Low angle joints usually result in this type of failure. Normally the thin edge of the wedge is exposed as
mining progresses and at some critical stage the unsupported weight of the wedge becomes excessive.
Face
Steep Dipping Joint
Low Angle Joint
Permanent Support Line
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Brows
Definition
A brow is a step in the hanging wall with a displacement of more than 20cm caused by poor blasting or a fall
of ground that is often associated with a prominent feature on at least one side of the brow.
Action
Rigid temporary support such as, heavy-duty mechanical support / mine poles must be installed
under the brow or around the vicinity of the fallen out area, until permanent support can be installed.
The brow should be demarcated and treated as would be a fault as per specific support instructions
on your mine.
BROW
Brow
Figure 1.158e Brows
Fractured Ground
Where stress fractures, blasting fractures, shear fractures and geological discontinuities such as joints,
bedding planes or faults are all present, and intersect, bad ground conditions will be created. Key blocks
may also be created; therefore any fractured ground must be supported to prevent falls of ground.
Stress fractures or Geological planes
Bedding
Back area
Face
Figure 1.158f Key Blocks
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Dangers associated with joints

Blocky ground conditions
Wedge formation
Key blocks
Sudden collapse can occur
Formation of brows
Treatment of joints
Identify
Demarcate / Mark
Treat Bar; Support; Barricade
When in doubt stay out.
Notify / Report / Declare in Safe declaration Book
1.5.3. Dykes
Igneous intrusions, which cut across the structural planes in the Rock mass.
Dyke
Figure 1.153a Schematic of Dykes and Sills
Dangers associated with dykes

Like faults, some Dykes are associated with displacement of the rock.
Very low cohesion on contact planes
Dykes are normally composed of very hard rock, which will slow down the face advance. More time
is being spent in bad ground.
Dykes store energy during the formation stage, (called tectonic stress). When mining towards them
we place (load) additional stresses into the feature, which can result in a sudden release of energy.
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It is extremely dangerous when a Dyke intersects the planes of strata, or layers, because the
hanging wall adjacent to such a dyke is broken into independent slabs that can be forced out by
lateral pressure.
Remember the more rigid the support, the less opportunity there is for the rock material in the vicinity
of the Dyke to move and the less likelihood of a rock fall.
A Dyke/Sill is an intrusive feature, which had forced its way in between the strata layers making the
ground around it weak and when mining through this rock, ground movement can occur.
Some Dykes contain very blocky ground requiring additional support. Place support as per mine
standard and recommendations, but place additional support where required. Ensure that support
density is adequate and install support as soon as possible after exposure of the feature.
Falls of ground
Injuries to people and damage to property
Brittleness
Treatment of Dykes
Identify
Demarcate / Mark
1.5.4. Potholes
Potholes are geological structures that cause a down warping of the reef. The reef may decrease in width to
such an extent that there is no reef in the bases of the potholes. In some cases, only a small roll occurs in
the reef. Often potholes are associated with an increase of jointing.
Low-angle jointing in the hanging wall is typically present around the margins of potholes, causing unstable
wedges in the hanging wall beam.
The reef when stretched down may still be present but may be thinner or the reef could be missing
altogether.
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Low angle Jointing
Reef
POTHOLE
Figure 1.157 Schematic of a Pothole
1.5.5. Domes
Domes are found in the immediate hanging wall of the Stopes on the Merensky and the UG 2
reef horizons.
Domes can vary in size and can be several meters in radius and also in height and are often
layered.
Domes are formed as a result of the cooling process that took place following the Magmatic
intrusions.
Dome
Joint
s
Figure 1.158a Schematic of a Dome
Dangers/ Hazards associated with Domes

Very low cohesion exists between the surfaces of the dome and the surrounding country rock. This
results in a deadweight problem.
Domes are unpredictable in terms of their size, location and thickness.
The interaction between a Dome and other geological features such as joints results in block failures
and potential Falls of ground.
It is usually very difficult to visually detect these features before they fall out and often we only
become aware of the Dome once the fall of ground has taken place.
Steep joints are often associated with the domes resulting in higher fall of ground risk.
Treatment of Domes
Identify
Demarcate / Mark
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Face
Low Angle Joint FOG
Permanent Support Line

Figure 1.157b Doming Failure
1.5.6 Fractured ground

Formed by stress and blasting fractures.
Key blocks may also be created, therefore any fractured ground must be supported to prevent
falls of ground.
Treatment of fractured ground

Identify
5-
6m
Figure 1.5.6 Fracture zone around and ahead of a stope
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13.2 Exercise Module 1
ONLY MARK THE CORRECT ANSWER
Question 1
What is Strata Control?
1. Strata control is the identification of hazardous rock conditions and having the knowledge to mine
and support the fractured ground around underground excavations to achieve safe conditions.
2. Strata control is not the identification of hazardous rock conditions and not having the knowledge to
mine and support the fractured ground around underground excavations to achieve safe conditions.
(1)
Question 2
Mark the five major causes of accidents underground.
1. Falls of Ground
2. Material Handling
3. Working to Mine Standards
4. Transport and Tramming
5. Rigging and Scraping
6. Slipping & Falling

(5)
Question 3
Mark the definition of a joint.
1. A joint is a fracture in the rock with no associated ground movement.
2. A joint is a fracture in the rock with caused by poor blasting.

(1)
Question 4
Mark the definition of a fault.
1. A fault is a fracture or break in the rock along which displacement has taken place.
2. A fault is an igneous intrusion that cut through the rock layers.

(1)
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Question 5
a. Mark the correct name for the following two types of faults and also indicate the weakest side of
each fault.
a) Reverse / Normal b) Reverse / Normal
(2)
Question 6
Mark two geological discontinuities.
1. Fault
2. Reef
3. Merensky
4. Joint
(3)
Question 7
Mark the definition of a pothole.
1. Potholes are geological structures that cause a down warping of the reef.
2. Potholes are geological structures that reduce the value of the reef.
(1)
Question 8
Mark the definition of a brow.
1. A brow is a step in the hanging wall with a displacement of more than 20cm caused by a fall of
ground or poor blasting.
2. A brow is a step in the hanging wall caused by reef duplication. (1)
13.3 Module 2 - Rock Breaking
FACTORS THAT INFLUENCE ROCK BREAKING:

Correct marking off
- Reference lines
- Correct spacing / burden.
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- Correct pattern.
- Top and bottom hole marking.
Correct drilling
- Direction of hole
- Angle of hole.
- Length of drill steel / hole.
- Use of drilling platforms / carriages (development ends).
Correct charging up
- No overcharging.
- Tamping.
Correct timing
2.1. BLASTING TECHNIQUES
Top hole marking:

The marking of these holes is important, and should be collared according to your mine
standard.
This distance may be altered when there is no open parting existing above the reef, as the
parting does contribute to fewer vertical fracturing into the hanging wall.
The distance between top holes along the face (burden) is marked according to your mine
standard.
Bottom hole marking:

Bottom holes to be marked according to your mine standard.
Avoid drilling these holes down into the footwall since this will result in mining unnecessary
waste.
The distance between bottom holes and top holes must be according to the mine standard.
Hangingwall
Top reef contact
MINE STANDARD
Burden as per
mine standard
Footwall
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2.2. BURDEN
Burden is the distance between shot holes, measured along the face as well as from the top to the bottom
holes.
Burden should be such that holes;
1. Break to their full length,
2. Do not blast out excessive hanging wall and footwall waste,
3. Do not crater (blow-out) causing excessive fly-rock and damage to support.
Overburdened holes
Results of overburdened holes:
Long sockets resulting in poor advance/blast,
Damage to the hanging wall and grade dilution,
Damage to support and blasting barricades from blown out shots,
Increased slabbing of the face and hanging wall ahead of the exploding shots due to excessive
concussion,
Poor face shape, causing delay in cleaning and support installation
2.3. HOLES DRILLED OFF-LINE
Causes of holes drilled off-line:
Badly marked or no direction lines given,
Machine Operators attempting to drill more than one hole from a single comfortable position,
Lack of proper supervision,
Poor discipline and attitude of machine operators,
Inaccurate collaring of holes due to drill steel slipping on the face,
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Paint marks being removed by slabbing of the face.
What happens when holes are drilled correctly and on line?

Improved face advance.
Improved fragmentation. (Size of rock broken)
Cleaning of the face is quicker and easier.
Panel remains straight.
Less support is blasted out or damaged.
As a result of better face advance bonus improves.
Mine costs are better controlled.
2.4. SHORT HOLES
Short holes increase the actual burden of the neighbouring holes at the back of holes.
This will lead to long sockets on these holes, which will cause an uneven face shape.
Causes of short holes are:

Purposely drilled short, for instance due to a late start,
Blocked holes in fractured ground,
Poor discipline & attitude of machine operators,
Lack of proper supervision,
Holes not blown out properly, or stones falling into the holes during charging-up, causing the
explosives to jam before reaching the back of the hole,
Under-gauge drill steel causing cartridges to jam.
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2.5. OVERCHARGING THE HOLES
The use of the correct amount and type of explosives in the holes combined with a correct burden should
cause the rock to be fragmented (broken) to the correct size for easy handling and mine requirements.
Overcharging of holes will cause damage to the surrounding rock mass, and damage to face support
elements, leading to support problems. This may leave the face area unsupported, and accidents can occur
when people go back to work in the face area after the blast.
No extra rock will be broken, apart from over-breaking into the waste rock of the hanging wall and footwall
and diluting the ore. There is NO advantage in overcharging holes. All it does is increase costs and
cause Strata Control problems.
EFFECTS OF POOR ROCK BREAKING PRACTICES

Damage to hanging wall (fractures).
Slabbing of the face.
Damage to support.
Poor advance / face shape
Question 1
Mark the five effects of over burdened holes.
1. Improved face advance
2. Long sockets resulting in poor advance/blast,
3. Damage to the hanging wall and grade dilution,
4. Damage to support and blasting barricades from blown out shots,
5. Increased slabbing of the face and hanging wall ahead of the exploding shots due to excessive
concussion,
6. Poor face shape, causing delay in cleaning and support installation (5)
Question 2
Mark six reasons why holes are drilled off line.
1. Badly marked or no direction lines given
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2. Machine Operators attempting to drill more than one hole from a single comfortable position
3. Lack of proper supervision
4. Poor discipline and attitude of machine operators
5. Inaccurate collaring of holes due to drill steel slipping on the face
6. Paint marks being removed by slabbing of the face
7. Improved face advanced (6)
Question 3
Mark the reasons for short holes.
1. Short holes being drilled on instructions from the Team Leader
2. Purposely drilled short, for instance due to a late start,
3. Blocked holes in fractured ground
4. Poor discipline & attitude of machine operators,
5. Holes not blown out properly, or stones falling into the holes during charging-up, causing the
explosives to jam before reaching the back of the hole.
(4)
13.5 Module 3 - Support
3.1. PRINCIPLES OF SUPPORT
Regional support
- Pillars
3.1.2. What do we support?

1. The immediate hanging wall beam of the working area. This means the hanging
wall from the stope face back to the barricade or backfill.
The hanging wall beam means the thickness of rock in the hanging wall, usually to
some geological plane of weakness.
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2. Fractured ground
Any fractured ground on account of mining operations needs to be supported to
remain stable.
3. Geological weaknesses
Joints, parting planes, faults, dykes, and fractured ground, all need to be supported
because of the bed separation, and therefore there is high risk of a fall of ground
4. Dead weight in the hanging wall
COMPONENTS OF SUPPORT
Quality of installation
- Correct size and spacing
- Correct angle ( 900 rule)
- Tensioning of nets
- Proper grouting
- Correct pre-stress pumping procedure.
Procedure of installation.
Removal of temporary support.
3.1.3. When do we install local support?

Support must be installed as soon as the working place has been cleaned, washed,
examined and barred down to ensure that the fractured rock does not fall out.
3.1.4. Where do we install support?

As close to the face as practically possible, the sooner displacement of the fractured
rock can be stopped, the greater the chance of creating a stable working place.
The support standard is a minimum requirement, and you are expected to intensify
the support standard if changing or bad ground conditions warrant it.
3.2. THE IMPORTANCE OF THE PRE SHIFT ENTRY EXAMINATION
During this examination, the responsible person will be examining the working area for misfires,
sockets, potential bad ground and the condition of the support, etc. It is equally as important to
examine the face and hanging wall thoroughly for geological weaknesses such as faults, joints and
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potholes. Any such weaknesses and their positions must be identified and demarcated where
necessary so that the appropriate support measures can be implemented immediately.
ENTRY EXAMINATION
Waiting place procedure.
Test for ventilation.
Test for gas.
Water down.
Examine and make safe.
- Barring
- Support
Misfires and explosives.
Safety devices.
Apply safety steps.
Safe declaration.
3.3. THE IMPORTANCE OF BARRING AND MAKING SAFE
Barring the loose fragments of rock from the hanging wall and face is vitally important because, if not
done properly, any other persons entering the working area are at serious risk of injury due to a
potential fall of ground. The need to bar down may occur several times during a shift.
Before barring commences the operator must ensure that he has the correct personal protective
equipment, and that it is in good condition. This applies also to the pinch bar, which must also be
the correct length for the mining height.
The following steps must be rigidly adhered to wherever proceeding to bar:
13 - STEPS TO SAFE BARRING (SHE 0024)

1. Always have a buddy close by in a safe place to assist
4. Use only pinch bars fitted with gaskets and sharp at both ends
6. Remove ALL personnel in the near vicinity behind and below the area to be barred
7. Is the escape way clear from obstruction
8. Are you standing on solid ground
9. Bar down from the up-dip side
10. Inspect behind for hidden joints
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11. Pay special attention to areas within 5m of the face

12. Continuous barring to be done whilst drilling, when drilling is completed and before
charging up
13. If the rock cannot come down with one pinch bar, use two pinch
3.4. THE IMPORTANCE OF GOOD QUALITY SUPPORT INSTALLATION

Not only is it important to know the correct support type for the conditions of that working area, but it
is also critical to maintain the highest quality standard of support installation. The following are some
basic points to remember, and the reasons why.
Any support unit installed in a development tunnel between hanging wall and footwall must be
installed at 90 to the hanging wall. Any installation less than 90 can allow the support unit to slip
out or fail under compression.
3.5. WHY DO WE PRE-STRESS SUPPORT

The reason for pre-stressing support is to install support so that it exerts a force to the hanging wall
immediately. It is necessary to do this in order to limit and control the downward deformation, taking
place in the hanging wall. The sooner pre-stressed support is installed, the faster and more
efficiently can the hanging wall be controlled. It would also prevent the support from being blasted
out.
3.6 SELECTING THE CORRECT SUPPORT
3.6.1. Temporary Support

Temporary Support is that support to be installed usually close to the working face and for a
limited period in time until permanent support is installed. Basically any support unit which
can be fairly easily removed is classified as temporary, whilst any support installed which is
usually never to be removed is permanent.
3.6.2 When do we remove support?

Temporary Support
a) Only if a permanent support unit has been installed close to it or
b) When all work is completed and it is not required anymore and then only by using a
remote device, from a supported area.
Permanent Support
Only when a permanent support unit has been installed close to it and then removed
according to your mine standard.
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3.6.3. Active Support versus Passive Support

Active support exerts a force on the hanging wall / footwall rock immediately after it is
installed, and maintains that force, even while it may be yielding under closure.
Passive support requires some movement by the rock, before it reacts with a counter-force.
Any support item that does not exert a force immediately upon installation is classified as
passive.
Question 1
Mark three types of permanent support.
1. Roof bolt
2. Camlock Prop
3. Packs
4. Mine Poles
(3)
Question 2
Mark the definition of active support.
1. This support exerts a force on the hanging wall / footwall rock immediately after it is installed, and
maintains that force, even while it may be yielding during closure.
2. This support requires some movement by the rock, before it reacts with a counter-force.
(1)
Question 3
Mark the description of passive support and give one example.
1. This support exerts a force on the hanging wall / footwall rock immediately after it is installed, and
maintains that force, even while it may be yielding under closure.
2. This support requires some movement by the rock, before it reacts with a counter-force.
(1)
Question 4
Which one of the following situations does not require support?
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1. The immediate hanging wall beam of the working place
2. Fractured Ground
3. Work place which is supported
4. Back area for stability purposes
5. All geological weaknesses
Fracture Zones and Stope faces

Question 1
How can fractured ground be stabilized?
Answer 1
By installing support that is sufficient to reduce the extent of displacement of the broken rock to a minimum,
and thereby inhibit movement of the fracture planes. The cohesion of intensely fractured hanging can thus
be maintained.
Question 2
How must support be so that it will generate adequate load in the workings close to the face, without allowing
separation of the strata to occur?
Answer 2
Support should be initially stiff or rapid loading but ultimately yielding so as to accommodate the irresistible
convergence forced upon it by the weight of the overburden.
Question 3
Who determines the type of support to be installed?
Answer 3
The rock mechanics department in conjunction with the manager determine the type of support to be
installed.
Question 4
Into which four categories can support be classed?
Answer 4
1. Temporary support.
2. Permanent support.
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3. Active support.
4. Passive support.
Question 5
Where is temporary support installed?
Answer 5
Between the face, and the last row of permanent support.
Question 6
Give an example of temporary support.
Answer 6
Mechanical props.
Question 7
Why do we install temporary support?
Answer 7
To provide immediate support, until such time that permanent support can be installed.
Question 8
When and why do we sometimes install headboards with this type of support?
Answer 8
The use of headboards is essential to ensure that a bigger area is supported. Especially in Friable Hanging
Wall conditions.
Question 9
Which are the main types of permanent support?
Answer 9
Pre-stressed elongates/Grout packs, rock bolts and crush pillars are the main types of permanent support.
Question 10
How is permanent support installed?
Answer 10
According to the Support Code of Practice / Mine Standards applicable to the working place.
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Question 11
What is the purpose of permanent support?
Answer 11
It acts to hold strata in the hanging wall together and promote elastic convergence thus stopping bedding
plane separation, as well as holding up local blocks of ground in the fractured hanging that would otherwise
fall.
Question 12
What is active support?
Answer 12
Active support exerts restraints on the rock immediately after its installation.
Question 13
Give examples of active support.
Answer 13
Camlock props, Pre-stressed elongate support, End anchored Rock bolts and Hydro bolts.
Question 14
Explain what is meant by passive support.
Answer 14
Any support that does not actively thrust against the rock from the moment of installation. It only begins to
function when the walls of the excavation moves sufficiently to compress it and so induce a reaction which
resists the movement.
Question 15
Give examples of passive support.
Answer 15
Grout packs and Shepherd Crooks.
Question 16
Name four types of Permanent support.
Answer 16
1. Pre-stressed Elongate support.
2. Rock bolts.
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3. Grout pack.
4. Wire meshing and lacing.
DEVELOPMENT SUPPORT
1. MECHANICAL PROPS
Mechanical props are installed as temporary support on the face for the machine operators. These
props are installed according to the support Code of Practice for the shaft and additional props may
be installed if required. Headboards are used if ground is friable.
1.1 INSTALLING MECHANICAL PROPS.

1. Test hanging wall
2. Place Mechanical props on solid footwall.
3. Extend the telescopic section to the hanging wall.
4. Insert supporting pin in hole just above securing device.
5. Rotate securing device until the Mechanical prop is tight
6. Friable hanging use headboard.
1.2 METHOD TO REMOVE MECHANICAL PROPS

1. Mechanical props can only be removed after permanent support has been installed and time
given for grout capsule to set i.e. once drilling is complete.
2. Test hanging wall before removing Mechanical props. Use releasing tool whilst standing 5 m
away in a supported area.
2. ROCK BOLTING
Generally referred to as roof bolts they are installed as active support as the face advances. These
bolts are installed in a set pattern according to the Support Code of Practice, but additional bolts may
be installed if required.
2.1 OBJECTIVES OF ROCK BOLTING

1. To prevent falls of ground at the face. The roof bolts binds rock to the hanging wall.
2. To create a competent rock mass surrounding the excavation. Roof bolts bind the fractured rock
mass surrounding the excavation together.
3. To restrict movement between slabs of ground and enhance the formation of keystones around
the excavation.
4. To bind together several thin strata to form a compound beam having a uniform load, which is
considerably stronger than the sum of the individual strata acting separately.
5. To keep sidewall layers in position to form support to the adjoining hanging wall.
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6. To restrict the parting of layers through which water may enter and mix with the mineral salts to
form crystals between the layers. These crystals cause further fracturing of the rock and general
deterioration of the tunnel.
2.2 DRILLING HOLES

Holes to be drilled 2,1 m long and as far as possible at 90 to the dip of the strata. If the bolt is
installed in only one layer it serves no purpose. When drilling rock bolt holes under gauge steel must
not be used.
2.3 ADVANTAGES OF ROCK BOLT SUPPORT

i. Immediate support. Assist rock to form competent support.
ii. Small unsupported area between advancing face and last support.
iii. Easily installed in minimum time
iv. Not obstructing clearances in haulages
v. Reduced fire hazard
vi. If properly installed longer lasting than sets
2.4 DISADVANTAGES OF ROCK BOLT SUPPORT

i. If scaling around the washer takes place these bolts loose their effectiveness (compare with
grouted ropes).
ii. Sheared by side movement of strata layers
iii. Slip of the expandable shell due to blast vibrations (re-tensioning necessary)
3. ROPE LACING
3.1 PURPOSE
Often the sidewalls of excavations are inclined to break away between rock bolts. By pulling de-stranded
hoist ropes in a set diamond pattern against the sidewall supported by the rock bolts or grouted ropes
loosened rocks are maintained in position.
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3.2 PATTERN
4. WIRE MESHING
4.1 PURPOSE
Diamond wire mesh is used with lacing to prevent loosened smaller rocks falling through the lacing.
NB: Additional roofbolts must be installed in hollows so as to make sure that the wire meshing is
in contact with the hanging and side wall. As far as possible any accumulation of loose
rocks on the wire meshing must be removed and the meshing rebolted against the rock
formation.
5. SHOTCRETTING
5.1 DESCRIPTION
Shotcreting is a concrete mixture consisting of cement, sand and crusher stone. This mixture is
forced onto the wire meshing with a shotcreting machine.
After the grouted ropes have been installed, the wire meshing is put in place and laced with scraper
ropes. Shot creting can be done over this meshing.
If friable and/or blocky ground, diamond mesh is pushed firmly against the hangingwall with
mechanical props (This serves to protect the Rockdrill Operators from Falls of Ground). Holes are
then drilled through the diamond mesh and rockbolts are installed and grouted. Once the grout has
set, rope lacing is threaded through the rockbolts, and is tensioned and clamped tight. In very friable
ground, or if there is excessive water or calcite present, shotcrete can be pneumatically sprayed over
the meshing and lacing to prevent oxidation of the rock and maintaining the integrity of smaller
pieces of rock, thus preventing bigger pieces to move.
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5.2 PURPOSE
Together with the wire meshing it forms a support for smaller rocks, scaling and crystallisation. A
further feature is that by forcing some of the cement and sand into the cracks the rock formation gets
bounded together.
6. TIMBER SETS
6.1 PURPOSE
1. To support friable ground
2. To support excavations on which there is a lot of pressure as a result of pillars above them.
3. To support the brows formed.
4. To support excavations under which travelling or tramming must take place.
5. A timber set consists of:
a. 4 legs - close to the sidewall.
b. 2 caps - installed across the excavation on the legs.
c. Cribbing - constructed in such a way that the pressure from the hanging wall is
projected onto the legs and not onto the caps. (Pig sty)
d. Studdles - installed between legs as close as possible to the top of the legs to
prevent the legs from collapsing.
CLEARANCES
When installing sets, the Legal Requirements pertaining to travelling way clearances should be
borne in mind. If it is not possible to comply with these Legal requirements bullhorn sets should be
installed. Where timber sets do not comply with the Legal requirements, they must be painted with
yellow and black zebra stripes to indicate the restricted clearance. Install the legs of the sets as far
away from the sidewall as is possible to prevent sidewall movement kicking them out.
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3. BULL HORN SETS

The bull horn set is constructed in the same way as the timber set. The only difference is that the
legs of the set are replaced by bullhorns pinned into the sidewall at such a height to comply with
Legal requirements 6.10. It is a poor method of support as it is very prone to side wall scaling and it
places load on the corners of the excavation, which are already highly stressed.
4. STEEL ARCH SETS

This is the best method of solid development support as they are designed to yield with the tunnel
deformation and unlike most other support systems are not destroyed by it.
5. BULL NOSE SUPPORT

These supports are installed at breakaways where the span from sidewall to sidewall is very great. It
is installed right in front of the bull nose in such a position as to comply with reg. 18.3.7. There are
mainly two types of support used, namely concrete piers and 570mm or 760m ventilation pipes filled
with concrete.
5.1 CONCRETE PIERS

Are built up to 2/3 of the total height of the excavation. A timber pack is constructed on top of the
pier to make it compressible. Where possible the concrete pier should be pinned into the bull nose.
5.2 INSTALLATION OF A 760MM VENTILATION PIPE FILLED WITH CONCRETE AS BULL NOSE
SUPPORT.
1. Determine position
2. Clean footwall
3. Drill pinning holes
4. Install pinning steel
5. Place pipe in position 2/3 of the total height of the excavation
6. Fill with concrete
7. Construct a pack on top.
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Examination & Making Safe of Workings

Definitions
Term Explanation
Entry Examination The first Employees that enter the working area after the re-entry period following the
Blast (Usually the cleaning Shift)
Re-Entry Examination Employees that enter the working area after the cleaning shift (change of shift)
usually the drilling and Blasting Shift
Safe Declaration A working area will be declared safe through consultation and signed joint agreement
by all members of the team. The legal accountability still rests with the appointed
Competent A person
Competent A The minimum competence requirement for any person to examine and declare an
underground workplace safe.
Competent B The minimum competence requirement for any person to install, maintain or remove
any support in an underground workplace.
Abbreviations
Abbreviation Explanation
MHSA Mine Health and Safety Act
w.r.t With regards to
ASG Advance Strike Gully
GDI Gas Detecting Instrument
Legal Requirements
MHSA and Regulations Chapter 14

MHSA 14.1
At every underground Mine where a risk of rock bursts, rock falls or roof falls exist, and at every other mine
where a significant risk of rock bursts, rock falls or roof falls exist the employer:-
(1)
may not permit any person, other than those persons examining and making safe, to enter any of the
following areas at the mine until such areas are declared safe by competent persons:
(a) the area between the face and the nearest line of permanent support; and
(b) access ways, travelling ways or places where persons need to travel or work
(2)
must ensure that the examinations for the purposes of regulation 14.1 (1) are carried out as often as may be
required, in terms of the Mines risk assessment, to maintain a safe working environment;
(3)
must ensure that a record of declarations contemplated in regulations 14.1(1) &14.1(5) is kept for a period of
at least three months
(4)
must ensure that where areas contemplated in 14.1(1) have not been examined, made and declared safe,
persons are prevented from inadvertently entering such areas:
(5)
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must ensure, if at any time a working place or part thereof becomes unsafe during the shift, that all persons,
other than those examining and making safe, are removed from such unsafe area and are not permitted to
return thereto until declare safe by a competent area
(6)
must ensure, that a quality assurance system is in place, which ensures that the support units used at the
mine provide the required performance characteristics for the loading conditions expected;
(7)
must ensure that only competent persons install, maintain and remove any support unit;
(8)
must ensure that the input of a competent person is properly and timeously considered and integrated into
mine design, planning and operations.
MHSA 14.2
No person, other than those examining and make safe, enter any of the areas contemplated in regulation
14.1 (1) until such areas have been declared safe as contemplated in regulations 14.1 (1) and 14.1 (5).
MHSA, Section 22 / Employees' duties for health and safety.
Every employee at a mine, while at that mine, must -
(1) take reasonable care to protect their own health and safety;
(2) take reasonable care to protect the health and safety of other persons who may be affected by any act or
omission of that employee;
(3) use and take proper care of protective clothing, and other health and safety facilities and equipment
provided for the protection, health or safety of that employee and other employees;
(4) report promptly to their immediate supervisor any situation which the employee believes presents a risk
to the health or safety of that employee or any other person, and with which the employee cannot properly
deal;
(4) co-operate with any person to permit compliance with the duties and responsibilities placed on that
person in terms of this Act; and
(5) comply with prescribed health and safety measures.
MHSA, Section 23 / Employees rights to leave dangerous working place.

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(1) The employees has the right to leave any working place whenever:-
a) Circumstances arise at that working place which, with reasonable justification, appear to that
employee to pose a serious danger to the health and safety of that employee;
b) The health and safety representative responsible for that working place directs that employee to
leave that working place.
(2) Every employer, after consulting the health and safety committee at the mine, must determine effective
procedures for the general exercise of the rights granted by subsection (1), and those procedures must
provide for:-
a) notification of supervisors and health and safety representatives of dangers which have been
perceived and responded to in terms of subsection (1);
b) participation by representatives of employer and representative of the employees in
endeavouring to resolve any issue that may arise from the exercise of the right referred to in
subsection (1);
c) participation, where necessary, by an inspector or technical adviser to assist in resolving any
issue that may arise from the exercise of the right referred to in subsection (1);
d) where appropriate, the assignment to suitable alternative work of any employee who left, or
refuses to work in, a working place contemplated in subsection (1); and [Par (d) substituted by s.
12 of Act 72/1997]
e) notification to any employee who has to perform work or is requested to perform work in a
working place contemplated in subsection (1) of the fact that another employee has refused to
work there and of the reason for that refusal.
(3) If there is no health and safety committee at a mine, the consultation required in subsection (2) must be
held with:-
a) the health and safety representatives; or
b) if there is no health and safety representative at the mine, with the employees
Responsible for Implementation
The MHSA Section 3.1.a appointee (Production Manager) through all legal appointed Mining Supervisors as
well as the whole team involved in declaring the required workplaces safe.
F.O.G.M / M.O.S.H (Mining Industry Occupational Safety and Health) Adoption Process
Examination and Making safe

The competent person (REG 14.1.1) is legally accountable
Responsibility on all members of the team / Supervised and coached by the Competent person
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Team agrees to team values, due process and mutual acceptance

Adequate pinch bars always present at point of work
Designated / demarcated points for storage of examination and making safe tools.
Principles in the Leading Practice for Entry Examination and Making Safe
Responsibility agreed and taken to the lowest level in the working team
Competent persons make safe and share the workload.
Each team member has a say and is empowered and valued
Balance between Empowerment and Rights vs. Responsibilities and accountabilities
Declaration must now be completed as intended after consultation with the whole team
Information sharing enhances the safety dialogue
Interdependency is enhanced Safety not dependant on one person only.
Each member aware of activities of other members
All members aware of barricaded or no go zones
Initial work planning can now be confirmed or re-directed as required
Group decision making has benefits over single person decision.
Guidelines for implementation of this Leading Practice

Involve organised labour form the start
Frontline Management role change: Positional power vs. Supportive role
Overcoming fear of commitment
Problem solving vs. victimizing
Leadership behaviour entrenchment
No shortcuts success lies in the detail
If you do not change the way that leaders interact, you will not change your current cultures and
you will not change your outputs.
Responsibility and Accountability lies with line management from the first line supervisors
Required Behavioural Duties:-
Team member Behavioural duties in terms of entry / re-entry examination

a) Each member will accept and understand his role and responsibility and that of the other
members of the team with regard to the prevention of uncontrolled falls of ground. (The team
members are given permission to care!)
b) Will identify hazardous ground and support conditions and at-risk behaviours
c) Rectify each Hazard and at-risk behaviours (Care for oneself and mutual support for each other).
Health & Safety Act 22-23.
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d) In case of unsafe ground condition, stop (withdraw) and make safe from a position of safety or
call for assistance when necessary.
e) Each member signs for being consulted, for agreeing all hazards have been identified and for
being in agreement of the rectifying actions on completion of the examination and making safe
process.
f) Each member has the right and responsibility to disagree with the decision made if appropriate,
and the team members have to discuss the applicable members concern, and the concern to be
addressed amicably.
g) Joint discussion and finalization of the Hazard rectification plan, to be noted in the declaration
document.
Comp A and Miner Behavioural duties in terms of entry and re-entry examination
a) Comp A and Miner to facilitate the team in creating a clear team pledge, ensuring each
members valued input in achieving enhanced team performance. Miner and Competent A to
ensure that each employee within the team knows and understands their individual role within
the team with respect to entry examination.
b) Team members are continuously coached to identify and evaluate hazards effectively.
c) All dangerous ground is effectively made safe, supported or barricaded off, or assistance is
timeously called for and persons are allowed to withdraw from dangerous situations.
d) Commend positive behaviour and participation of team members
e) Eliminate short cut behaviours within the team.
f) Each member of the team is allowed to sign his / her consensus on the declaration sheet and
allowed to discuss his or her views on the state of the safety of the workplace without fear of
ridicule or reprisal. Full team participation.
Shift Supervisors Behavioural duties in terms of entry and re-entry examination

a) Team members agree when asked whether their team is cohesive and functioning well. (right
skills available)
b) Effectively informs and communicates the key required behaviours and values to the team
members and provides reassurance of support to these behaviours and values.
c) Regularly tests understanding of team members regarding required safe acts and safe
conditions during inspections.
d) Provide feedback on the teams performance with regards to behaviours and values as per
pledge on a regular basis (at least weekly).
e) Ensures all persons are aware of work schedules and any changes thereof.
f) Assumes full accountability for sufficient availability of fit for purpose materials and equipment for
use by the teams
g) Conduct Planned Task Observations, share outcomes and commend correct performances
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h) Discourages unsafe behaviours through appropriate coaching and constructive disciplinary

controls when required.
Mine Overseers and Management Behavioural duties in terms of entry and re-entry examination
a) Re-enforces team cohesiveness through their pledge. Mine overseer to put systems into place to
ensure that every team understands their individual roles within the team Entry system.
b) Enhance communication and facilitation process. Ensure that systems are in place to effectively
ensure communication lines are open to the workers.
c) Through follow-ups during audits and discussions, ensure that Production Supervisors are
continually training and coaching teams in the examination and making safe processes.
d) Control Production Supervisors early shift roster and activities.
e) Analyse information from Production Supervisors in order to provide specific feedback on results.
(Checklist review)
f) Positively reinforce the Team Examination Process during underground visits.
Statutory duties of Mining Supervisors in terms of examining and declaring an underground

workplace safe
Responsibilities
1) The Manager shall:

i. Appoint a Shift Supervisor in writing for every area of the mine where persons are required to
travel, and areas where persons are required to perform their duties.
ii. Such areas shall be indicated in the Shift Supervisors Logbook.
2) The Mine Overseer shall:

iii. Ensure each Shift Supervisor in his/her section shall perform at least one early shift per week
in the area which he/she is appointed for.
iv. File the completed Safe Declaration Books for a period of three months
3) The Shift Supervisor shall:

v. Appoint all competent persons for his/her specific area of responsibility in the Shift Supervisor
Logbook.
vi. Appoint trained and competent persons (Competency A) to conduct Entry Examinations and
Safe Declarations at:
a. Areas where blasting has taken place for every working shift
b. Areas where no blasting has taken place. Such areas shall be examined and make
safe at intervals as per Mine Specific Risk Assessment. Such areas may be
examined more frequently as the Shift Supervisor may deem necessary if conditions
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present requires more frequent examination, or when instructed to execute more

frequent examinations.
vii. At least once a week, accompany a Competent A person during entry examination of the
workplace.
viii. Over inspect lifter sockets in the ASG and development ends.
ix. Scrutinise daily Safe Declaration book for details, sign it and file the original page in the
Logbook.
x. Hand over the completed Safe Declaration Book to the Mine Overseer.
xi. Issue new Safe Declaration Books by a reference number.
xii. Ensure role clarity and total involvement of whole team.
4) The Miner shall:

xiii. Check and test gases and Ventilation (Velocities)
xiv. Support effectiveness and standard compliance (Tendons where applicable as per Mine
specific Standard)
xv. Damaged and Blasted out support replaced (Adequately replaced with Mechanical jacks)
xvi. Prominent Geological features demarcated, assessed and correctly supported
xvii. Check installation of Temporary support and nets where applicable as per Mine Specific
Standard.
xviii. Remove all treated misfires by Competent A person
xix. Examine all cut and lifter sockets in gully and development ends
xx. All back areas (non working areas) clearly barricaded off as per Mine Standard
xxi. Check correct completion of Safe Declaration Book and sign off
xxii. Ensure role clarity and total involvement of whole team
2. Anglo Platinum Requirements
2.1 Corporate (Mining Executive) approved requirements

a. Safety Principles
Zero Mind Set
No Repeats
Simple non-negotiable Mine Standards
b. Anglo Platinum Values

We put safety first
We deliver on our promises
We value and care about each other
We act with honesty and integrity
We are one team
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We are passionate and take pride in everything we do
c. Rules of life
Never work under loose or suspect hanging and side walls (when in doubt STAY OUT!).
Never enter or work in area with poor or re-circulating ventilation or dead ends (When in doubt
STAY OUT!).
Never start to scrape without first tightening the scraper ropes.
Never work in the danger triangle or take up an unsafe position near any working machinery
or equipment!
Never work or travel in any area which is not your authorised place or work or travel.
Never work at heights or in any steeply inclined place or near a rock pass or other openings
without a safety harness
No unauthorised riding on or operating of mechanical equipment or doing any work for which
you are not trained.
Never operate or work on any equipment where safety devices are not working.
Never work on power or equipment without it being properly locked out.
Never abandon or leave unlocked explosives unattended or poor controls.
You must refuse to work under these conditions i.e. if any of these rules are being broken or if you
are expected to break any of these rules!!!!!!!
d. AFRS (applicable to Underground Mining)

Equipment Safeguarding Standard
Isolation Standard
Working at heights Standard
Lifting Operations Standard
Underground Ground Control
Underground Equipment Standard
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e. Documentation to be available (Entry and Re-entry examination)

Anglo Platinum Group Standard Procedure for Examining and declaring Underground
Workplace safe (This document)
Addendum to this document - Mine Specific Standard Procedure / latest approved
Safe Declaration Book
Communications Book
All applicable equipment checklists
Back to Basics Reference Book
Appendix 3:
3. Generic Critical Principles:-
3.1 Mining Cycle

Mining Cycle
Re-Entry
Blasting Shift period Cleaning Shift
Blasting Entry
Examination
Charging Face
up 7 1 Cleaning
2
and timing 6
5
4 3 Re- Entry
Drilling Examination
Face Blasting Shift
Support
Preparation
Marking
Support
Blasting
Shift
Blasting
Shift
However this also includes secondary activities (Vamping / Reclamation / Wire Mesh and Lacing / Drop
Raising / etc.)
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3.2 8 Entry Examination Supervision points
1. Waiting place procedures

2. Ventilation
3. Test for gases
4. Water down
5. Examine and make safe
6. Misfires and explosives
7. Test safety devices
8. Apply the 5 steps of safety
3.3 5 Steps to Safety
1. Is this a dangerous situation?

2. Are there any tools / equipment that are dangerous?
3. Are the workers doing anything dangerous?
4. What am I going to do about it now ?
5. If in doubt stay out!
3.4 13 Golden rules of barring
1. Always have a Buddy close by in a safe place to assist.

4. Use only pinch bars fitted with gaskets and sharp at both ends.
6. Remove all personnel in near vicinity behind and below the area to be barred.
7. Is the escape way clear from obstructions?
8. Bar down from the up dip side.
9. Inspect behind for hidden joints.
10. Continuous barring to be done whilst drilling, when drilling is completed and before charging up.
11. If loose rock is identified and cannot be barred down with one pinch bar, a second pinch bar must be
utilized.
12. If he rock still cannot be barred down, this area must be barricaded off by means of danger tape.
13. Never work under loose or suspect hanging and side walls (when in doubt STAY OUT!).
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3.5 Buddy Barring

Whenever barring operations take place, the person performing the barring, must always be
accompanied by a second person who shall assist him to detect, recognise and bar down
hanging wall.
3.6 Tools and equipment

At least 5 x 1,2 m and 2 long pinch bars
1 x elephant foot bag
1 x 2-way aluminum blow pipe
Approved scraper wire
Spray paint
1 x shovel
1 x 12.5 mm water hose
1 x 8 kg hammer
Danger tape
Socket plugs
All Supervisory Tools (Back to Basics Tool Bag / Whirling Hygrometer / Approved equipment to
measure Ventilation Velocity / 30m Tape / etc)
GDI
3.7 Geological features
Refer to Anglo Platinum Group standard: Geological Discontinuities requiring additional support:
The following Geological features are critical:
Faults
Dykes
Joints
Brows
Key-blocks
Domes
Reef in hanging
Appendix 4:
4. Supervision Points
4.1 The 8 General Supervision points

Station (Only at the station)
Safety
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Services
Sleepers
Spillage
Sludge
Storage
Stope entrance
Entry Examination for Development section
13.6.1 Two types of barriers are used to prevent unauthorised entrance into the Development blasted area
namely:
a) Primary Barrier
This barrier will be situated at the entrance of the developers demarcated area of responsibility,
which could be the waiting place barrier
The primary barrier must have the following signs attached to the chain No Entry, Blasted Area
and Danger Blasting signs.
At the end of each shift the Competent A person appointed for the development end must
close the barrier.
b) Secondary Barrier
This barrier will be situated in the development end at a pre- determined distance from the face
as per mine specific standard
This barrier must have the mine specific signs conspicuously attached
If a raise / winze is being developed this barrier will be placed at the entrance.
The traveling route from the waiting place to this Primary Barrier must be physically examined at
intervals as per Mine specific Risk Assessment normally once a week not exceeding 10 days, by the
appointed competent A person. This area must be fully examined by applying the entry supervision
points as described. The safe declaration of this area must be done in the Traveling way Declaration
Book provided.
At the Secondary barrier must be a fully equipped Entry Examination Tool board
13.6.2 Entering into the working place
The whole Team must accompany the Competent A person through the barrier.
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Sequence of entry examination from primary to secondary barrier.
Examining and making safe to be done by applying the eight (8) entry examination supervision
points:
1. Waiting Place procedure
Guard and substitute appointed (waiting place controls)
Collect all clocking cards of gang (card control)
Safety meeting / Team values discussion
Job planning (instructions / based on communications book information / route to be followed)
Team inspection (PPE and physical ailments)
Briefing of the entry examination team (all members require to participate in the examination)
2. Ventilation
Ventilation Columns (sizes / distances from face / Overlap distances / suspensions as per mine
specific standard)
Examine for leakages and blockages
Fans (sizes / suspension / grid in place / electrical connections and boxes)
Examine to confirm no Re-circulation
Velocities and quantities as per mine standard
3. Gasses
At Pre-Determined positions as stipulated in the mine standard.
At all high places / Faults / Dykes / Water fissures / Functional Electrical boxes / behind brattices
and any additional places where gasses are suspected/ top of Panel / Gully Face
No traces of Flammable gas to be allowed
Noxious gasses as per Mine specific standard
4. Watering down
All directions
Dust allaying purposes
Expose cracks and to identify geological features
Use a water hose and fittings, delivering water under constant and adequate pressure of at least
150 kpa
5. Examine and make safe

Apply the 13 Golden rules of Barring
Visual observation (Identify and evaluate risk of geological features)
Sound (Hollow or solid sound with pinch-bar)
Feel and test the rock (Pinch-bar)
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Quality and quantity of the permanent support as per mine specific standard requirements
6. Dealing with misfires and explosives

Deal with misfires and old explosives as per regulation.
Storage and control of explosives and old explosives as per regulation
Storage and spacing of explosives containers as per Mine specific standard
Destruction of old explosives as per Mine specific standard
Use of and availability of 2 way blowpipes
Use of and availability of approved scrapers
Cleaning and inspection of rig holes for explosives
7. Testing Safety Devices

Lifelines and their anchors
Scraper winches and rigs (Checklist)
Mono Winch (Checklist)
Loco / Loader (Checklist)
Travelling way (Breaks / handrail / etc.)
Tips
Heights
Back area barricades
Any other protection devices
Rail Switch devices
Fouling marks and T- Sprags
Sub-stations and Electrical Boxes
Pilot Board if applicable
8. Five steps to safety

1) Is this a dangerous situation?
2) Are there any tools / equipment that are dangerous?
3) Are the workers doing anything dangerous?
4) What am I going to do about it now ?
5) If in doubt stay out!
From the Secondary Barrier to the Face
Crew collect entry tools and do a full entry examination by applying the remaining seven entry examination
points.
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On completion of the entry examination, and the Competent A person is satisfied that the area is safe he
may declare the area as safe, by completing and signing the safe declaration book. Once consensus has
been achieved the whole team will sign off the safe declaration in the space provided before work may
commence.
Note: If there is any major event (fan stoppage, gas etc.) during the shift the workers must be
withdrawn to a safe place in through ventilation. The area must be re-examined and declared safe
before any work commences.
Development Examination Differences
Steps / Actions Entry Examination Re-Entry

Centralised Waiting Place Yes At working place, waiting place
Above the muck pile (face and
The whole face and sidewalls
Misfires and face examination sidewall) and as face becomes
down to the footwall
visible during cleaning operations
Above the muck pile on the face From the footwall to the hanging
Gas Testing
from the bottom upwards wall on the face
Examine permanent support Install safety nets if applicable as
(Tendons) for effectiveness and per mine specific standard in face
Support
missing support as per mine area
specific standard
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Safe Declaration Book
Example of the safe Declaration Book
SAFE DECLARATION
DATE Indicate
DAY NIGHT
with STOPING DEVELOPMENT
SHIFT SHIFT
(X)()()
SUMMARY of Previous Shifts Findings in Communication Book Comments Report

----------------------------------------------------------------------------------------------------------------------------- -------------------
---------------------------------------------------------------------------------------------------------------- --------------------------------
______________________________________________________________________________________
_____________________
I, ______________________________, the appointed Miner / person in charge of workmen, for working
area ______________________ hereby instruct the following Competent A person
(________________________________) to examine and make safe the following working place:
______________________ and focus on the above shift communications. Reg. 2.10.6.
__________________ ____________ ____:____ _______________________________
______________ _____:_____
(Miner/ P.I.C. Signature) (Date) (Time) (Competent A Acknowledge Instruction)
(Date) (Time)
EXAMINATIONS:
Area / Item Go Stop Fix Action taken to fix Go Stop Time
No persons
past :
Barricade
Travelling &
Access :
ways
Gasses :
Ventilation :
Temperature :
Support :
ffff
Joint/Brow :
Fault/Dyke :
Explosives
:
(Reg.4.4.1.i)
The area made safe includes the area between the face and the nearest line of permanent support, all
access ways, travelling ways or places where persons need to travel or work (Reg 14.1a). Areas not yet
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examined must be barricaded off and only entered when declared safe. Notwithstanding
this safe declaration, every employee still has the right to leave the workplace if it is unsafe.
Potential Risks Identified have been communicated with the whole Gang \ Crew and they are aware thereof.
1.
2.
3.
4.
5.
6.
7.
I, the person in charge or the instructed competent A Person, hereby declares that the working
place is examined, and is safe to work in.
Name: Safe Sign: Time: :
And if relevant (Reg 4.4.1.f) - I, the person in charge, hereby acknowledge that I have reviewed the
safe declaration.
Name: Safe Sign: Time: :
The Original shall be kept on record in the Mine Overseers office. (Kept for 3 months)
Examination Team
I assisted in the entry examination, furthermore I am satisfied that the workplace that was examined is Safe. I
agree with the Competent A Safe decision and have in no way been forced to sign this form.
Coy No Signature
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Question 1
When shall an underground working place that has been blasted, be examined?
Answer 1
Question 2
What must the Rock Breaker/Miner do in making safe?
Answer 2
Question 3
When must an examination in a develop end that has not been blasted be done?
Answer 3
Question 4
Where vamping is being done, when must an examination take place?
Answer 4
Question 5
How long shall the Rock Breaker/Miner be responsible for the safety of persons in his crew?
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Answer 5
Question 6
How must the appointed responsible competent person in charge test for flammable gas?
Answer 6
Question 7
What is required by the appointed responsible competent person in respect of loose material?
Answer 7
Question 8
If an attempt to bar down dangerous ground was unsuccessful, what must be done?
Answer 8
Question 9
Who is responsible for the crew during making safe?
Answer 9
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Question 10
If flammable gas is detected, are you allowed to work there?
Answer 10
Question 11
What does initial examination consist of?
Answer 11
1. Watering down.
2. Making safe (barring down and installing temporary support).
3. Mark visible misfires.
Question 12
What is the minimum water pressure allowed when water down?
Answer 12
150kPa when all appliances are open.
Question 13
How do you detect bad hanging?
Answer 13
By sight and sound.
Visually inspect the area.

Test the hanging wall, sidewalls and face for any hollow sound.
Question 14
What must be identified when visually examining an Area?
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Answer 14
1. Cracks in hanging.
2. Loose rocks
3. Faults
4. Dykes
5. Slips
6. Partings
7. Friable ground
8. Damaged support
Question 15
What tools and equipment are needed when making safe?
Answer 15
1. 1,8kg hammer
2. Pinch bars (different lengths) with gaskets.
3. Temporary support
4. Hose and water
5. Shovel
6. Lockable elephant foot bag
7. Socket scraper.
8. Socket plugs.
9. Barrier tape.
Question 16
How is the surrounding ground sounded?
Answer 16
1. Test from safe side.
2. Remove persons from down dip side.
3. Use hammer and pinch bar to sound.
4. Listen for hollow sound
5. Turn around and examine backwards every 2m.
Question 17
What are the 13 steps to safe barring?
Answer 17
1. Always have a Buddy close by in a safe place to assist.
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4. Use only pinch bars fitted with gaskets and sharp at both ends.
6. Remove all personnel in near vicinity behind and below the area to be barred.
7. Is the escape way clear from obstructions?
8. Bar down from the up dip side.
9. Inspect behind for hidden joints.
10. Continuous barring to be done whilst drilling, when drilling is completed and before charging up.
11. If loose rock is identified and cannot be barred down with one pinch bar, a second pinch bar must be
utilized.
12. If he rock still can not be barred down, this area must be barricaded off by means of danger tape.
13. Never work under loose or suspect hanging and side walls (when in doubt STAY OUT!).
Question 18
What is a misfire?
Answer 18
It is a shot hole, or part of a shot hole in which any explosives, or any portion thereof has failed to explode.
Question 19
How must a misfire be dealt with temporarily if not immediately treated?
Answer 19
1. Draw a circle around the misfire using chalk or paint supplied by the manager.
2. Write MF next to the circle.
3. Turn the fuse back into the hole.
4. Plug the hole.
Question 20
Detail the procedure when conducting an initial examination of a blasted or unblasted Stope face.
Answer 20
1. Water down all areas affected by the blast.
2. Make safe
Inspect visually.
Sound the hanging wall, sidewalls and face.
Remove or cause to be removed all loosed rock, mineral ground.
Install temporary support where required.
Mark misfires.
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Barricade off all areas that cannot be made safe within a reasonable time, posting the appropriate no
entry signs.
Place a guard to prevent access into any dangerous area that cannot be made safe within a
reasonable period of time.
Question 21
List the tools required to conduct an initial examination.
Answer 21
1. Water hose.
2. Long and short pinch bar.
3. Bow saw.
4. Measuring staff.
5. 1,8kg hammer.
6. Shovel.
7. Chalk, paint and brush.
8. Copper/Aluminium Scraper, 2-way blow pipe.
9. Elephant foot bag.
10. Barrier tape
Question 22
List the material required to conduct an initial examination.
Answer 22
1. Socket plugs.
2. Temporary Support
Question 23
List the 4 people that the appointed responsible competent person takes along to assist him with initial
examination.
Answer 23
1. One person for watering down and washing sockets plus plugging sockets.
2. One person to install temporary support.
3. One person to examine rigging and signalling devices.
4. One person of the particular panel to help with barring and other tasks.
Question 24
Give 2 reasons why workings must be watered down.
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Answer 24
HRD Officer to do a full entry Examination Development until all Learners are fully conversant with
Entry Examination
1. To allay all accumulations of dust.

2. To expose all cracks, loose ground, friable hanging, faults, dykes, slips, etc. to identify potentially
dangerous ground conditions.
EXERCISE
1) HRD Officer to present FOGM Power Point presentation.

2) HRD Officer to do Hazard Identification / Strata Control route underground till full competence.
3) HRD Officer to demonstrate the installation of Temporary Support and Safety Netts and Removal
of Temporary Support Units Learners to practise
4) HRD Officer to demonstrate the installation of a full column grouted rod (Learners will do it
practically during the Development Operator Phase).
5) HRD Officer to do a full entry Examination Development and Learners to practice until all Learners
is fully conversant with Entry Examination.
NOTE** From now on Learners to do an Entry / Re-Entry examination every time when entering a
Development section for the first time for that specific day
Safe declaration books to be kept as proof of the completed examination.
14 PTV & Construction
14.1 P.T.V. Tools
ITEM USES
1. Flat Spanners To tighten or loosen M12, M16, M24 and M30 Hex Bolts
2. T-Spanner To install and extract tirefond rail fasteners.
3. Wrench To screw or unscrew pipe fittings up to 100mm in diameter
4. Hammers 1,8kg for installing Elastic- and Dogspikes.
5. Scotch eye auger 16mm to drill holes for rail fasteners into sleepers, 19m for boxfront bolts
6. Beater Pick For loosening ore and ballasting
7. Shovel For lashing
8. Clino Rule To measure distances and angles
9. Chalk For marking
10. Tape For measuring distances
11. Rail Tongs For lifting and manipulating rails
12. Track gauge 61cm for checking track gauge
13. Line Level For doing long distance levelling
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14. Long Handled Scraper For levelling and cleaning

15. Hack saw For cutting metal
16. Ventilation pipe chisel For cutting ventilation pipes
17. Cold set For cutting bolts and chain
18. Marlin spike For lining up holes
19. Mason line To take grade and direction
20. Toolbag To carry tools
21. Boltcutter For cutting bolts and chain
22. Jimcrow For bending and breaking rails.
23. Loco Jack For lifting and lining up of tracks. For re-railing locos and hoppers.
24. Pipe Lifter Device assisting in the lifting of heavy pipes.
Pinch Bars
25. Barring rock levering
(1.2m 1.8m)
26. Material car For transporting material U/G
14.2 P.T.V. Material
ITEM USES
Used as tracks for rolling stock. 22kg rails for crosscuts. 30kg rails for
1. RAILS
haulages
2. SLEEPERS Support rails
3. TIE SLEEPERS Support the wide portion of a switch
ELASTIC RAIL SPIKE,
4. Secure rails to sleepers
DOGSPIKE, TIREFOND
5. FISHPLATES Join rails
6. FISHPLATE BOLTS Secure fishplates
7. RAIL SWITCHES For turnouts on tracks
SWITCHING DEVICE
8. Changes the direction of the switchblades.
(TIMBLER)
9. DRAIN SECTIONS Drain the water out of the workings.
M16 x 65mm to join 200mm Flanged pipes.
M16 x 50mm to join 100mm + 150mm Flanged pipes.
10. HEX BOLTS
M16 x 40mm to join 50mm Flanged pipes
M12 x 40mm to join Ventilation pipes.
GASKETS (RUBBER AND
11. Seal joints between flanged (black) pipes
CLINKERITE)
VENTILATION PIPE
12. Seal joints between ventilation pipes
GASKET
BLACK PIPES (200mm,
13. Air and Water service pipes
150mm, 100mm, 50mm)
VENTILATION PIPES
14. (1016mm, 762mm, Are used as ventilation columns
571mm, 406mm.)
FANS (ELECTRIC AND
15. Creates air flow
AIR)
PIGTAIL EYEBOLTS
16. Suspend pipes
(45CM AND 1,5m)
17. LONG LINK CHAIN For pipe suspension
18. S-HOOKS Suspended pipes from pipes or electric cables form pipes.
19. VALVES Regulate or shut off air or water flow
20. MANIFOLDS Provide multiple take offs at ends of pipes.
21. INSPECTION FLAP Installed on intake side of fan for inspection
22. T-PIECES For 90 take off in pipe columns.
23. Y-PIECES For multiple take off in pipe column
24. LATERALS For one sided take off has different angles
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25. BENDS For 90 bends

26. REDUCERS For changing from one diameter pipe to another
27. COUPLINGS Join male threaded pipes and pipe fittings
28. NIPPLES Join female threaded pipefittings.
Screwed onto threaded pipe or pipefittings to make joints.
200mm 8 holes
29. SCREW FLANGES 150mm 6 holes
100mm 4 holes
50mm 4 holes
Peened or riveted onto ventilation pipes.
406mm 6 holes
30. VENTILATION 571mm 9 holes
762mm 12 holes
1016mm 15 holes
31. PEEN FLANGES Peened onto ends of pipes to make joints.
32. BLANK FLANGES Blank off pipe columns
VENTILATION WEDGE
33. Change direction of pipe column.
PIECES
BLACK PIPE WEDGE
34. For pipe turns
PIECES
35. ELBOW For 90 bends
36. WRE WATERBLAST For dust allaying + diluting blasting fumes.
37. JUMPSET For temporary track extension.
15 Basic Pipe Work
PIPES of various types and sizes are used underground to supply water and compressed air and in
some cases for cementation or to transport slimes for back filling.
WATER
Purpose:
a) Drinking water
b) Service water to allay dust and to wash and examine working faces prior to marking of holes for
drilling.
c) Chilled water to cool hot working places in deep mines (Refrigeration)
Regulation:
Drinking water shall be available at points reasonably accessible to working places
NOTE: On many mines, drinking water is supplied in separate pipes, and many only be available at the
stations or other central points.
Regulation:
No person must negligently permit water to run to waste.
Water pressure:
One liters of water = one kilogram.
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1 m of water = 1000 liters = 1000kg = 1 ton.
This mass of water exerts a certain amount of force pressure due to its weight
(mass x gravity),
This is measured in Newtons (N) Pascals (PA).
NOTE: A Newton is the force which, when applied to a body with a mass of one kilogram, will give it
the force of one Newton per square meter.
Because acceleration due to gravity is 10 m/s, a vertical water column, one meter high, will exert a
pressure of 10 kilopascals. To obtain a water pressure of 150 Kpa (as required by Regulations, we
will need a minimum vertical height of 150 = 15m.
10
The size of a dam will only influence the amount of water available; it will not affect the pressure
which only depends on vertical height.
THE RETICULATION OF SERVICE WATER

Most mines have supply dames on every or every second level. If the dam is situated one level above your
working place, it would, in most instances, give sufficient pressure but, if we develop a tunnel upwards (a
Raise), then the water pressure will lessen as the vertical difference between the dam and the developing
end decreases; therefore, the supply dam is usually two or more levels above the working place and from
there, the water gravitates to the working places.
Once it has been used, it runs down to the lower level and back towards the shaft. In water raises or bore
holes, it may descend another few levels until it reaches a settler dam where the sludge and dirt is filtered
out and the clean water is pumped back to a main supply dam on an upper level, to be re-used and over
again as service water. Although the water has been treated, it is not as clean as drinking water.
Only some mines pump out all water and replace it with fresh water. Most mines recycle service water and
use fresh water only to make up for losses (sludge). Many mines also use ground water which seeps into
the mine through fissures in the rock.
NOTE: In order to allow the water to run back towards the shaft, all tunnels are developed slightly
up-grade from the shaft towards the working places.
Remember now: Under normal conditions, water is not pumped to the working
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Places, but gravitates there from a dam on a higher level and builds up pressure due to its own weight. Do
not attempt to change the pipe lay-out on your own.
By connecting your supply column to another one on a lower level, or by creating a Ring feed, you may get
high pressure in the bottom panels but no water or low pressure in the top-panels.
Remember also: Every miner should know where his water supply comes from so that, in the case of a
break-down, he can trace the fault.
Important: Never allow drain water to run into ore passes! A large quantity of water may accumulate inside
and when the box is opened a mud-rush can occur. This has caused many fatal accidents.
COMPRESSED AIR
Purpose:
To supply power for:
a) Rock-drills
b) Mechanical loaders
c) Small winches
d) Small fans
Regulation:
Nobody must use compressed air for cleaning any skip or truck underground, or the foot-wall of any stope
(sweeping) or any development end other than by means of any tool approved by the I.O.M.
Nobody must blow out any hole or socket with compressed air unless it is applied together with water
through a blow-pipe approved by the I.O.M., except when the collar of the hole is under water.
NOTE: If you do not observe these regulations, you will create dust.
SUPPLY AND USE OF COMPRESSED AIR

Compressors on surface compress air and force it into pipe columns which go down the shaft and into the
furthermost corners of the mine.
Compressed air is expensive. It should only be used to operate machinery and not to ventilate working
places. On some mines, we occasionally use a ventury to ventilate small areas, but we should never use a
water blast or a compressed air hose for ventilation.
The air, which is compressed on surface, contains a certain amount of moisture which condenses into water,
Therefore, we install water-traps usually at the stations to drain the water.
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To achieve maximum efficiency from our rock drills etc., we need an air-pressure of 550 Kpa. Although this
pressure may be available at the station, long pipe-columns with numerous leaks may reduce this pressure
to 500 Kpa or less in the working places.
A large number of rock drills, supplied by the same column, may also cause a pressure drop during peak
periods.
Remember: A 25mm pipe can only supply one rock drill effectively. If you connect wo taps onto one
25mm T-piece, each rock drill will only receive half the amount of compressed air.
PIPE CONSTRUCTION WORK
a) What type of pipes do you use at your mine (i.e. black pipes, plastic, pipes,
galvanized pipes, ect)
50mm Type : Plastic / Galvanized. Length: Rolls

100mm Type: Galvanize / Steel / Plastic. Length:
150mm Type: Galvanized / Steel. Length:
200mm Type: Galvanized / Steel. Length:
b) What diameter pipes do you normally use?

In haulages: Compressed air: 200mm Water: 150mm
In x cuts: Compressed air: 150mm Water: 100mm
In center gullies: Compressed air: 150mm Water: 100mm
In strike gullies: Compressed air: 50mm Water: 50mm
How and where do you suspend pipes at your mine?

Unless Pipe hangers are used where the pipes are next to each other, we always suspend the water
columns below the compressed air pipe, because:-
a) The compressed air pipe is usually the larger of the two,

b) In hot mines, moisture in the air will condense around the water pipe
(difference in temperatures) and, if this was allowed to drip onto the compressed air pipe, it would
cause rust.
Mine standard:
Type of eyebolt: Pigtail, Distance apart: 4.6m
Method of suspension (i.e. chain, S hook, etc.): 10mm Longlink chain with C hook
Position of pipes (i.e. above drain of in traveling way)
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Distance from in development ends: Max: 20m
c) List the pipe fittings normally in use at your mine:
Couplings Sizes: 50mm 100mm 150mm 200mm

Nipples Sizes: 25mm 50mm
Flanges/Clamps Sizes: 50mm 100mm 150mm 200mm
Reducers/Adaptors Sizes: As required
Tee pieces Sizes: As required
Bends/Elbow bends Sizes: As required
Valves/Taps i.e. gate valves or butterfly valves etc. Sizes: As required
Branch Columns
a) To construct a branch column, we need a Tee-piece in the main column. If not already in position, it is a
task in itself to install one without causing too much delay to the stoping section.
b) Because the branch column is usually of a smaller diameter that the main column, we need reducers or
adaptors.
c) Because the branch column leads off in a different direction to the haulage, we need bends.
d) I the main column is on the opposite side of the new X-cut, we must start the branch column with a
cross-over, high enough to allow locos to pass through.
e) Every branch column must have its own control valve, otherwise we would have to close off the
main column (which also supplier other sections) every time we work on or extend the branch
column.
Cross-over
At junctions or break-aways, the pipe columns must be high enough to allow free passage to locos. We
may then have to fit short lengths of piping with bends on either side to life the pipe columns against the
hanging.
A Cross-under is basically the same but is usually of a temporary nature. As long as blasting of a break-
away is in progress, we fit stand-pipes with bends on either side and lower the pipe columns onto the
footwall, where we can cover them up to protect them from the blast. We often use 10nn rubber hoses for
such temporary connections.
Pipe bends
Curves can be negotiated by means of 45 bends or 90 elbows. At smaller bends, we can insert a wedge-
ring between the two flanges.
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On some mines, we use a cutting-torch to heat up the pipe and bend it to whatever shape we need, We
must, of course, avoid having one sharp bend and create instead, a series of small crinkle-bends over a
long distance but, even so, it is not a very good method because:-
a) A pipe which has been bent in such a way, cannot be reclaimed and re-used elsewhere.
b) Ever crinkle weakens the pip and narrows the pipe diameter, causing a restriction.
Peening of pipes
When a pipe has to be cut, in order to fit a Tee-piece at a specific point, or when old pipes with badly
damaged threads are used, or when a pipe is damaged and a short piece must be cut-out and replaced, we
cannot use a screw-type flange, because there are no threads on the pipe.
We will then knock on a peen-flange with a hammer until the pipe protrudes 1 cm past the flange.
This end of the pipe is bent over and flattened against the flange so that the pipe cannot pull out. This
process is called peening and was used a lot in the past but, on modern mines, we usually have a fitter
available who will cut the pipe and weld on another flange.
With victaulic fittings, we may have to roll on another ridge or shoulder every time we cut a pipe, so that
we can fit the victaulic lamp.
VENTILATION PIPES
Purpose:
To ventilate development ends where there is no natural through flow of ventilating air.
Regulation:
Every development and shall be so ventilated that harmful smoke, dust and fumes from blasting are
effectively expelled.
Ventilation systems:
By making use of fans and ventilation pipes, we can either
a) Force or blow the air into the tunnel, or
b) Exhaust or draw the air out of the tunnel, or
c) We can use a combination of the two systems.
The most common method is the force system which delivers fresh air onto the face where it is needed
most.
The exhaust system is used mostly in multi blast tunnels, where fumes and gases from blasting must be
extracted before they can pollute any other working places.
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If we use a combination of the two systems, we must ensure that the exhaust column is larger than the force
column, otherwise we will force in more air than we can exhaust and fumes and gases would remain in the
tunnel.
Whichever system we use, the ventilation column must always overlap sufficiently far into the main
ventilation stream, so that a short-circuiting of ventilation is impossible.
The air must never be drawn into the tunnel for a second time.
Minimum air quantity required on a development end face:

Regulation:
The quantity of air supplied at the working face of any development end shall not be less than 150 cubic
decimeters per second for each square meter of the cross-sectional area of the tunnel. (150 cubic
decimeters per second = 0,15 cubic meters per second and 3m high = 9m face area)
Example:
Face dimensions = 3m(height) x 3m (width)
Step 1:
Determine face area:
Area = height x width
= 3m x 3m
= 9m
Step 2:
Determine minimum quantity required.
Quantity required: = Face area x Legal requirement

= 9m x 0,15 m per m
s
= 1,35 m /s
What sizes of ventilation pipes do you use on your mine and where?
Diameter Used in: Length:
305mm Small ends or Boxes 1m
406mm Raises or Winzes 2.7m
570mm X cut (force) or Inclines 2.7m
760mm Haulages (exhaust) or Inclines 2.7m
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How do you suspend ventilation pipes on your mine?

Mine standard:
Position of ventilation column (in center or on which side of the development end?)
Position in X-cut : T/Way side / 2.6m Suspension.

Position in Raise : As Required
Method of suspension (with sling wire or chain from eyebolts or grouted rods etc.)
Method in X-cuts or haulages: Wire/Chain (10mm)

Method in raises: Wire
Distance from sling-to-sling or chain-to-chain: 2.6m
Maximum distance from face (force in tunnels): 15m
Maximum distance from face (exhaust in tunnels):20m
Maximum distance from face (in raises): 15m
NOTE: Numbers leaks on a long column can seriously affect the quantity of air delivered at the face. If the
column is not suspended as high as possible against the hanging, an over-loaded truck will soon
damage it.
Repairs:
Leaks frequently occur at joints when either:
a) The gasket has not been properly placed or,
b) Some bolt have left out or not tight. But the pipe itself can get damaged and wrapping a sheet of plastic
around it usually repair a leak. What methods do you use at you mine?
Protection:
When blasting, the ventilation pipe can get damaged or fines and even small rocks can enter the pipe
column and block it. Especially in raises, where these rocks slide down and accumulate at one place, this
can create problems. We install a protection screen and/or a short piece of ventilation pipe with an opening
at the bottom in front of the column.
Cut and Peen a Ventilation pipe

When a damaged pipe has to be replaced, or when we want to construct a small bend (5 or less), we can
easily cut a ventilation pipe to whatever angle we require and fit it with a flange.
The end of the pipe is bent over and flattened against the flange so that it cannot pull out. (Preening)
Exercise
HRD Officer to take Learners to the Store and Sputnik to familiarise themselves with all the
different Parts / Material and tools for Development construction.
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Learners to make notes and re-build the Sputnik as the exact replica
16 Basic Track Work
TRACK WORK
In Developing and on Logistics on conventional mines, you will be required to install tracks underground. A
good working knowledge is thus required.
Track work, when done correctly will require a minimum of maintenance, assuring the safe conveyance of
men, material and ore. Derailments are always time consuming, dangerous and costly.
This module will enable you to obtain both knowledge and skill to do this work.
HRD Officer to demonstrate each of these tasks as the Learners re-equip the Construction X/Cut
ALLIGNING RAILS
STEPS ELEMENTS
1. Lengths of mason line

2. Tape
1. SELECT TOOLS
3. Chalk
4. 2 Cap lamps.
1. Use relevant direction pegs

2. Hang mason lines from pegs
2. AFFIX LINES 3. Tie a weight on end of each line
4. Steady lines
1. Stand 2m behind line

2. Shine cap lamp over 2 lines
3. SIGHT
3. Align eye with two lines
PROJECT LINES
1. Hold chalk vertically
2. Shine lamp on chalk
4.1 ONTO FACE AND
3. Marking areas
HANGING-WALL
a. 2m from face on hanging wall
b. At face on hanging wall
4. c. 3 Positions on the face
4. Marks to be within 10mm of direction line.
1. Place nought of tape on centre of crown

2. Place lamp behind tape
4.2 USING TAPE
3. Line up
4. Tracks to be within 10mm of direction line.
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GRADING RAILS
STEPS ELEMENTS
SELECT TOOLS 1. Lengths of mason line

2. Tape
1.
3. Chalk
4. 2 Cap lamps.
1. Use relevant direction pegs

2. AFFIX LINES 2. Span mason lines
1. Stand 2m behind line

2. Shine cap lamp over lines
3. SIGHT
3. Align eye with two lines
PROJECT GRADE 1. Hold chalk horizontally

2. Shine lamp on chalk
4.1 ONTO FACE 3. Marking areas
a. 2m from face on sidewall
b. At face on sidewall
c. Positions on the face
4. 4. Marks to be within 10mm above and
below the grade line.
1. Hold tape vertically

4.2 USING TAPE 2. Place lamp behind hole in grade staff
3. Tracks to be 1,2m below grade line
unless otherwise stipulated on Survey
Note.
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PREPARE WORKING AREA
STEPS ELEMENTS
1. Water hose
2. Long and short pinch bar
3. Two M19 x 24mm flat spanners
4. Tape
1. SELECT TOOLS AND MATERIALS 5. Two lengths mason line
6. Three sleepers
7. Beater picks
8. Shovels
9. Clino rule
1. Dust allaying
2. SAFETY 2. No loose rocks
1. Load excessive ore

3. CLEAN UP 2. Remove unnecessary material and
equipment
1. Loosen fishplates
REMOVE JUMPSETS 2. Remove required amount of Jumpsets
4.
3. Store observe clearance
1. Position 3 sleepers
2. Use grades
3. Check
5. CHECK FOOTWALL ELEVATION
a. 1,2m Below grade
b. Excavate to 1,2m below
grade
LAYING OF SLEEPERS
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STEPS ELEMENTS
1. 13 Sleepers
2. 2 x 9m Rails
3. 52 Elastic rails spikes
4. 2 x Oval Fishplates
1. SELECT TOOLS AND MATERIALS
5. 2 x Round Fishplates
6. 8 x Cup Oval 20mm Nuts & Bolts
7. 1,8kg hammer
8. Track gauge
1. Determine top of sleeper

2. PLACE SLEEPERS ON FOOTWALL 2. Position sleepers approximately
1. Lift rail on to sleeper with rail tongs

3. POSITION RAIL 2. Place rail under direction line
1. Mark from ends of rail to centre

a. 1st Sleeper under joint
MARK OFF SLEEPER b. 2nd Sleeper 375mm from end of rail
4.
to centre of sleeper
c. Remaining sleepers to centre of rail
750mm centre to centre.
1. Lift rail slightly

2. Place sleepers
a. Under marks at right angles to rail.
5. POSITION SLEEPERS
b. Holes of sleepers next to flange of
rail.
1. Insert left hand elastic rail spike into pre-

drilled hole.
a. Vertically
b. Right angles to rail
c. Spike to face larger area of sleeper.
6. SECURE RAIL TO SLEEPERS
2. Drive in left hand elastic rail spikes
a. Use 1,8kg hammer
b. Strike spike over the top arch from
behind.
c. Required tension is when split ends
are in line.
1. Place rail on sleepers

7. INSTALL 2ND RAIL 2. Secure rail to sleepers
3. Use track gauge
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MAKING A FISHPLATE JOINT
STEPS ELEMENTS
1. Marlin Spike
2. M24 x 30mm flat spanner or box spanner
3. Oval and round fishplate
1. SELECT TOOLS AND MATERIALS
4. Cup Oval 20mm Bolts & Nuts
5. 1.8kg Hammer
1. Place rails end to end

2. Line up rails
2. LINE UP RAIL
3. Rails on same elevation
1. Place fishplate
a. In channel of rail
b. Hollow side facing web
3. POSITION FISHPLATE c. Arrow showing up towards crown
2. Line up holes with marlin spike
1. Head of bolt on inside of rail

INSERT FISHPLATE BOLTS
4. 2. Fasten nut
1. Place spanner on nut and tighten nuts.

a. Push spanner palm open
b. In sequence
5. TIGHTEN c. Hit fishplate between bolts whilst
tightening with 1,8kg hammer.
In sequence first inside nuts then outside nuts.
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LINING UP TRACK WITH LOCO JACK
STEPS ELEMENTS
1. Complete loco jack

2. Lengths mason line
1. SELECT TOOLS 3. Tape
4. Beater picks
5. Shovels
1. Positions
a. Nearest end of track
b. Centre of track
2. DETERMINE POSITION OF JACK c. Furthest end of track.
2. Take lines
3. Pinpoint of line position.
1. Dig out
3. EXCAVATE SLEEPER ENDS
1. Loco jack horizontal on a sleeper
2. Extend jack
POSITION JACK
4. 3. Lock thumb piece
4. Place loco jack handle in a vertical position
1. Operate jack
2. Check line
5. SWING TRACKS ON LINE
3. Level up ballasting
1. Unlock thumb piece

6. REMOVE LOCO JACK 2. Operate jack
3. Move to next position.
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GRADING TRACKS WITH LOCO JACK
STEPS ELEMENTS
1. Loco jacks
2. Lengths of mason line
1. SELECT TOOLS 3. Tape
4. Beater picks
5. Shovels
1. Positions
a. Nearest end of track
b. Centre of tracks
c. Furthest end of tracks
2. POSITION JACK
2. Excavate under sleeper for loco jack
3. Place jacks vertical claws under sleeper
4. Lock thumb piece.
1. Operate jack
2. Check grade
3. Ballast sleepers using beater pick in cross-beating
3. ELEVATE TRACKS
method.
4. Fill up spaces between sleepers.
1. Unlock thumb piece

REMOVE JACK 2. Lower loco jack
4.
3. Move to the next position.
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INSTALLING DRAINS
STEPS ELEMENTS
1. Gumplanks & nails

2. Beater picks
1. SELECT TOOLS AND MATERIAL 3. Shovels
4. 1,8kg hammer
5. Pre-mixed concrete
1. Pick
2. Lash out from next to drain side rail up to sidewall solid
2. EXCAVATE TO FOOTWALL
footwall
1. Place gumplanks on solid footwall.

FIX GUMPLANKS TO SLEEPER
3. 2. Hammer gumplanks to sleeper sides with 100mm nails.
SIDES
1. Fill excavated area between gumplank and drain rail with
4. LEVEL OFF concrete.
2. Re-ballast under point of load on drain side.
5. FINAL LEVELLING OFF 1. Level off concrete with top of sleeper
Gumplank
Concrete
Drain
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USING A JIMCROW TO BEND A RAIL
STEPS ELEMENTS
6. Jimcrow
7. Long and short pinch bar
1. SELECT TOOLS
8. Marlin spike
9. Chalk
3. Place jimcrow on inside of curve

4. Place claws over crown of rail
5. Position shoe on mark
2. POSITION JIMCROW
6. Support jimcrow level on crown of the rail with short
pinch bar
3. Tighten spindle by hand holding shoe on mark

3. TIGHTEN JIMCROW 4. Tighten spindle with marlin spike for initial tightness
MARK NEXT POSITION 1. Mark on both sides of leading claw on the rail.
4.
1. Turn spindle back with pinch bar.
5. LOOSEN JIMCROW
MOVE JIMCROW TO NEX
6. 1. Continue bending.
POSITION
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INSTALLATION OF A SWITCH
STEPS ELEMENTS
1. Select tools and material

2. Determine position
1. PREPARE THE AREA
3. Remove Jumpsets
4. Check footwall elevation
1. Lay down all sleepers, see sketch

2. Place drain section at blade spacer position
2. POSITION SWITCH 3. If tumbler place bearers with drain section
4. Lay switch on sleepers
1. Line up switch
3. JOIN UP SWITCH 2. Make fish-plate joints
SECURE SWITCH TO
1. Position sleepers
4. SLEEPERS
2. Drive in elastic spikes
1. Use survey grades
2. Elevate
5. GRADE SWITCH & BALLAST
3. Support
1. Check excavation
6. INSTALL DRAIN 2. Install drain sections
7. INSTALL SWITCHING DEVICE 1. Install switching device.
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EXTENDING A STRAIGHT SET OF TRACKS

Tools and materials needed
Material
14 Sleepers 22kg (13 x 30kg)
2 x 22kg Rails/30kg
52 Elastic rails spikes (22 or 30kg)
4 Fishplates (22 or 30kg 2 x oval, 2 x round.)
16 x Cup Oval Bolts & Nuts 75mm x 20 or 90mm x 20.
Tools
4 Shovels 2 Rakes
4 Beater picks 2 Loco jacks
2 x M24 x 30mm Flat Spanners 2 Marlin spikes
2 x 1,8kg hammers 1 Track gauge
1 Elastic spike extractor 4 Lengths mason line
1 Tape 1 Toolbag
STEPS ELEMENTS
1. Transport material and tools to working place.

2. Remove all unnecessary material and equipment.
1. PREPARE THE AREA 3. Remove Jumpsets
4. Place sleepers in position
5. Check footwall elevation.
1. Place 1st rail under direction line.

PLACE SLEEPERS AND RAILS IN
2. 2. Place 2nd rail in position.
POSITION
1. Make fishplate joints.
JOIN-UP RAILS ONTO
3.
PERMANENT TRACKS
SECURE RAILS TO SLEEPERS
4. 2. Knock in rail spikes
1. Swing tracks approximately on line

5. LINE UP TRACKS 2. Support sleepers
1. Place Jumpsets in position

2. Join up with rails use one fishplate.
6. CONNECT UP JUMPSETS
3. Install sliding rails.
LINE UP 2ND LAST SET OF 1. Use survey lines

7.
TRACKS 2. Move tracks on line.
1. Use survey grades

ND 2. Elevate tracks
8. GRADE 2 LAST SET OF TRACKS
3. Support.
1. Ballast
BALLAST 2ND LAST SET OF
9. 2. Level off
TRACKS
10. INSTALL DRAIN 1. Check excavation
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2. Install drain
11. RETURN TOOLS TO STORE 1. Put everything back in its place.
INSTALLATION OF A CURVE
STEPS ELEMENTS
1. Transport material and tools to working place.
2. Remove all unnecessary material and equipment.
PREPARE THE AREA
1. 3. Remove Jumpsets
4. Check footwall elevation.
1. Determine position of curve.

PLACE SLEEPERS AND RAIL IN 2. Lay down sleepers.
2.
POSITION 3. Lay outside rail on sleepers.
1. Mark start of curve.

a. If switch 2m from switch.
b. Where curve starts.
3. BEND RAIL
2. Bend rail with jimcrow
a. One turn on first mark (90)
b. Two turns from then on (180)
1. Mark off sleeper position (on outside rail) (If not
4. MARK OFF SLEEPER POSITIONS
enough, 90 right through again).
1. Swing rail approximately into position.
5. JOIN UP RAIL. 2. Make fishplate joint.
3. No fishplate bends.
6. SECURE RAIL TO SLEEPERS 2. Knock in rail spikes.
1. Lay inside rail on sleepers.

PLACE INSIDE RAIL ON
7.
SLEEPERS
1. As outside rail
8. BEND INSIDE RAIL
2. Use holes in sleepers as a guide.
1. Swing rail in position

2. Make fishplate joint.
9. JOIN UP RAIL.
3. No fishplate bends.
10. SECURE SLEEPERS TO RAIL 2. Knock in rail spikes.
1. Line up 2m straight section with switch.

11. LINE UP TRACKS 2. Support sleepers.
1. If more than one set of tracks from the curve.

12. COMPLETE THE CURVE
2. Complete curve.
1. Swing curve.
13. LINE UP CURVE
2. Observe travelling way clearance.
1. Use survey grades.
14. GRADE CURVE.
2. Elevate tracks
1. Beat in ore under point of load.
15. BALLAST
2. Level off.
1. Check excavation
16. INSTALL DRAIN SECTIONS
2. Install drain section
17. RUN LOCO OVER CURVE. 1. Check for sag.
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SUPER ELEVATION
STEPS ELEMENTS
1. Tape
2. Chalk
3. Loco jack
4. 1,8kg hammer
1. SELECT TOOLS 5. Clino rule
6. Beater pick
7. Shovel
8. Rake
1. Measure length of curve on the web of the outside rail.

2. Fold tape double holding the ends at the start of curve.
2. DETERMINE CENTRE OF CURVE
3. Mark centre of curve on the crown of the rail.
1. Excavate under sleeper for loco jack at mark.

3. POSITION LOCO JACK 2. Place jack vertically under sleeper at mark.
1. Place clino rule in position.

a. Horizontally across the rails.
POSITION ELEVATION
b. On mark at right angles to the rail.
4. EQUIPMENT.
2. Place 1,8kg hammer under grade staff.
a. On inside rail
b. Hammer handle 30mm
1. Support track with pinch bar at end of curve to present

side movement.
5. ELEVATE OUTSIDE RIAL.
2. Jack up rail till the line level is level.
1. Beat in broken ore under points of load of all effected

6. REBALLAST sleepers.
1. Level of ballasting.
7. REMOVE LOCO JACK
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POSITIONING OF A RAILSWITCH
Question 1
What is meant by the SOS position of a switch?
Answer 1
The SOS position (Start of Switch) is a mark painted on the sidewall of the excavation where a switch is to
be installed.
Question 2
How is the SOS position determined?
Answer 2
There are mainly two methods:
i. The SOS position is either provided by the survey department on a survey note.
ii. It can be calculated 21/2 times the length of the switch measured from the bull nose position.
SUPER ELEVATION
Question 1
What is meant by super elevation?
Answer 1
Super elevation is when the outer rail on a curve is raised above the inner rail.
Question 2
When is super elevation done?
Answer 2
Super elevation can only be done after a curve is completed (Ballasting included).
Question 3
What happens when trains are rounding a curve?
Answer 3
The centrifugal force developed by a train rounding a curve, causes the wheel flanges to press against the
outer rail. The magnitude of this force depends upon the speed of the train and the radius of the curve.
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Question 4
Why are curves super elevated?
Answer 4
To counter act the centrifugal force developed by a train rounding a curve.
Question 5
What are the advantages of super elevation?
Answer 5
i. It reduces the pressing of wheel flanges against the outer rail.
ii. It increases the stability of a moving vehicle.
GAUGE WIDENING
Question 1
What is meant by gauge widening?
Answer 1
Gauge widening is done on a sharp curve where either the inner or outer rail is slightly widened using a wide
gauge.
Question 2
When is gauge widening done?
Answer 2
When installing curves.
Question 3
Name the two types of gauge widening.
Answer 3
i. 12mm for locos moving at speed of less than 8km/h
ii. 25mm for locos moving at speed of more than 8km/h
Question 4
What are the advantages of gauge widening?
Answer 4
i. Facilitate the passage of trains around a sharp curve due to fixed wheelbase.
ii. Reduce resistance due to fixed wheelbase.
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CHECK RAIL
Question 1
Where are checkrails installed?
Answer 1
Checkrails are installed on the inside of the inner rail on a shaft curve.
Question 2
How is a check rail identified?
Answer 2
An ordinary full length of track, bent exactly the same as the inner rail, with both ends tapered off to ensure
that wheel flanges are engaged when moving into it.
Question 3
What is the purpose of a checkrail?
Answer 3
The purpose of a checkrail is to prevent the outer wheel of a vehicle from mounting the outer rail on a curve
by engaging the flange of the inner wheel and so limiting side movement.
Question 4
What are the advantages of a correctly installed checkrail?
Answer 4
Properly installed check rails ensure the following:-
i. Safe curve negotiation.
ii. Reduces crown wear on outer rail.
iii. Reduces wear on wheel flanges
INSTALLATION OF A BOX FRONT
OBJECTIVE
To establish a safe and correct procedure for Spillmanator chute installation
The Anglo Platinum Safety Rules are to be applied at all times with special reference to: Mining
Operations
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BOXFRONT INSTALLATION
Site preparation
1) Ensure that all safety precautions and special instructions are in place so as to prevent persons from
unintentionally entering the area where the blasting of the cubby and hanging wall slot is to take place.
2) Ensure that precautions have been taken to prevent damage to electrical cables and service columns, if
present, prior to blasting taking place.
3) Place a stop sign and a T sprag, one rail length, on either side of the proposed excavation.
4) At all times adhere to the dimensions of the survey note.
5) Prior to the commencement of any construction, a pre work assessment is to be conduct.
6) The rails are on line and grade
NB The final blasted excavation is not to exceed the dimensions of the survey note.
NB If the excavation size exceeds the survey dimensions, a standard installation is not to be
installed, the Engineer is to be consulted regarding the re-design of the box front structure
Blasting of cubby
1) Drill and blast the cubby opposite the boxhole positions 1.0m deep and 3.0m wide for a cubby the full
height of the crosscut or haulage.
2) A 9 hole burn-cut is to be drilled to create a free breaking face as per AEL recommendations Annexure
A
3) Grid holes to be marked and drilled with a burden and spacing of 50 cm.
4) All holes to be drilled to an effective hole length of 1.0m.
5) The perimeter holes to be drilled with a spacing of 30cm
6) Stope fuses are to be used to initiate all charged holes
7) All grid, perimeter and cut holes are to be charged with Anfex
8) The lifter holes to be charged utilising Powergel (816 25 x 270 cartridge explosives)
9) All perimeter holes to be charged utilising Energex Barrel and primers to be made of Powergel (816 25 x
270 cartridge explosives) to ensure smooth wall blasting.
10) The round is to be timed with Stopeline igniter cord.
Box Hole Position
Cubb
Haulage / X/cut
y
1.0 m
Sectional View
Not to scale
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Haulage / X/cut
Cubby
Box Hole
3.0m
Position
Plan View
Not to scale
Do not remove the broken rock but use it to stand on to drill the hang wall slot
Blasting of the hanging wall slot

1. Drill and blast a slot from the end of the cubby to the boxhole position 1.4m into the hanging wall and
3.0m wide the full cross sectional width of the crosscut or haulage.
2. A 9-hole burn cut to be drilled to create a free breaking face. Annexure B
3. The grid holes to be marked and drilled with a burden of 50cm and a spacing of 45cm. All holes to
be drilled to an effective hole length of 1.0m.
4. The perimeter holes to be drilled with a spacing of 30 cm.
5. Stope fuses to be use to initiate all charged holes.
6. All grid, perimeter- and cut holes should be charged with Anfex.
7. All perimeter holes to be charged utilizing Energex Barrel and primers to be made of Powergel 816
25 x 270 to ensure smooth wall blasting.
8. All perimeter holes must be properly tamped with approved tamping material.
9. The round is to be timed with Stopeline Igniter cord.
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1.4 m
Slot
Box Hole Position
Cubb
Haulage / X/cut
y
1.0 m
Sectional View
Not to scale
Cubby
Slo
3.0m
Box Hole
t Position
Haulage / X/cut
Plan View
Not to scale
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Developing the boxhole
1) The hanging wall slot must be examined and declared safe by a Competent Person and record that that
the hanging wall has been found competent or record any special instructions have been carried out to
secure the brow in the case where the brow has been found to be incompetent.
2) Support Standards and Procedures must, at all times, be adhered to.
3) Drill and blast the first 0.9m round at the boxhole stub break away according to the Survey note.
4) A drilling platform suspended from 4 eyebolts must be installed at a distance that will ensure that the
machine operator and person charging up the face can work safely
5) A safety platform must be installed 2m below the drilling platform after the boxhole has advanced a
distance of 6m
6) Install a safety net secured to 4 eyebolts 2m below the drilling platform for the first 6m advanced and
move the safety net to 2m below the safety platform after the face has advanced a distance of 6m
7) A chain ladder must be installed from the position when the drilling platform is installed and suspended
from 2 separate eyebolts and extended to the entrance of the boxhole
8) A 25-mm blower must be installed before the third round is drilled and will advance forward with the
drilling platform. The boxhole is to be flushed out with compressed air for at least 15 minutes before any
person enters or attempts to enter after it has been blasted or has remained idle for more than a shift.
This is to ensure that there is not a deficiency of oxygen or an accumulation of harmful or noxious
gasses. The maximum from the face will be 2.0m at all times.
9) The boxhole must be equipped with a swing barricade 2.0m from the entrance of the boxhole.
10) The total length of the boxhole will not exceed 8.0m
11) Not more than 3 persons are allowed to be in a boxhole at any one time. All persons entering a boxhole
shall wear a safety belt which shall be attached to the ladder, lifeline, platform, or eyebolt.
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Developing of the boxhole

The total length of the boxhole will not
exceed 8.0m
25-mm Compressed air blower

Drilling platform
Safety net
Swing barricade
2.0 2.0
m m
Chain ladder
Slot
Life line
Fastened every
3.0m by means of
pig tail eye bolts
Cubb
1,5m Angle of boxhole

Grade as per survey
y
line note
1,2m
Sectional View
Not to scale
Blasting of the bulkhead

1) Once the boxhole has been developed to the distance as specified by the survey note, all
equipment/material is to be removed from the boxhole except for the swing barricade, 25mm
blower and chain ladder.
2) The bulkhead excavation is then to be blasted, with the breaking point inside the boxhole (to
protect the competence of the bulkhead brow after blasting operations has taken place)
3) After the bulkhead excavation has been blasted, rig holes are to be drilled so as to assist in the
lifting of the steelwork. Adhere to mining standard WG-240-0001 Lifting procedure.
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Rig holes for

lifting steelwork
Bulkhead
excavation
Breaking point during

0.8m
bulkhead blasting
0.5m operations is to be from
the boxhole side
Cubby Slot
Grade 1,5m
line
1,2
m
Sectional View
Not to scale
Bulkhead 0.8m 0.8m

excavation
Slot C/L
Haulage / X/cut
Back Elevation
Not to scale
Haulage / X/cut
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Rig holes for

lifting steelwork
0.8m
0.5m
Breaking point during
Slot bulkhead blasting operations
is to be from the boxhole side
Haulage / X/cut
Cubby
1,5m
Grade
line
1,2
m
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MIX AND POUR CONCRETE

1 Use eye and skin protection when mixing and handling cement.
2 Only use standard 40 MPa pre-mixed aggregate. This construction strength has been
designed and calculated by engineers to ensure safety if used correctly when using 2lt of
potable water per bag of pre-mix or as stipulated on package.
3 Pour concrete in one pour
4 A sample of the concrete will be taken for testing purposes. The results will be kept by the
Engineer or other person for the life of such a box
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NB After the steelwork and pinning steel has been installed, before the concrete is poured, the
Engineer or other appointed person is to examine and approve the steel work and pinning steel. The
Engineer or other appointed person will take photographs of such steelwork and pinning steel for
reference purposes. The photographs will be kept by the Engineer or other appointed person for the
life of such a box
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Record Keeping
A tracking file to be implemented for each box front installation with the following information:
1) Shaft, Section, Workplace & Box Front Number
2) Survey notes of the completed excavation signed off by the Section Manager, Mine Overseer, Shift
Supervisor, Miner, Surveyor and Section Engineer or appointed delegate.
3) Installation checklist signed off by all responsible persons during installation, complete with photographs
taken during each phase of installation.
4) All Shift Supervisor monthly inspections, as per attached monthly examination checklist, for the total time
that the box front is in operation.
5) All artisan monthly inspections, as per attached monthly maintenance checklist, for the total time that
the box front is in operation.
Note:
SAP works order needs to be generated for all inspections and maintenance and final findings captured
on SAP.
Monthly inspections must continue till the box front is dismantled and the orepass properly plugged at
the top and bottom.
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CONSTRUCTION EXAMINATION CHECKLIST

DATE: _____________ SHAFT: ____________________
SECTION: __________ WORKINGPLACE: __________
BOX No.: ___________
I, the undersigned, have examined the above box front installation and construction using the
checklist below and found it to be in accordance with the procedure
No. ITEM NAME SIGN

1. STOP- & WARNING SIGNS, SPRAGS, IN PLACE
2. EXAMINED FOR FLAMMABLE GAS
3. HANGINGWALL, SIDEWALL BARRED, MADE SAFE

4. BROW AND SLOT SUPPORTED AS PER SUPPORT STANDARDS AND PROCEDURES
5. RAILS GRADED CORRECTLY AND ON LINE
6. SWING BARRICADE
7. RIG HOLES DRILLED FOR LIFTING OF STEELWORK
8. HOLES DRILLED FOR PLATFORM AND PINNING STEEL.
9. PINNING STEEL INSERTED AS PER REQUIREMENT
10. PINNING STEEL INSPECTED BY ENGINEER OR HIS APPOINTED DELEGATE BEFORE

CONCRETE POUR & PHOTOGRAPHS TO BE TAKEN.
PINNING INSTALLATION PHASE SIGNED OFF BY ENGINEER OR APPOITED DELEGATE AND
RESPONSIBLE MINE OVERSEER IN ORDER TO CONFIRM STANDARD AND GIVE APPROVAL
FOR NEXT CONSTRUCTION PHASE
11. BOXING FIRMLY CONSTRUCTED TO PREVENT CONCRETE SPILLAGE
12. CORRECT CONCRETE MIX: 40 MPa READYMIX OR APPROVED EQUIVALENT, MIXED WITH
POTABLE WATER ONLY STRICTLY AS STIPULATED ON PACKAGING
13. CONCRETE ALLOWED TO CURE FOR 48 HOURS
14. BOXING REMOVED AFTER 48 HOURS

ENGINEER OR APPOINTED DELEGATE TO INSPECT CONCRETE AND TO TAKE
15.
PHOTOGRAPHS
CONCRETE INSTALLATION PHASE SIGNED OFF BY ENGINEER OR APPOITED DELEGATE
AND RESPONSIBLE MINE OVERSEER IN ORDER TO CONFIRM STANDARD AND GIVE
APPROVAL FOR NEXT CONSTRUCTION PHASE
16. CHUTE INSTALLED BY COMPETENT, APPOINTED PERSON
17. LADDER INSTALLED
18. PERMANENT PLATFORM AND HAND RAILS ERECTED TO STANDARD
19. SYMBOLIC SIGNS DISPLAYED ON PLATFORM BARRICADE
20. PNEUMATIC CONTROLS INSTALLED
21. FINAL INSPECTION AND SIGN OFF BY ENGINEER OR APPOINTED DELEGATE POUR &
PHOTOGRAPHS TO BE TAKEN
INSTALLATION COMPLETE, LOGGED AND SIGNED OFF ON PLAN BY ENGINEER OR HIS

APPOINTED DELEGATE RESPONSIBLE MINE OVERSEER (INSTALLATION DECLARED SAFE
FOR USE)
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A copy of this form to be handed to the survey department in order for this examination to be logged
on the Development sheet. Original copy and photographs to be filed at the appointed Engineers
Office or other appointed person for the entire life of this box.
SHIFT SUPERVISOR MONTHLY EXAMINATION CHECKLIST

DATE: _____________ SHAFT: ____________________
BOX No.: ___________
I, the undersigned, have examined the above box front and stope chute installation using the
checklist below and found it to standard
NO. ITEM NAME SIGNATURE
1 HANGINGWALL, SIDEWALL BARRED, MADE SAFE
2 PLATFORM
3 PLATFORM BARRICADE
4 SYMBOLIC SIGNS DISPLAYED ON PLATFORM BARRICADE
5 H FRAME CONDITION
6 STOPE CHUTE BOLTS AND NUTS IN PLACE, SECURE, TYPE 8,8 HIGH
TENSILE STEEL
7 STOPE CHUTE BODY UNDAMAGED
8 CONDITION OF RADIAL DOOR, TRUNIONS SECURED AND NOT

EXCESSIVELY WORN
9 PNUEMATIC CONTROLS IN ORDER
10 COMPRESSED AIR CYLINDER
11 COMPRESSED AIR LEAKS
12 COMPRESSED AIR CYLINDER ATTACHMENT POINTS
13 CONDITION OF COMPRESSED AIR HOSES, FITTINGS & SUSPENSION
14 LADDER TO PLATFORM - SECURE, CLEARANCE TO ROLLING STOCK 500

mm MINIMUM
15 CONCRETE CONDITION
16 STEELWORK CONDITION (VISIBLE STEEL)

REMARKS
Responsible Shift Supervisor: ______________________
The original copy of this form to be filed at the responsible Engineer or other appointed delegate for
the entire life of this box.
In addition a SAP works order needs to be generated and final inspection findings captured on SAP
as well.
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MONTHLY ARTISAN MAINTENANCE CHECKLIST

DATE: _____________ SHAFT: ____________________
BOX No.: ___________
I, the undersigned, have examined the above box front and stope chute installation using the
checklist below and found it to standard
NO. ITEM NAME SIGNATURE
1 H FRAME CONDITION
2 STOPE CHUTE BOLTS AND NUTS IN PLACE, SECURE, TYPE 8,8

HIGH TENSILE STEEL
3 STOPE CHUTE BODY UNDAMAGED
4 PNUEMATIC CONTROLS IN ORDER

CONDITION OF RADIAL DOOR, TRUNIONS SECURED AND NOT
5
EXCESSIVELY WORN
6 COMPRESSED AIR CYLINDER
7 COMPRESSED AIR LEAKS
8 COMPRESSED AIR CYLINDER ATTACHMENT POINTS
9 CONDITION OF COMPRESSED AIR HOSES, FITTINGS &

SUSPENSION
10 CONCRETE CONDITION
11 STEELWORK CONDITION (VISIBLE STEEL)

REMARKS
Responsible Artisan: ______________________
The original copy of this form to be filed at the responsible Engineer or other appointed for the entire
life of this box at the SAP PM office.
In addition a SAP works order needs to be generated and final inspection findings captured on SAP
as well.
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IDENTIFIED HAZARDS PERFORMING PTV and CONSTRUCTION OPERATIONS:
16.1.1.1.1.1 HAZARD / RISK 16.1.1.1.1.2 POSSIBLE RESULT 16.1.1.1.1.3 CONTROL

Search and make safe Apply seven
1. Bad hanging and sidewalls Falls of ground injuries to persons golden rules of barring Report
dangerous situations to your supervisor
Conduct early entry examinations to
2. Unidentified and
detect brows, slips, faults and dykes
unsupported brows, slips, Falls of ground injuries to persons
and support on both sides as per
faults and dykes
standard
3. Inadequate, defective or
persons not wearing No protection can result into Examine, maintain and wear PPE as
Personal Protective injuries prescribed by mine standards
Equipment
Do not bar hazardous ground prior to
4. Barring Falls of ground injuries to persons
installing temporary support
5. Methane Explosions and Supervisor to conduct tests as per std.
Gassing or injury to persons
intersections Immediately report any intersection
6. Presence of poisonous Report any strange smells or abnormal
Gassing of persons
gasses visible gasses to your supervisor
7. Not using correct tools for
Injury to persons as a result of Always use and maintain the correct
the task as specified by
improper tool usage tools as per standard
mine standard
8. Tip barricades not to
Persons falling into tips Ensure all tips are properly barricaded
standard
9. Supervisors not checking Explosions, fires or gassing of
Supervisors to check their instruments
their gas testing persons as a result of the
daily
instruments presence of harmful gases
10. Working places not being Undetected hazards or persons Working places must be watered down
watered down contracting lung diseases. as per standard
11. Unauthorised entry into old FOG injuries or gassing of Do not enter barricaded areas
areas persons
12. Substandard rigging or Undoing of rigs or wrong Report sub-standard rigging to the
signalling signalling can result into injury to supervisor and give signals as per code
persons of signals
13. Inadequate ventilation Heatstroke and gassing of Immediately report poor ventilation
persons conditions to your supervisor
14. Hot, humid conditions Persons contracting heatstroke Immediately report to your supervisor
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15. Lifting and handling heavy Back and other injuries to persons Handle heavy material as per standard
material
16. Slippery or steeply inclined Slip and fall injuries to persons Refrain from slippery surfaces and use
surfaces a safety belt
17. Unauthorised re-start of Injuries to persons in scraper Adhere to lock out procedures Do not
winches paths operate winches if you are not trained
and competent
18. Persons performing work Undoing of rigs can result into Never situate yourself or fellow
inside the triangle of pull serious injury to persons workman inside the Death Triangle
formed by the scraper when the winch is operational
ropes
19. Performing work near Exploding misfire Immediately report misfires to your
misfires supervisor
20. Pressurised Hoses and Injury to persons if fittings come Check hoses and fittings and
pipes loose under pressure immediately fix or replace defective
hoses and fittings
21. Excessive noise whilst Damage to hearing of persons Wear and maintain ear protection
drilling
22. Moving machinery and Improper handling can result into Correct handling as per mine standard
equipment injuries
23. Excessive accumulation of Lung diseases Water down properly
dust in air
24. Damage to hanging wall as Falls of Ground Follow direction and grade lines when
a result of poor drilling drilling
25. Poor visibility Persons unable to see hazards Drain water from air on a daily basis
and risks resulting into injury to and during the shift if necessary
persons (Watertraps)
26. Poorly constructed drilling Injuries as a result of persons Construct drilling platforms as per mine
platforms falling down platforms standard
27. Not using or not securing Injuries as a result of persons Always wear a safety belt that is
safety belts whilst falling down platforms or into properly secured when performing work
performing tasks on open excavations on a platform or over open excavations
platforms or over open
excavations
28. Limited clearance whilst Injuries by moving parts of Report limited, confined spaces to your
performing tasks machinery as a result of limited supervisor
clearance
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29. Persons not always alert to Injuries as a result of explosions, Be always alert of flammable and other
the presence of flammable or gassing of persons harmful gasses
gasses
30. Old explosives present in Explosions causing injury to Immediately report the presence of
the face and old areas persons explosives to your supervisor do no
tamper with explosives
31. Obstructions in Haulages Limited work clearance and Clear obstructions and / or report to
and Cross cuts possible slip and fall injuries your supervisor
32. Moving Rolling Stock Persons being run over by When performing work or travelling in
moving Rolling Stock tramways follow mine specific
procedures
33. Performing work in the Possible damage to equipment or Report damaged electrical equipment to
vicinity of electrical prior damaged equipment can your supervisor and when performing
equipment and cables result into injuries to persons work near electrical equipment follow
procedures
34. Unauthorised use of Lack of training and competence Do not use any equipment when not
equipment could result into injury to persons trained and found competent
HRD Officer to take the Learners to the Practical Construction X-cut and Learners to fully re- equip
the x-cut to the satisfaction to the HRD Officer
1) Install the full vent columns and fan
2) Install a rail turn out
3) Install tracks (Learners to be demonstrated how to bend a rail and how to break a rail)
4) Install drain segments
5) Extend tracks by means on Jump sets and Sliding rails
6) Install air and water services with manifolds
7) Install a drilling platform at the Face
8) Install a swinging barricade
17 Drilling; charging and Timing
17.1 Percussion Machine

Drilling Equipment
1. Rockdrills
Typically a lightweight Seco X215 Rockdrill is used. It has a percussion (hammering) as well
as rotating (turning) action. It is powered by compressed air, which should be supplied at a
pressure of at least 400kPa. The pipes must be within the mine standard from the face and
the hoses not have many joints (restrictions) or any leaks.
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Water passes through the machine in the water tube. It must not be tampered with or removed. The
water tube gap must be measured.
2. Telescopic Air legs

Telescopic air legs which are pneumatically powered push the Rock drill and thus the drill steel forward.
3. Drill steel
Typical lengths used for stoping are:
1,4m for face-holes (effective hole length 1,1m)

2,4m for all other development shot holes (effective hole length 2,1m) and roof bolt holes in crosscuts
and haulages.
1,8m for rig holes in ASGs.
1,5m for roof bolt holes in Raises, Winzes, Reef drives, and ASGs, as well as ASG shot holes.
4. Hoses and Fittings

25mm diameter for compressed air and 12m for water, both with wing nuts, stems and spuds.
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Percussion Machine
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Question 1
What must the water pressure be on a machine drill?
Answer 1
Question 2
How much water flow should there be through the drill steel?
Answer 2
Question 3
May a machine with obstructed front head release ports be used?
Answer 3
Question 4
What distance must the water tube be from the drill steel?
Answer 4
Question 5
May a branch connection be fitted to a hose supplying water to a machine?
Question 6
When must a water tube be examined?
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Answer 6
Question 7
May a machine with a damaged water tube be used?
Answer 7
Percussion Drill Machine
Question 1
What personal protective equipment does a machine crew require?
Answer 1
1. Long arm gloves.
2. Eye protection
3. Collaring gasket
4. Knee guards.
5. Ear protection.
Question 2
What tools and equipment does a machine crew require?
Answer 2
1. Jumper extractor.
2. Wire clamps.
3. Hose menders.
4. Spuds and stems.
5. 15cm nail.
6. Wrench.
7. 25mm compressed air hose.
8. 10mm water hose.
9. Lubricators.
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Question 3
What is the method of connecting up a percussion machine?
Answer 3
1. Connect compressed air and water hoses to manifolds.
Empty water taps on column.
Open valves on manifolds to check availability of air and water.
Check gaskets inside spuds.
Secure stems into spuds.
2. Blow out the hose.
Open control valves on manifold.
Allow compressed air to blow out hose for about 15 seconds.
Blow-out connection on machine.
Check for air or water leaks.
Check water pressure (min 150 kPa).
3. Rule of Thumb
Hold end of hose vertical water to discharge for a distance of at least 15cm vertical.
With hose connected to machine, hold machine vertical water to discharge for a distance of at
least 40cm vertical.
4. Close control valves on manifolds.
5. Connect lubricator to machine.
6. Connect compressed air hoses to lubricator and air legs.
7. Connect water hose to water tube connection.
8. Close control valves on machine and air legs.
9. Open control valves on manifolds.
10. Open control valve on machine halfway to lubricate the machine before starting to drill. For at least
1 minute.
Question 4
What are the duties of the machine crew?
Answer 4
1. To wear personal protective equipment.
2. To check the availability and condition of their equipment.
3. Rock drill operator must collect his lubricator on surface every morning before going
underground (sachet of lubricant).
4. The operators assistant must collect the required drill steel on the station.
5. Only to drill on the position, direction and dip as marked or indicated by the Competent
Person or miner.
6. To clean and store all equipment in a safe, clean and dry place when not in use.
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7. The operators assistant must return all drill steel to the station at the end of the shift.
8. All drill steel to be used in rotation.
9. Drill operator to return lubricator to surface for refilling at the end of the shift.
Question 5
What 3 defects can be encountered on a percussion machine drill?
Answer 5
1. Poor lubrication reduced penetration and rotation speed.
2. Loose side rods may result in machine not operating or poor performance and is recognized by a
slight air leak between the machines handles and body joint.
3. If the machine is not operating at all, the piston being in a position closing off the airport may cause
it. Inserting a drill rod into the chuck of the machine and pushing the piston back past the port can
rectify this. Ensure you do not ram it in to protect the water tube.
CHECKING OF ROCKDRILLS
Purpose
To check whether the rock drill complies with the Mines and Works Act and Regulations
Apparatus Required
Water tube gap rod
This rod is used the gap between the end of the water tube and the end of the jumper when in operating
position. There are many types of gap measuring rods. The simplest consist of a wooden rod approximately
300mm long and 20cm in diameter marked at 5cm intervals.
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RISKS REGARDING ROCKDRIL OPERATIONS
IDENTIFIED HAZARDS PERFORMING DRILLING OPERATIONS
HAZARD / RISK POSSIBLE RESULT CONTROL

35. Bad hanging and sidewalls in Falls of ground injuries to
golden rules of barring Report
scraper gullies and stope face persons
36. Temporary support not installed to Falls of ground injuries to Install support according to mine
standard persons standard
37. Distance of permanent support to Falls of ground injuries to Install support according to mine
face are sub - standard persons standard
38. Unidentified and unsupported Falls of ground injuries to
detect brows, slips, faults and dykes and
brows, slips, faults and dykes persons
support on both sides as per standard
39. Inadequate, defective or persons
No protection can result into Examine, maintain and wear PPE as
not wearing Personal Protective
injuries prescribed by mine standards
Equipment
Conduct proper early entry exams, water
Drilling into misfires will cause
40. Undetected misfires in the stope or down properly as to detect misfires.
the misfire to explode causing
gully face Immediately report misfires to your
injury to persons
supervisor
Falls of ground injuries to Do not bar hazardous ground prior to
41. Barring without temporary support
persons installing temporary support
42. Methane Explosions and Supervisor to conduct tests as per std.
43. Temporary support not installed Falls of ground injuries to Never perform work in unsupported
prior to commencement of work persons areas
Report any strange smells or abnormal
44. Presence of poisonous gasses Gassing of persons
visible gasses to your supervisor
Injury to persons as a result
45. Not using correct tools during early Always use and maintain the correct
of improperly conducted early
morning examination tools as per standard
entry exams
Rock splinters can cause Wear the correct PPE and warn other
46. Breaking rocks
injuries to persons persons in the vicinity
47. Tip barricades not to standard Persons falling into tips Ensure all tips are properly barricaded
Explosions, fires or gassing of
48. Supervisors not checking their gas Supervisors to check their instruments
persons as a result of the
testing instruments daily
presence of harmful gases
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Undetected hazards or
49. Working places not being watered Working places must be watered down
persons contracting lung
down as per standard
diseases.
FOG injuries or gassing of
50. Unauthorised entry into old areas Do not enter barricaded areas
persons
Undoing of rigs or wrong Report sub-standard rigging to the
51. Substandard rigging or signalling signalling can result into supervisor and give signals as per code
injury to persons of signals
Heatstroke and gassing of Immediately report poor ventilation
52. Inadequate ventilation
Do not handle explosives if you are not
Explosions or underground
53. Improper handling of explosives trained and report improper handling to
fires
your supervisor
Persons contracting
54. Hot, humid conditions Immediately report to your supervisor
heatstroke
Back and other injuries to
55. Lifting and handling heavy material Handle heavy material as per standard
persons
56. Slippery or steeply inclined Slip and fall injuries to Refrain from slippery surfaces and use a
surfaces persons safety belt
Adhere to lock out procedures Do not
Injuries to persons in scraper
57. Unauthorised re-start of winches operate winches if you are not trained
paths
and competent
58. Persons performing work inside Never situate yourself or fellow workman
Undoing of rigs can result into
the triangle of pull formed by the inside the Death Triangle when the
serious injury to persons
scraper ropes winch is operational
Immediately report misfires to your
59. Performing work near misfires Exploding misfire
supervisor
Check hoses and fittings and
Injury to persons if fittings
60. Pressurised Hoses and pipes immediately fix or replace defective
come loose under pressure
hoses and fittings
61. Falls of ground when removing Injury to persons as a result Adhere to mine standards when
support of FOG removing support
Damage to hearing of
62. Excessive noise whilst drilling Wear and maintain ear protection
persons
63. Moving machinery such as drill Moving parts can pull persons Wear PPE and do not wear loose
jigs and rockdrills in or cause injuries to persons clothing whilst drilling
Ensure Air leg is properly secured prior
64. Slipping air leg Injury to persons
to opening the air valve
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65. Excessive accumulation of dust in

Lung diseases Water down properly
air
66. Damage to hanging wall as a Follow direction and grade lines when
Falls of Ground
result of poor drilling drilling
67. Explosives pumped under Explosives entering eyes of
Wear eye protection whilst charging up
pressure into shot holes persons
Persons unable to see
Drain water from air on a daily basis and
68. Poor visibility hazards and risks resulting
during the shift if necessary (Watertraps)
into injury to persons
69. Poorly constructed drilling Injuries as a result of persons Construct drilling platforms as per mine
platforms falling down platforms standard
70. Not using or not securing safety Injuries as a result of persons Always wear a safety belt that is properly
belts whilst drilling on a platform falling down platforms secured when drilling on a platform
Injuries by moving parts of
71. Limited clearance whilst Report limited, confined spaces to your
machinery as a result of
performing drilling operations supervisor
limited clearance
Injuries as a result of
72. Persons not always alert to the Be always alert of flammable and other
explosions, or gassing of
presence of flammable gasses harmful gasses
persons
73. Persons not performing charging Explosions causing injury to Conduct charging up operations as per
up operations as per standard persons standard
Immediately report the presence of
74. Old explosives present in the face Explosions causing injury to
explosives to your supervisor do no
and old areas persons
75. Not using the correct equipment to Exploding misfire causing Use the correct equipment as per mine
pump out misfires and sockets injury to persons standard
Support should only be removed as
76. Premature removal of support Falls of Ground injuries
prescribed by the standards
ECXERCISE
HRD Officer TO TAKE Learners to the Practice Development end
EXERCISE
1) HRD Officer to facilitate assembling of Machines
2) HRD Officer to Facilitate Development Face Preparation before drilling can commence
3) HRD Officer to let Learners operate the Machine and Air Leg inside the Practice Development end
4) HRD Officer to Facilitate of constructing a Drilling Platform
5) HRD Officer to take Learners and let them physically practise Collaring and Drilling of Development Holes
and Support Holes
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17.2 Charging up and timing
Charging Up
General
Once drilling is completed the face must again be barred solid. This is very important as drilling loosens rock
on the face, especially if the face is under pressure. Before the blast and/or as the shots detonate loose
rocks may fall onto and cut the igniter cord, or pull the shock tube out of the connectors when using shock
tube assemblies.
Anfex and low density Anfex readily dissolves in water losing power and becoming insensitive to detonation.
That is why it is so important to desludge the holes with compressed air and blow them dry.
There are several initiating systems on the market so we will use Shocktubes Fuses are inserted into the
holes and then filled with Anfex using a Lategan Loader.
N.B. Holes should only be charged to about 30cm from the collar.
Overcharging of holes can result in the following:
1)Damage to support.
2)Damage to blasting barricades.
3)Over break and damage to hanging wall and footwall.
N.B. All holes to be tamped using supplied tamping if required.
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Working with explosives and accessories

1. Only tools and equipment of which the construction and design are approved by the Chief Inspector of
Mines may be used when working with explosives.
2. Only containers of which the construction and design are approved by the Chief Inspector of Mines may
be used for the transporting and storing of explosives.
3. All containers must be lockable.
4. No person may smoke whilst working with explosives and no naked light may come closer than 10m from
any explosives.
5. Only a competent person may work with explosives.
6. When transporting or storing explosives the following must be complied with.
o Cartridge explosives must be stored and transported separately from any other explosives.
o Ammonium nitrate based explosives must be stored and transported separately from any other
explosives.
o Shock tube initiators may be transported and/or stored together but separately from any other
explosives.
Explosives and accessories remaining on completion of charging operations

1. Explosives are separated into their different categories and placed in lockable transport containers
2. Explosives are transported to and locked in their respective containers, ensuring that the required
quantities are not exceeded
Explosive accessories not used during timing are transported and stored according to specified
requirements.
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3. Explosives are separated into their different categories i.e. primers are dismantled into shock tube and
cartridges, excess burning cord, fuses and explosives are collected
4. All excess explosives and accessories are placed in separate lockable transport containers.
Reporting
At the end of shift give full reports to your supervisor regarding:
1. Problems experienced during the shift.
2. Hazardous areas to be attended to
3. Hazards dealt with
4. Accidents and incidents
Timing
1. Once the drilled holes to be charged have been effectively de - sludged timing of holes can commence
2. The timing of the round commences from the cut of the A.S.G. to create a free breaking point for the
stope face
3. The cut is timed in such a way that the shock tubes in the cut initiate first and the easers second and so
on
4. The inner holes are always initiated before the sides
5. All the perimeter holes are initiated after the inner holes to reduce surrounding rock damage
6. The free breaking point of the Stope face is charged with a EZ Stoper, initiated with a EZ trunk line
shock tube
7. The remainder of the holes up to the top of the Stope face are timed in sequence with the remaining
shock tubes, to ensure sequential blasting
8. Once the priming of the A.S.G and the face has been completed the connecting process begins
9. Connections must be sequence with all the shock tube connector blocks facing in the direction of
initiation
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Shock Tubes
TIMING A ROUND
Unsafe ground conditions
1. When encountering friable unsafe ground conditions, remove all workers to a safe well-ventilated area.
2. Barricade off the affected area and inform your supervisor and/or the person in charge of the workplace to
deal with the unsafe ground conditions.
Typical unsafe ground conditions are:

1. Loose rocks.
2. Unsupported slips.
3. Unsupported faults.
4. Unsupported dykes.
5. Unsupported brows.
6. Unsafe support conditions.
7. Friable ground conditions
Unsafe support conditions

1. When encountering unsafe support conditions, remove all workers to a safe well-ventilated area.
2. Barricade off the affected area and inform your supervisor and/or the person in charge of the workplace to
deal with unsafe support conditions.
Typical unsafe support conditions are;

1. Support not to mine standard
2. Damaged support.
3. Missing support.

Risks related to the working with explosives and accessories are;
1. Explosions, and
2. Fires
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Requirements
1. All persons handling explosives must be adequately trained in the handling of explosives.
2. No person may use contraband whilst handling explosives.
3. All explosives and accessories must be transported and stored in lockable containers.
4. The construction and design of explosive containers must be approved by the Principle Inspector of Mines
and it must be the type supplied by Management.
5. Explosives and accessories must not be exposed to any condition that might cause heat conditions.
6. No person may handle frozen explosives.

Risks related to explosives and accessories remaining on completion of charging operations are;
1. Explosions
2. Fires
3. Inadvertent detonation during cleaning operations
4. Explosive theft resulting in possible sabotage
5. Premature initiation of the round
Requirements
Explosives are separated into their different categories and placed in lockable transport containers
Explosives are transported to and locked in their respective containers, ensuring that the required quantities
are not exceeded
When timing a round or circuit with shock tubes, the following requirements must be followed:
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1. Always start timing at the cut
2. The cut is timed with the shock tubes that have the lowest number
3. The easers are timed with the next lowest number
4. The remaining holes are timed with the following lowest numbers in sequence up to the inner perimeter
holes
5. The perimeter holes are timed with the highest numbered shock tubes
6. The initiating cord (cortex) is connected to the shock tubes in such a way as to ensure that the blast is
initiated in sequence from the lowest numbered shock tube to the highest numbered shock tube.
Applications of and reasons for various timing patterns:
Ground conditions, types and quantities of explosives used are the main factors that influence the mines
guidelines on which patterns should be used.
The following patterns are typically used:
1 Burn cut
2 Sliping
Burn cut:
The burn cut is so called because the concentrated charges of explosives literally burn out the initial opening
(cut) into the solid rock. It consists of a number of parallel holes which are used to provide a free breaking
face for the rest of the round and the burn cut is normally used in raises and ore passes.
Sliping:
Sliping is holes that are drilled to enlarge existing tunnels or areas and are drilled as per requirements
Concept of the EZ Drifter.

The connection concept is as follows:
Connect the EZ Drifter connector block of the first unit to the shock tube of the next unit.
As per sketch one can see that the signal comes from the shock tube of the unit that was detonated initially.
If more than one unit is to be initiated, up to three shock tubes can be inserted into the connector block.
The micro cap or surface detonator has a delay of 200ms before it detonates the shock tube of the next unit.
After the shock tube of the next unit has been initiated the signal travels in both directions, setting off the in-
hole detonator and the surface detonator.
Before the next surface detonator in the connector block detonates, it again has a delay of 200ms.
The in-hole detonator has a delay of 3800ms before it detonates the explosives in the charge hole.
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3800 divided by 200 equals nineteen (19). Therefore 19 surface detonators in the connector blocks will
initiate, before the first in-hole detonator detonates.
BURN CUT DRILL DESIGN
TL
CUT DESIGN & CONNECTIONS
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NINE HOLE BURN-CUT
EZ Drifter
Cut rules:
Holes must be drilled on the marks
Use the correct design
Drill holes to the correct length
Holes must be parallel
All the holes must be drilled
Only one hole must fire at a time, EZ Trunkline
to avoid excessive cast & pipe
damage
BURN FRONT
An important benefit of the EZ Drifter nonelectric initiation system is that it provides the blaster with a
consistent burning front, i.e. the distance the connector blocks initiate ahead of the exploding holes.
The system provides a 19 connection burning front. When the tube of the first hole has been initiated, the in-
hole detonator will fire only 2.0 seconds later. Between this initiation and firing time of the detonator, 19
connections (3800ms/200ms =19 connections) up the panel have initiated their in-hole detonators.
Shock tube initiates at 2000ms

Average blasting time for a tunnel = 2 to 2.5sec
Average blasting time for a panel = 20 to 21sec
Detonators are equivalent to a 8D detonator

Shock tube products do not:
Burn with a flame (not visible)
Produce fumes / gasses (no smell)

Smoke (not visible)

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THE DOS AND DONTS OF EZ DRIFTERS
ALWAYS
1. Always Treat as an explosive.
2. Always Transport and store in accordance with the
regulations.
3. Always Ensure there are minimal loops, slack or kinks in
the shock-tube
NEVER
4. Always Use an EZ Drifter for what it was made.
5. Always Treat misfires as per regulations.
6. Always Remember the connector block contains a
detonator and must be treated accordingly.
1. Never Maltreat product, or expose to unintended energy.
2. Never Cut or trim units.
3. Never Kink or place undue tension on shock-tube.
4. Never Dismantle detonators.
5. Never Expose to temperatures of more than 65C.
6. Never Use an EZ Drifter for anything other than
what it was made for.
7. Never Allow units to be entangled with
equipment etc.
8. Never Use damaged units.
BEST PRACTICE
MASTERSTARTERS
Do not wrap the

shock-tube
around the
mini-det plastic
Ensure that the connector
Masterstarter
does not cross
over and come
into contact

with the shock-
tubes
Do not connect
the igniter cord
connector to
the shock-tube
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EZ DRIFTERS
Correct and Incorrectly connected Connector Blocks
Ensure that not

more than six (6)
Shocktubes are

inserted into the
DO NOT
Connector Block
overload the
Connector
Ensure that
Shocktubes do
Block with
Shocktubes

not cross-over
in the Ensure that
Connector Shocktubes are
Block fully inserted
Ensure that
Shocktubes are
completely
into the
Connector
Block
inserted into the
Connector
Block
Precautions to prevent inadvertent entry of persons:

Ensure that the required precautions are taken to prevent inadvertent entry of persons.
Adhere to mine specific requirements in terms of barriers, guards and/or notices.
Persons inadvertently entering may disrupt the timing and connecting process or may not be aware of
the risks associated with timing and connecting, which may lead to personal injury.
Timing requirements:
From the breaking point, connect the connector block of the first unit to the shock tube of the next unit.
Connect the connector block of each following unit to the next until all the charged shot holes on the
developing end face has been connected.
The signal comes from the shock tube of the unit that was detonated initially.
If more than one unit is to be initiated, up to three shock tubes can be inserted into the connector block.
The micro cap or surface detonator has a delay of 200ms before it detonates the shock tube of the next unit.
After the shock tube of the next unit has been initiated the signal travels in both directions, setting off the in-
hole detonator and the surface detonator.
Before the next surface detonator in the connector block detonates, it again has a delay of 200ms.
The in-hole detonator has a delay of 3800ms before it detonates the explosives in the charge hole.
Connect the J hook end of the trunk line to the first shock tube unit and leave the other end of the trunk line
where the person responsible for initiating the blast can connect it to the appropriate detonator.
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If the timing and connecting procedures are not correctly done (according to specified requirements, misfires
may occur which will result in production delays.
Burn cut
1. The nine hole burn cut is the most commonly used cut in platinum mining and consists of a stab hole
with eight holes drilled 15 cms apart commencing from the stab hole
2. When timing the round with shock tubes, the inner 4 holes of the burn cut are charged with no. 1s.
Note: The stab hole is not timed
3. The outer 4 holes of the cut (cut easers) are timed with no.2s
4. The remaining holes up to the inner perimeter holes are timed systematically with the remaining shock
tubes, from lowest number to highest
5. The perimeter holes are then all timed with same highest remaining shock tubes
6. The remaining holes up to the inner perimeter holes are timed systematically with the remaining shock
tubes, from lowest number to highest
7. The perimeter holes are then all timed with same highest remaining shock tubes
Sliping
1. Sliping usually has a free breaking point and is drilled that the holes break to the free breaking point
2. When timing sliping the lowest numbered shock tubes are used
Teamwork is important to achieve the maximum safe results and includes the following:
1. Two-way communication - communicate all work to be done with the team. Ask for ideas, listen
carefully and implement the best idea/solution.
2. Addressing subordinates - when addressing subordinates, always remember that they are people with
feelings. Address them in the same manner that you like to be addressed.
3. Avoiding conflicts - avoid conflict at all times. If conflict is inevitable, ask your supervisor to intervene.
4. Feedback-give appropriate feedback regarding important matters.
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The shock tubes collected must be inspected for and transported as follows:
1. The required number of shock tubes must be collected
2. There is a sufficient number of shock tubes of each number group available
3. The plastic tubing must not be broken, bent or in any other way damage
4. The number sticker must be on the shock tube
5. The shock tubes must be transported separately in an approved lockable transport container
Timing the blasting round or circuit in the developing end is.

1. Once the drilled holes to be timed have been effectively de-sludged timing of holes can commence
2. The timing of the round commences from the cut
3. The cut is timed with no.1 shock tubes and the cut easers with no.2 shock tubes
4. The inner holes up to the side and top hole easers are timed with no. 3, 4, 5 and 6 shock tubes
5. All the perimeter holes are charged with the highest numbered remaining shock tubes
6. Once the timing has been completed the connecting process begins
7. Connect the initiating cord (cortex) to the cut first in order of initiation, then connect the remaining shock
tubes in number sequence from the cut to the perimeter holes
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1. Only tools and equipment of which the construction and design are approved by the Inspector of Mines
may be used when working with explosives.
2. Only containers of which the construction and design are approved by the Inspector of Mines may be
used for the transporting and storing of explosives.
3. All containers must be lockable.
4. No person may smoke whilst working with explosives and no naked light may come closer than 10m
from any explosives.
5. Only a competent person may work with explosives.
6. When transporting or storing explosives the following must be complied with;
o Cartridge explosives must be stored and transported separately from any other explosives.
o Ammonium nitrate based explosives must be stored and transported separately from any other
explosives.
o Fuses, burning-cord and initiators may be transported and/or stored together but separately from any
other explosives.

1. Explosives are separated into their different categories and placed in lockable transport containers
3. Explosives are separated into their different categories i.e. primers are dismantled into fuses and
cartridges, excess burning cord, fuses and explosives are collected
4. All excess explosives and accessories are placed in separate lockable transport containers.
Explosives are transported to and locked in their respective containers, ensuring that the required quantities
are not exceeded
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RISKS PERTAINING TO CHARGING-UP AND TIMING
IDENTIFIED HAZARDS PERFORMING CHARGING-UP OPERATIONS
17.2.1.1.1.1 HAZARD / RISK 17.2.1.1.1.2 POSSIBLE RESULT

17.2.1.1.1.3 CONTROL
Bad hanging and sidewalls in Falls of ground injuries to
golden rules of barring Report
scraper gullies and stope face persons
Temporary support not installed Falls of ground injuries to Install support according to mine
to standard persons standard
Distance of permanent support Falls of ground injuries to Install support according to mine
to face are sub standard persons standard
Unidentified and unsupported Falls of ground injuries to
detect brows, slips, faults and dykes and
brows, slips, faults and dykes persons
support on both sides as per standard
Inadequate, defective or
No protection can result into Examine, maintain and wear PPE as
persons not wearing Personal
injuries prescribed by mine standards
Protective Equipment
Conduct proper early entry exams, water
Drilling into misfires will
Undetected misfires in the stope down properly as to detect misfires.
cause the misfire to explode
or gully face Immediately report misfires to your
causing injury to persons
supervisor
Barring without temporary Falls of ground injuries to Do not bar hazardous ground prior to
support persons installing temporary support
Methane Explosions and Supervisor to conduct tests as per std.
Temporary support not installed Falls of ground injuries to
Never perform work in unsupported areas
prior to commencement of work persons
Report any strange smells or abnormal
Presence of poisonous gasses Gassing of persons
visible gasses to your supervisor
Injury to persons as a result
Not using correct tools during Always use and maintain the correct tools
of improperly conducted early
early morning examination as per standard
entry exams
Tip barricades not to standard Persons falling into tips Ensure all tips are properly barricaded
Explosions, fires or gassing
Supervisors not checking their Supervisors to check their instruments
of persons as a result of the
gas testing instruments daily
presence of harmful gases
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Undetected hazards or
Working places not being Working places must be watered down
persons contracting lung
watered down as per standard
diseases.
Unauthorised entry into old FOG injuries or gassing of
Do not enter barricaded areas
areas persons
Undoing of rigs or wrong Report sub-standard rigging to the
Substandard rigging or
signalling can result into supervisor and give signals as per code
signalling
injury to persons of signals
Heatstroke and gassing of Immediately report poor ventilation
Inadequate ventilation
Do not handle explosives if you are not
Explosions or underground
Improper handling of explosives trained and report improper handling to
fires
your supervisor
Persons contracting
Hot, humid conditions Immediately report to your supervisor
heatstroke
Lifting and handling heavy Back and other injuries to
Handle heavy material as per standard
material persons
Slippery or steeply inclined Slip and fall injuries to Refrain from slippery surfaces and use a
surfaces persons safety belt
Adhere to lock out procedures Do not
Unauthorised re-start of Injuries to persons in scraper
operate winches if you are not trained
winches paths
and competent
Persons performing work inside Never situate yourself or fellow workman
Undoing of rigs can result into
the triangle of pull formed by the inside the Death Triangle when the
serious injury to persons
scraper ropes winch is operational
Immediately report misfires to your
Performing work near misfires Exploding misfire
supervisor
Not using the correct equipment Use equipment as described according
Exploding misfire
to treat a misfire to mine standards
Improper handling of explosive Follow mine standards and procedures
Explosions
while charging-up when conducting charging-up operations
Transporting explosives (not Follow mine standards and procedures
Explosions
using approved containers) when transporting explosives
Ensure explosives is stored in approved,
Not storing explosives correctly Explosions
locked containers as per mine standard
Injury to persons if fittings Check hoses and fittings and immediately
Pressurised Hoses and pipes
come loose under pressure fix or replace defective hoses and fittings
Excessive noise whilst drilling Damage to hearing of Wear and maintain ear protection
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persons
Excessive accumulation of dust
Lung diseases Water down properly
in air
Damage to hanging wall as a Follow direction and grade lines when
Falls of Ground
result of poor drilling drilling
Explosives pumped under Explosives entering eyes of
Wear eye protection whilst charging up
pressure into shotholes persons
Persons unable to see
Drain water from air on a daily basis and
Poor visibility hazards and risks resulting
during the shift if necessary (Watertraps)
into injury to persons
Not using or not securing safety
Injuries as a result of persons Always wear a safety belt that is properly
belts whilst charging-up on a
falling down platforms secured when charging-up on a platform
platform
Limited clearance whilst
Injuries as a result of limited Report limited, confined spaces to your
performing charging-up
clearance supervisor
operations
Injuries as a result of
Persons not always alert to the Be always alert of flammable and other
explosions, or gassing of
presence of flammable gasses harmful gasses
persons
Persons not performing
Explosions causing injury to Conduct charging up operations as per
charging up operations as per
persons standard
standard
Immediately report the presence of
Old explosives present in the Explosions causing injury to
explosives to your supervisor do no
face and old areas persons
Not using the correct
Exploding misfire causing Use the correct equipment as per mine
equipment to pump out misfires
injury to persons standard
and sockets
Premature removal of Support should only be removed as
Falls of Ground injuries
temporary support prescribed by the standards
Damage to explosives boxes Supervisor to always have his explosive
No explosive box keys.
and/or keys boxes keys on his person
Persons charging up the face Explosions as a result of Never commence with charging up of
whilst drilling of holes are still in RDOs drilling into shotholes holes if the drilling of all shotholes hasnt
progress. already charged up. been completed.
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EXCERCISE
1) HRD Officer to present Power point presentation on Blasting Products and their usage
2) HRD Officer to practically facilitate the receiving and storage of Explosives with example of a control book
till Learners can do the Balance sheets of the explosives control
3) HRD Officer to Facilitate the construction of Explosive Boxes and spacing thereof
4) HRD Officer to present Power point presentation on Timing and sequential firing
5) HRD Officer to facilitate Timing in the underground models
6) HRD Officer to arrange and visit the actual blasting models
7) HRD Officer to charge up and time panel together with the Learners in the exercise Development end.
8) Return the next day measure the advance and facilitate the previous day breaking of the end this to
measured and plot on the 1;200 plan
18 Water Control
WATER CONTROL
Question 1
Sketch a plan view of a development end showing single cover drilling.
Answer 1
Single cover drilling
Question 2
Sketch a plan view of a development end showing double cover drilling.
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Answer 2
FULL OR DOUBLE COVER DRILLING
Question 3
To what length are pilot holes drilled in relation to the length of the round?
Answer 3
One and a half times the length of the longest hole drilled in the round.
Question 4
Sketch the position and direction of pilot holes in:
1. Lateral ends
2. Inclined ends
Answer 4
Question 5
How many litres of water are required to fill a hard hat?
Answer 5
Two litres.
Question 6
What should the developer check as to the condition of a pilot board?
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Answer 6
Painted red
Fully equipped
Positioned as per mine recommended procedure
Question 7
List the contents of a pilot board.
Answer 7
2 x telescopic pipes fitted with T-pieces and HP Cocks
2 x tapered pipes fitted with T-pieces and HP Cocks
6 x steel wedges
6 x wooden wedges
2 x clamps
4 x 1,0m eyebolts with expanding shells
4 x 25mm nipples
2 x 2m x 10mm long link chain.
Question 8
When will one use the emergency hole plugging equipment?
Answer 8
To assist in plugging holes where the quantity and pressure of water intersected is too great to be plugged
with the pilot board equipment.
Question 9
Where must the emergency hole plugging equipment be kept underground?
Answer 9
On each shaft station and must be labelled as such.
Question 10
Describe the procedure when intersecting water.
Answer 10
Stop drilling (all work)
Withdraw all persons
Test for methane
Estimate quantity of water (rule of thumb):
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If it is a large quantity that could affect the pumping operations of the mine plug immediately.
If it is only a small amount of water allow it to run for 2 hours and then plug it
Report to your Shift boss / Shift Supervisor.
Question 11
Describe the procedure to plug a hole with a telescopic pipe.
Answer 11
Drill two eyebolt holes 30cm on either side of the hole issuing water and insert eyebolts
Insert telescopic pipe into the hole (HP Cock open)
Tighten coupling at back of the telescopic pipe so as to expand the rubber washers inside the hole
until they affect a tight grip.
Wedge the pipe into position with steel wedges and plug the gaps between the steel wedges with the
wooden wedges
Secure clamp around telescopic pipe and secure with chains to eyebolts.
Close of HP Cock
Nobody must be in direct line behind pipe when closing HP Cock.
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DIAMOND DRILL SAFETY RIG
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STANDARD 12mm TELESCOPE PIPE
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19 Cleaning
METHODS TO CLEAN DEVELOPMENT ENDS

FLAT END
Jumpsets consisting of 3m lengths of 22kg rail with 10mm plate welded sleepers are used between the
permanent rails and sliding rails which are pushed forward in an inverted position by the loader and are held
in position by G clamps.
The footwall of the haulage is carried at drain level to allow adequate depth for the rail, the sleeper and the
drain.
Permanent rails are kept within 18 meters of the face. (3 Jumpsets plus sliding rail length).
Loaders operated by compressed air loading rock into hoppers and which are trammed by a loco to the main
tips at the shaft station.
Calculate the tonnage blasted

Dimensions 3,2 x 2,7m
Advance 1,8m
RD 2,7
Tons = Volume x density
Tons = 3.2 x 2.7 x 1.8 x 2.7 = 42 Tons
RAISES AND WINZES

Dipping at 10 to 25 winches with scrapers are to be used to clean these ends.
BOX HOLES
Rock gravitates down box holes. Initially a mechanical loader is used to clean the stuff. Once box holes are
developed, they must be equipped with a Boxfront and chute with controls and air cylinder. The stuff can
then be cleaned directly into a hopper.
Question 1
When an ore pass has holed into a raise, what must be done before work may resume in the raise?
Answer 1
Means must be provided to prevent persons from inadvertently falling into the ore pass.
A box front must be installed before a robust grizzly is installed and the platform is removed.
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Question 2
Name the safety requirements at a stope tip.
Answer 2
Must be effectively barricaded off.
A travelling way around the tip.
Notice No Entry on barricade.
Properly constructed grizzly.
Correct tools for clearing the grizzly.
Lighting.
Proper drains to avoid water entering tip.
Hanging wall to be well supported.
Safety belt goggles and gloves available
Certificated driver, or trained and experienced person to work on the tip.
Never blast big rocks on grizzly.
Do not over-fill the tip.
Repair any damage to grizzly immediately.
Signalling device to be within reach.
Question 3
What safety precautions must be adhered to when persons are working on a close to a haulage way?
Answer 3
Effective warning signs shall be placed at safe distances on either side of such persons to warn a driver of
their presence.
When persons are working on railway lines, stop signs shall be placed at a safe distance on either side, and
the driver of the locomotive shall not proceed beyond such stop sign, unless permitted to do so by the person
in charge of the work.
Persons working on railway lines shall wear reflective strips on their clothing.
MACHINERY
REASON FOR THE MODULE

The mine as an assistance to reduce time, labour and costs and to increase production supplies different
types of machinery
Machinery can only be utilised effectively when they are in a good condition, well maintained and operated
according to the laid down procedures
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Many accidents have already resulted through not adhering to the Legal requirements and recommended
procedures pertaining to the safe handling and use of machinery
This module provides both knowledge and skills which is required for the effective and safe use of machinery
RESOURCES
Consult - Module
- HRD Officers
- Mines Health and Safety Act and Legal requirements
MODULE CONTENT
1. Mines Health and Safety Act and Legal requirements
2. Locomotive Tramming
3. Mechanical Loader
LEGAL REQUIREMENTS
OBJECTIVE
ACTION : Answer questions in writing
CRITERION : Answer to comply with the information given in the

Mines Health and Safety Act and Legal requirements
SUB OBJECTIVE
GIVEN : No reference
ACTION : Recall from memory the answer to the questions
CRITERION : Answer to comply with the information given in the

Mines and Works Act and Legal requirements
DEVELOPMENT
LEGAL REQUIREMENTS
LOCOMOTIVE TRAMMING
Question 1
Who may drive a locomotive?
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Answer 1
Question 2
Who may ride on any car or truck underground?
Answer 2
Question 3
Who may ride on the buffer of a loco or hopper?
Answer 3
Question 4
When may a person board or alight from a locomotive or any other vehicle whilst it is still in motion?
Answer 4
Question 5
Must all trains have lights underground?
Answer 5
Question 6
Under what conditions are locos allowed to operate in the underground workings of a mine?
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Answer 6
Question 7
i. What is required of the air entering an engine, and
ii. Of the exhaust gases being expelled by the engine?
Answer 7
Question 8
Where must equipment for extinguishing fires be kept concerning locomotive Tramming underground?
Answer 8
MECHANICAL LOADER
Question 1
Who may drive a mechanical loader?
Answer 1
TYPES OF LOCOS
Example BATEMAN TRIDENT
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TYPES OF LOADERS
ATLAS
EIMCO
SALZGITTER
LOCOMOTIVE TRAMMING
RECOMMENDED PROCEDURE ON THE MINES REQUIRE:
1. Each locomotive shall be equipped with a key lock system. The operation of each locomotive shall only
be enabling while the key is engaged and removal of the key shall institude immediate fail-safe
shutdown of the control system.
2. Testing device should be installed at the battery bay or in the haulage, depending on the level layout, to
test whether the locomotive unit is functioning properly. Test shall be done at the start of shift and if not
functioning the locomotive shall be stopped and the electrician called to replace.
3. Locomotive lights are according to Anglo specification AMS 100 and OEM specifications.
4. Both white lights shall be illuminated in direction of travel with one light as the minimum requirement.
5. Red lights shall flash on both sides of the train when stationery
6. The reading should exceed the minimum level of 10 lux. Should the reading not be achieved the
locomotive shall be taken out of service until rectified
7. Every locomotive shall be equipped with an effective braking system. This shall include a combination of
service, park and emergency brake configurations, to hold the loaded train at a gradient of 1 in 200 or
as per tables for gradients other than 1 in 200.
8. Locos to stop at intersections. Stop signs, fouling marks and T-sprags are standard requirements at
these intersections
9. The sounding of hooters or bells when approaching blind corners or when passing persons is require
10. Coupling hooks to be used for coupling or uncoupling of rolling stock
11. All guards must have whistles and the loco must only move on signals from the guard
BEFORE GOING UNDERGROUND

1. Collect loco lamp and loco key from lamp room and inspect the lamp
2. Collect coupling hook from tool store
3. The driver should always notify his guard when it is known that he will not be at work
RESPONSIBILITY OF DRIVERS
1. The operator is issued with a license to operate the locomotive and the license must always be on
his/her possession.
2. The operator must be updated in the requirements of the task at intervals as decided by the Health and
Safety Committee of the mine.
3. Only a competent licensed person may operate a locomotive.
4. The locomotive operator must be appointed to do the task.
5. The requirements for appointments are: He/she must be familiar with the workplace and work-related
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hazards applicable to the operation of a locomotive.
BEGINNING OF SHIFT BEFORE OPERATING THE LOCO

1. Conducting a pre-use inspection make use of the checklist
Locomotive examination
1. Before conducting a pre-use inspection, sprag the locomotive by applying the loco brake and placing a
skid sprag in front of the front wheel and one behind the rear wheel.
2. Check the loco cabin, it must be clean and free of material, equipment and unnecessary tools.
3. The fire extinguisher must be situated inside the operators cabin. Check visible damage, service date,
locking seal and ensure it is full.
4. Check the rubber lining on the chair; it must be secured properly and without damage.
5. Press the chair downwards and ensure the spring is in order.
6. Ensure the adjusting bolt with its chain is in place and in order
7. Ensure the control handle operates smoothly by moving it forward and backwards.
8. Ensure the hand brake wheel operates smoothly by turning it in a clockwise and anti-clockwise position
9. Test the siren.
10. Check the rear and front lights
LOAD A BATTERY ONTO AND REMOVE IT FROM A LOCOMOTIVE

1. Park the locomotive at the stop block close to the battery stand; fasten the handbrake by turning it in a
clockwise direction and sprag the locomotive with a short piece of chain or skidsprag.
2. Disconnect the power plug and remove the battery securing pins.
3. Ensure there are no persons positioned in the path of the crawl and with the control panel, maneuver it
so that the lifting equipment is positioned above the battery. Lower the lifting equipment onto the battery
and attach it to the four lugs/shackles at the four corners of the battery casing.
4. Give warning to persons standing in close vicinity and in the crawl pathway; use the control panel and
lift the battery off the locomotive chassis till it clears the locomotive chassis casing.
5. Get assistance and steady the battery to prevent it from swinging. Care must be taken not to stand
underneath the battery whilst steadying it.
6. Whilst steadying the battery, maneuver the battery until it is aligned with the locomotives chassis or with
the battery stand, depending where it must be placed. Slowly lower the battery whilst the operator and
assistant guide the battery to its position. Whilst guiding the battery to its position, care must be taken
not to put your hands underneath the battery or at the bottom corners.
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7. Once the battery is in its position, secure it with the locking pins.
OPERATOR THE LOCOMOTIVE

1. Before setting the locomotive into motion, the operator must ensure that all persons in close vicinity of
the locomotive are safely positioned and must sound the siren of the locomotive to warn persons of
his/her intension to move the locomotive.
2. The operator reacts to signals given by the guard on his/her pea whistle.
3. To move the locomotive into a direction, the locomotive key is inserted into the control. Moving the
control forward will cause a forward movement of the locomotive and moving the control backwards will
cause the locomotive to move backwards
4. The travelling speed of the locomotive is determined by how far the control is pushed into a direction. To
maintain a certain speed, push the control into the required direction until the correct travelling speed is
obtained.
5. The required travelling speed is normally equivalent to the travelling speed of a person walking fast.
6. To stop the locomotive, reduce speed by manipulating the control to neutral position and by turning the
brake wheel in clockwise direction
Maintaining the required travelling speed

1. The travelling speed of the locomotive is determined by how far the control is pushed into a direction. To
maintain a certain speed, push the control into the required direction until the correct travelling speed is
obtained.
2. The required travelling speed is normally equivalent to the travelling speed of a person walking fast.
Stopping the locomotive

1. To stop the locomotive, reduce speed by manipulating the control to neutral position and by turning the
brake wheel in clockwise direction.
RESPONSIBILITIES OF LOCO GUARD

Loco guards shall:-
Reduce speed and stop the locomotive in front of the arresting device.
The loco guard enters the intersection and ensures the way is clear for the locomotive to enter. He removes
the arresting device, walks into the intersection, checks again if the way is clear, checks if the switch position
is correct and gives the signal to the loco operator to proceed. Whilst the loco is proceeding into the
intersection the loco guard gives warning with his pea whistle.
The loco guard repositions the arresting device once the locomotive has passed the switch position.
Once the arresting device is repositioned the loco guard changes the direction of the switch to its original
position, takes his place in the guard car and signals to the loco operator to proceed.
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VENTILATION DOORS
1. Slow down the locomotive and stop in front of the arresting device.
2. The loco guard removes the arresting device and proceeds to the ventilation door.
3. He/she opens the trap door in the large ventilation door to reduce air pressure. Once the air pressure is
reduced he opens the small door, enters and checks if the way is clear for the loco to enter. If there is
no oncoming traffic he/she opens the arresting device on the inside, opens the large door and signals
for the locomotive operator to enter.
4. Once the locomotive has entered the area between the two ventilation doors the loco guard repositions
the first arresting device, closes the ventilation door and repositions the second arresting device. He
now signals for the loco operator to proceed to the second door.
5. Repeat the procedure when opening the other ventilation doors.
AT VENTILATION DOOR
1. Care must be taken not to take the door on the edge when opening it. When opening ventilation doors
make use of the handles that are secured on the door.
2. Do not attempt to open the ventilation door if the air pressure is not released.
3. Ventilation doors must be kept closed at all times.
4. Arresting devices must be in position and closed at all times to prevent unauthorised entry of other
rolling stock.
Negotiating bends, rail turnouts and restricted areas

1. Bends and restricted areas are normally indicated by red shining lights. To negotiate bends and
restricted areas, reduce speed and if unsure due to poor visibility etc, the guard must disembark and
guide the locomotive through the area.
2. When approaching rail turnouts, the operator must reduce speed and stop in front of the arresting
device. The guard disembarks and checks all directions to ensure that the way is clear of other rolling
stock, changes the direction of the switch, open the arresting devices and gives the signal for the
locomotive to enter the area.
3. Once the locomotive has entered the area, the guard repositions the arresting device, change the
switch to its original position, gets on the loco chair and gives the signal to proceed.
Negotiating traffic control systems and barricades

1. The locomotive operator must stop at barricades that are positioned to prevent entry of rolling stock into
an area. No persons other than the person who has positioned the barricade may remove or open it.
2. When approaching traffic control systems, the operator must reduce speed and stop in front of the
arresting device. The guard gets off his chair and check on the colour of the robot or on the tags on the
tagging system board. If the robot is red or tags are placed on the x/cut/haulage or drive to be entered
the locomotive must remain stationary until the way to be entered is clear.
3. If the robot is green and/or if there are no tags on the tagging system board, the guard changes
direction on the switch, opens the arresting device and gives the signal for the locomotive to enter.
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4. Once the locomotive has entered, the guard closes the arresting device, changes the switch to its
original position and changes the robot to red and/or place the locomotive tags on the tagging system
board and signals for the locomotive to proceed.
Transport rock, material and equipment by means of rolling stock

1. All material cars are to be pulled with the locomotive. No pushing of cars with the locomotive is allowed.
2. The loco lamp must be shining and a loco lamp in red mode must be attached to the rear of the last car.
3. No riding on material cars is permitted.
4. An agterloper positioned behind the material cars accompanies the train as it proceeds into the
section.
Transport rock
1. Signal to the driver to move forward until the tail end hopper is positioned under the box
2. Signal to the driver to move the loco forward until the next hopper is in position underneath the chut
then signal the driver to stop (Last hopper first to be filled
3. Check conditions at the ore pass box before pulling ore:-
4. Check for spillage on the platform and scrape off with a shovel into the hopper below if any.
5. Check if the ladder and handrail is in order.
6. Check if bothhopper anti-roll devices is in position before pulling ore from ore pass.
7. Check hanging wall and side wall in box hole cubby.
8. Inspect the air connections to the control box and cylinder, condition of hoses etc.
9. If no water in the ore pass and the hopper in position the guard open the back - up door (door on
outside) door to remain open whilst loading.
10. Then open main door and fill hopper, then close main door.
11. Then close back up door
12. Signal to the driver to move the loco forward until the next hopper is in position underneath the chute,
then signal the driver to stop (Last hopper first to be filled)
13. When large rocks cause a blockage at the chute door, proceed as follows:-
14. The driver to ensure the locomotives handbrake is on, remove the magnetic key from the controller and
position himself at the chute control
15. The guard climbs onto the chute platform and use a long pinch bar to dislodge the rocks while the driver
operates the door controls
16. If a rock prevents the door from being closed, open the door fully to free the rock and close the door to
prevent over filling and spillage
17. Driver to move back to the loco cab when the obstruction is removed from the chute opening, then the
guard to resume filling the hoppers
When any spillage occurred during the filling procedure, remove obstruction from the tracks before
signalling the driver to move forward
18. Excessive spillage must be lashed into the hoppers by the loco crew before moving to the tip
19. When last hopper is full, the Guard lock-out the control levers of the Spillminator Chute
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20. When all the hoppers are full, the guard moves to the front and walks three rail lengths ahead of the
loco, signalling the loco to follow
21. Driver to move at walking speed and stop at the fouling mark
22. The guard enters the main haulage, check for approaching traffic from both directions
23. Replace the locomotive lamp prior to proceeding to the tipping area.
Tip attendants
The tip attendant shall:
1. Assist with the cleaning of hoppers and use the correct tool
2. Not hammer the outside of a hopper with any object in order to loosen any fines sticking to the car
3. Withdraw the tipping cylinder before giving a signal to the loco driver
3. Break up rocks on cracker platforms and not on grizzly
5. Open tip rail door immediately before tipping and close same after tipping of the whole span
6. Not work over the grizzly bars without wearing safety belt
7. Maintain the tip area in a clean condition
8. Always have the following tools available at the tip:- Tip hook, 8 kg hammer, safety belt, gauze goggles,
car cleaning tool
9. Be conversant with the signals
END OF SHIFT /LOCKING-OUT OF THE LOCOMOTIVE

1. Remove the locomotive key from the control and keep in your possession.
2. Engage the brakes and secure the wheels of the locomotive with skid sprags.
3. Place a Do not use tag or a STOP sign on the controls.
4. Remove the battery according the procedure and put on charge.
5. On surface sign the loco lamp and key back to the lamp room.
THE FOLLOWING ITEMS MUST AT ALL TIMES BE AVAILABLE ON THE LOCO

1. Jack and handle and at least one skid sprag.
2. Fire Extinguisher
3. Coupling hooks and pins
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Re-rail a track bound unit

In order to re-rail a unit the following procedure must be followed:
Lower the loco jack so that the lifter fits underneath the buffer of the loco/ hopper or other unit.
Position the loco jack in the centre of the buffer and on solid ground or on a piece of gum plank.
Insert the lifting handle into the lifting handle aperture and lever the jack till it takes the weight of the
unit to be lifted.
Ensure no persons are positioned between the loco/hopper and the sidewall on the drain side or any
area where they may sustain injuries.
Position yourself in such way so as to prevent injuries to your face or body should the lever slip
whilst under tension and lever the jack till the derailed wheels clear the tracks.
Take a timber stick, again position yourself in such way so as to prevent injuries should the stick slip
and manoeuvre the unit to the required direction.
When the re-railing of the unit is completed, remove all tools, material and equipment used, check if
the derailment has not caused damage to the track-work, remove the stop signs and carry on with
your daily tasks.
Report the incident to your supervisor or the person in charge.
Although the method used to re-rail a loco/hopper will always remains the same, there are times that
you have to use additional measures to accommodate for circumstances.
There are times that you have to make use of a sleeper to place it underneath the derailed wheels in
order to re-rail the hopper/loco. In such instances, do not use your bare hands to position the
sleeper. Make use of a pinch bar/hammer or any other object to push the sleeper into position.
The lifting height of the hopper/loco also depends on circumstances. Should it be required to lift the
hopper/loco higher than normal, then take care that no person is positioned where he/she can
sustain injuries should the jack slip as this may cause the loco/hopper to slip sideways.
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IDENTIFIED HAZARDS RELATING TO TRUCKS AND TRAMMING
HAZARD POSSIBLE RESULT CONTROL

1. Tramming area not
Do not enter areas that have not been
examined and declared safe Falls of Ground.
declared safe by a competent person.
by a competent person.
2. Working places not being Poor ground conditions not being Ensure working place is well watered
watered down. identified. Excessive dust in air. down at all times.
3. Unsafe ground conditions. Falls of Ground. Examine and make safe.
4. Incompetent, untrained Only trained, competent and appointed
Injury or death to persons
persons operating the locomotive personnel must operate the locomotive.
5. Persons not using correct PPE PPE is supplied to protect the user
Use and maintain prescribed PPE as
when conducting tramming and against injuries or to reduce severity
per mine standard.
transport operations of injuries
6. Inadequate or no warning
Collisions as a result of no warning Ensure to post warning signs as
signs posted in emergencies or
to oncoming traffic. required by the standard procedures.
during breakdowns.
Poor Housekeeping. Inadequate
7. Improper stacking of material Stack material with adequate clearance
clearance between rolling stock and
and equipment. as per mine standard.
pedestrians.
8. Material and equipment not

Persons being struck by falling Ensure to stack material as required by
secured as required by standard
material. standard procedures.
procedures
Injuries to persons, property Sprag rolling stock not in use as per
9. Run away rolling stock.
damage mine standard.
10. Unauthorised driving of Serious accidents, fatals, property Ensure that only appointed persons
locomotives damage. operate locomotives.
11. Over speeding whilst
Serious accidents, fatals, property Adhere to speed limits as per standard
conducting trucks and tramming
damage. procedures.
operations
No signalling arrangements
Ensure an effective signalling system
for locomotive while No means to stop loader or loco
exists when lashing with the mechanical
mechanical loader is operator in an emergency situation
loader.
operating.
Dangerous material stacking
Material falling onto persons Stack material as per standard
in crosscuts.
Defective Locomotive Unable to stop locomotive Conduct pre-use inspections and take
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brakes. corrective action

Tramming and Maintenance
Crews invisible to operators of Ensure all crews wear PPE and
crews not wearing protective
rolling stock Personal injuries reflective clothing as per standard
and / or reflective clothing.
Tracks and rail turnouts in Derailments causing injuries to Report substandard track and turnout
substandard condition. persons and property damage. installations
Limited clearances between
rolling stock and the Persons being crushed against the Ensure all limited clearance areas are
sidewalls in travelling ways sidewall demarcated
not demarcated.
Hoppers coupled with chains
Runaway rolling stock causing Use only the approved, standard
or unapproved coupling
injuries and / or property damage coupling devices.
devices.
Rails in sub - standard
Derailments causing injuries to Report substandard track and turnout
condition causing
persons and property damage. installations
derailments.
Rolling stock invisible to
Loco lamp not taken Ensure spare lamps are available
pedestrians and operators of other
underground. during all tramming shifts
rolling stock
Persons walking in travelling

Slipping and falling causing persons Stand still in a cubby or against the
ways whist locomotives are
to be run over by rolling stock sidewall until the train has passed
passing.
Operating locomotive without
Do not operate the loco if no means to
an effective signalling No means to communicate
signal is not available
system.
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Persons not standing in safe When a loco approaches, head for the
positions when locomotives Serious injuries to persons nearest safe position and stand still until
derail. the train has passed.
Persons walking between Persons being run over by rolling
Always walk in the travelling way
tracks. stock
No signalling between
Do not operate the loco if no means to
locomotive operator and No means to communicate
signal is not available
guard.
Locomotives pushing
hoppers, material cars or Derailments, persons being struck The guard must clear the way and lead
explosives cars into cross - by rolling stock the loco into crosscuts
cuts.
Derailments injuries and property
Broken sleepers. Report broken sleepers
damage
No fire extinguisher on A fire extinguisher must always be
No means to extinguish fires
locomotive. available.
Conduct pre-use examinations and deal
Sub - standard loco jacks. Injuries to persons
with substandard conditions
Sub - standard condition of Conduct pre-use examinations and deal
Injuries and property damage
rolling stock. with substandard conditions
Not negotiating ventilation
Injuries to persons and damage to Negotiate ventilation doors as per
doors as per standard
property standard
procedure.
Slipping and falling in Keep travelling ways clean and walk in
Injuries to persons
haulages and crosscuts travelling ways only
Objects protruding from Persons being struck by protruding Ensure material cars are loaded as per
material cars. objects standard and no objects are protruding
No ballasting supporting Derailments causing injuries and
Report poorly ballasted sleepers
sleepers. property damage
Pedestrians not clearly visible to Report poorly illuminated tramways to

Poorly illuminated tramways.
Tramming crews the supervisor
Accumulations of broken Slipping and falling, derailments
Lash broken rock into a hopper prior to
rock/mud below stope causing injuries and property
continuing with Tramming operations
chutes. damage
Blocked drains. Flooding causing derailments Keep drains open
No drains. Flooding causing derailments Report condition to the supervisor
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Excessive mud in cross - Derailments injuries and property

Keep crosscuts clean and free of mud
cuts. damage
No pumps in cross - cuts. Flooding causing derailments Report condition to the supervisor
Stack timber in timber bays or material
Stacking of timber in Inadequate clearance between
cubbies Not in the crosscut travelling
travelling way side. timber and persons
way
Loco operator not
Collisions, injuries to persons, Respond promptly and acknowledge
responding to signals from
property damage signals received.
the loco guard.
Verify and ensure early entry
Early entry examination Serious injuries to persons, dust
examination was thoroughly done.
conducted improperly or not inhalation, falls of ground, presence
Refuse to enter working places that was
conducted at all. of harmful gases.
not examined and made safe.
Transporting the loader Bucket dropping to the rails during
Ensure the bucket is securely locked
without securely locking the transportation causing derailments
prior to transportation.
bucket with the bucket pins. that could result in injuries.
Sub-standard sliding rails, Derailments and consequently Adhere to sliding rail, jump-set and
jumpsets or track installation injuries and production loss. track installation standards.
Neglecting to conduct a pre- Defective parts resulting in
Ensure the pre-use examination is
use inspection and not breakdowns, property damage,
conducted and the checklist completed
completing Pre-use production loss and / or injuries to
and signed.
checklist. persons.
Transporting the loader
Centralise and securely lock the upper
without securely locking the Persons / pedestrians being struck
carriage to the chassis prior to
upper carriage to the by the swaying upper carriage
transportation.
chassis.
Neglecting to disengage and
Damage to property. Loader
lock the loader clutch in Ensure the loader clutch is locked in
derailing causing injuries to
neutral prior to neutral prior to transportation.
persons.
transportation.
Transporting the loader with

Derailments, collisions causing Do not exceed normal walking speed
the loco at excessive
injuries and property damage. when transporting the loader.
speeds.
No guard on foot preceding
Inadequate warning, collisions with Ensure a guard precedes the loader
the loader whilst being
oncoming traffic / pedestrians. during transportation.
transported.
Neglecting to use an Derailments around curves resulting Use only the approved 500mm towbar
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approved 500mm Towbar to in injuries and / or property damage. to couple the loader securely to the
attach the loader to the loco hopper or loco. Do not use hopper
or hopper for transportation. shackles, slings or chain.
Exercise
HRD Officer to ensure that all learners a conversant with and knows how complete the checklist/s
HRD Officer to ensure that all learners conducting a pre-use inspection make use of the checklist/s
HRD Officer to ensure that all learners conducting the load a battery onto and remove it from a locomotive
Mechanical loader
Only certificated/competent and appointed persons may operate a Mechanical Loader. The loader operator
is a key worker and very important to every crew. It is therefore very important that arrangements shall be
made in good time to replace a loader operator should he go on leave
AT THE START OF SHIFT, BEFORE LOADING

Examine Loader Bucket
The loader bucket must be examined for wear and tear.
Check that all bolts and nuts holding the bucket to the cradle arms are in place and tightened properly.
Use the 24-mm x 30-mm flat spanner to check the tightness of these bolts.
If any bolts are missing it must be reported to the supervisor.
If the edge of the bucket is to thin it will start to buckle.
This must be reported to the supervisor immediately for rectification.
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Examine slings on loader

The slings on the mechanical loader are used to keep the cradle with bucket in position on the
chassis of the mechanical loader.
Check the following:

All the slings must be equally tensioned.
All the slings must be equally tensioned to prevent breakage due to weight being placed on one
sling only. To prevent the sling from loosening during the loading process
The lock nuts on the slings must be in place and securely locked
Make use of the 36-mm ring/flat spanner to tension the slings.
Examine Bucket Operating Chain

The one side of the bucket operating chain is attached to the bucket operating motor pulley with a
pin that is locked to the flange of the pulley with a screw.
The other side of the chain is attached to a bracket on the loader with a pin through the end link that
is secured with a split pin.
The chain must be examined for broken or damaged links.
Check the attachments on both sides of the chain to ensure that they are in place.
The chain must be lubricated with grease.
Examine Shock Absorber

The two springs and the two rubbers on the bar must be in position.
The purpose of the springs and rubbers is to absorb shock whilst tipping broken rock.
If any of the springs or rubbers is missing the loader must not be operated.
Report any defects to the supervisor
Examine Lubricator
Before the main air supply is coupled to the lubricator the oil level must be checked.
Clean around the plug with a piece of rag before the plug is removed.
Remove the plug and check the oil level visually.
If it is too low fill to high level mark or 25mm from the top.
The oil that is used to fill up the lubricator is S.A.E. 30 oil. The loader will use 500ml of oil during
an eight-hour shift.
Check functioning of lubricator

When the loader is in operation the functioning of the lubricator must be checked.
There is a sight glass on the top of the lubricator that will show you whether it is functioning correctly.
When the lubricator is correctly set you will be able to see oil dripping through the sight glass.
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The dripping of the oil must be 60 drops of oil per minute.
Examine Bucket Stop Block

The bucket stop block must be secured to the chassis of the loader with a welded bracket and a pin.
If the welding is cracked it must be reported to the supervisor.
The stop block must be checked for excessive wear and tear; it should be able to move freely and
must not be bent.
Examine Loader Wheels

The flanges of the wheels must be checked for wear and tear.
If a flange on a wheel is worn 50% or more, it must be reported to the supervisor for repairs.
The axle locking bolts must be checked for tightness and ensure the wheels are properly secure on
the axle.
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Examine Rubber Guard

The rubber guard is situated on top of the side plate just above the controls and lubricator.
The rubber guard protects the loader operator when tipping rocks into the hopper
Ensure that the rubber guard is in good condition.
Check that all bolts and nuts which keep the guard to the side plate are properly tightened.
Should any rock fall out during the tipping process it will fall onto the rubber guard that will deflect it
away from the loader operator
Examine Transport-locking Pin

The purpose of the transport-locking pin is to lock the top desk of the loader to the bottom deck of
the loader.
Ensure that the locking pin is not bent and that the chain is secured to the head of the pin and the
holder of the pin
If the arm of the steering cylinder is bent, it will not operate effectively and it can also cause the
loader to overturn when the top deck is not centre with the bottom deck when tipping ore into the
hoppers
Examine Steering Cylinder

The purpose of the steering cylinder is to assist the operator to load the broken ore on the sides.
Also check the split pin and washer that keeps the arm attached to the pin on the top deck.
If this pin is not in position when transporting the loader the top deck will swing from one side to the
other side and this will result in injuries to persons travelling in the haulage.
It can also result in derailments and damage to the loader, causing a loss of production.
50-mm diameter Air Hose

The purpose of the air hose is to supply air to the motors.
The air hose is connected to the air column by means of a male and a female spud.
A valve situated on the air column controls the airflow through the hose to the loader.
The male spuds that are connected to the hose must be properly secured with clamps and not with
wire.
Ensure the rubber seals inside the female spuds are not missing or broken.
To ensure no air leaks occur
Before the air hose is connected to the lubricator it must be blown out fora few seconds to get rid of
all the dust and dirt trapped inside the hose.
Ensure the discharge end of the hose is not directed towards the footwall or any person standing in
close vicinity.
Small particles of rust or dirt may cause eye injuries or pepper wounds to the body
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Examine Clutch
Check that the clutch lever moves smoothly up and down. If the clutch lever is in the up position the
clutch is disengaged.
When the clutch lever is switched to the down position the clutch engages and the loader can be
used for loading.
When the loader is transported the clutch on the loader must be fully disengaged (up position).
Examine Loader controls Air Hoses

All hoses from the controls must be examined for cracks cuts and leaks.
Hose must be secured with clamps to the nipples and not with wire
Examine Controls
Controls must be able to move smoothly in all directions and self centre automatically.
Sticky controllers will result in uncontrolled movement of the loader.
Safety catches must be in position on both controllers and in good condition.
Ensure that the bolts on controller handles are in position and secured with a split pin.
If any part on the controller is worn it must be reported to the supervisor for rectification.
Deal with Oil Leaks

All visible oil seals must be checked for leaks.
If any leaks are detected it must be reported to the supervisor
Examine Bolts and Nuts

All bolts and nuts must be in place and tight.
Make use of the spanners supplied to check tightness of bolts and nuts.
Particular attention must be given to the nuts and bolts on the wheels.
OPERATING THE MECHANICAL LOADER

Connect male spud
Before the male spud is connected to the female spud on the main air column the following must be
checked:
Check the rubber gasket inside the female spud it must be in place, not broken or perished.
This will result in air leaks, which will influence the performance of the loader
Ensure no person is standing directly in front of the valve and open it slightly to clean valve of dirt
and grit.
Close the valve and connect the male spud to the female spud.
Attach the safety chain to the 50-mm air hose behind the clamp and lock it in position with a bolt and
nut. Connect the other end of the hose to the air valve on the main column and secure it with a
safety chain.
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Connection and suspension of Compressed air/hydropower hose

Before connecting the male spud of the 50-mm air hose to the female spud on the lubricator the following
steps must be taken:
Ensure that the air is properly closed off at the main air column and the air control lever is in the off
position on the lubricator.
Inspect the rubber gasket inside the female spud for damage. If damaged replace it with a new
rubber gasket.
Insert the male spud of the 50-mm air hose into the female spud on the lubricator, but do not lock in
position.
Connect the safety chain that is attached to the loader side plate to the 50-mm air hose behind the
clamp on the air hose. Make use of a bolt and nut and lock the safety chain in position.
Remove the male spud from the female spud on the lubricator; hold it tight with both hands.
Ensure the discharge end is not directed towards a person or the footwall
Instruct another person to open the air valve and blow out the 50-mm hose.
Close the valve on the main air column and connect the air hose to the lubricator and lock the male
spud in the female spud.
The air hose is blown out to ensure it is clean and free of dirt and water which may cause damage to
the mechanisms of the loader should it enter the mechanisms.
Open the air fully on the main air column and check for leaks on the 50-mm air hose, check for leaks
at the connection of the air hose to the main air column and at the lubricator. Do not open the air
control on the lubricator yet.
Air leaks will impede the loading process. Air leaks must be prevented at all times. It causes
excessive noise and is a very expensive commodity.
Clutch engagement
The clutch is used to put the loader in motion.
Switch the air control lever to the on position on the lubricator to let the air run through to the
controls.
Engage the clutch with the clutch lever and use the control to regulate the movement of the
mechanical loader.
Move the handle to allow the motor to run at the slowest possible speed until the clutch engages
(loader starts moving).
If the speed gets too high before engagement, release the handle and try again
After engagement of the clutch, reverse the motor several times at low speed to allow the clutch to
seat properly.
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Operation of controls
Left hand control
The left-hand control is used to move the loader and for the swinging of the top deck. Remember to remove
the transport- locking pin before the handle is operated.
Push control towards the side plate.
- Top deck swings to the right. (Away from the operator)
Pull control towards operator.

- Top deck swings to the left. (Towards the operator)
Push control over to the left side (Towards the bucket).

- Loader moves forward
Push control over to the right hand side.

- Loader moves backward
Right hand control

The right-hand control is used for tipping and loading. The bucket stop block must be hinged
backwards before the control is operated.
Push control over to the left-hand side.
- Bucket lowers for loading
Push control over to the right-hand side.
- Bucket unloads. (Tipping)
Tip Broken Rock

Before discharging broken rock ensure persons are positioned safely.
Discharge the bucket in one smooth motion into the hopper by manipulating the discharging control.
Once discharging is completed reposition the bucket to the correct position to continue with the
loading operation. Continue with the process until the hopper is full.
When a hopper is full the loco guard signals to the operator to remove the full hopper.
The full hopper will be parked in the nearest lay-bye and an empty hopper will be shunted into the
development end in order to continue with the cleaning process.
Re-positioning of sliding rails
To re-rail the front wheels of a mechanical loader the following procedure must be followed:
Lock the bucket in transport position with the bucket stop block. Lock the top deck to the bottom
deck with the transport-locking pin.
Ensure all persons are standing in a safe position behind the loader.
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Place the sliding pipe push-bar inside the rails of the de-railed wheels.
Place the top of the sliding pipe push-bar diagonally against the opposite side of the loader on the
attachment point on the side plate.
Ensure that the sliding pipe push-bar is firmly locked to prevent slipping.
With short movements, move the loader forward until the front wheels lift clear off the rails.
When the wheels have centralised above the rails reverse the loader slowly until the wheels re-
position on the rails.
When re-railing the back wheels of the mechanical loader the following procedure must be followed:
Lock the bucket in the transport position to prevent the bucket from swinging side-ways
Lock the top deck to the bottom deck with the transport-locking pin to prevent uncontrolled
movement of the top deck during the re-railing process to prevent the bucket from swinging side-
ways.
Remove all workers to safe position.
Place sliding rail push-bar inside the rails of the derailed wheels.
Place the sliding rail push-bar diagonally against the opposite side of the loader on the attachment
point on the side plate.
Ensure that the sliding rail push-bar is firmly locked to prevent slipping.
Manipulate loader controls with short movements, reversing the loader until the wheels have lifted
above the rails.
Lower the loader slowly when the wheels are centralised above the tracks by moving the loader
forward.
ON COMPLETION OF LOADING
1. Clean loader
i. Remove all small rocks from rocker guides
ii. Wash down loader removing all fines
iii. Clean off all excessive oil and grease
2. Prepare loader for transport

i. Secure bucket
a) Raise bucket so that the bucket arms are above the holes in the side plates
b) Push short pinch bar through the holes in the side plates
c) Lower bucket rocker arms slowly onto pinch bar
ii. Disconnect 50mm compressed air hose

a) Close valve on manifold
b) Open forward/backward control handle to release the pressure in the hose
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c) Disconnect hose from loader

d) Remove safety chain
iii. Disengage clutch
iv. Align cradle with chassis insert traverse pin
v. Couple loader to loco use standard draw bar and coupling pins
vi. Hook loco lamp onto bucket
3. Transport loader where possible loader must rather be pulled than pushed
TOOLS AND EQUIPMENT OF A LOADER DRIVE

The following tools, material and equipment are required for this competence:
Safety chain
Bucket stop block
Transport locking-pin
Tow bar
Loader bucket
50-mm diameter air hose
Set of spanners
Hammer
1 Pipe push-bar
Fish-plates
Marlinespike
Rail tongs
Pinch bar
Kimberley clamp
Jump-sets
Sliding rails
SAFETY RULES FOR USING A MECHANICAL LOADER

1. Work calmly and smoothly move the control without jerking
2. Become accustomed to the loader, before driving it at full capacity.
3. Always close the main valve when you leave the loader. It should be closed during all servicing of the
loader, as well as when anyone is to work within the range of the bucket.
4. The safety catch for the controls should always be put in the locked position whenever work is stopped.
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5. When the machine is not in use the bucket should rest on the ground or be blocked in the raised position
with the special retainer/pin for the cradle. The upper part of the loader should then be locked in the
centred position by means of the bolt/traverse pin situated at the rear of the machine.
6. Always use hoses of good quality and see that they are properly connected and secured.
7. Do not run the bucket motor so quickly that the bucket chain goes slack, and never reverse the direction
of the motor in order to take up the slack chain.
IDENTIFIED HAZARDS / RISKS OPERATING A LOADER
Hazard / Risk / At Risk

Possible Result Control
Behaviour
Only trained, competent and appointed
Unauthorised operation of loader. Serious injuries to persons persons must be allowed to operate a
mechanical loader.
Verify and ensure early entry examination
Early entry examination Serious injuries to persons,
was thoroughly done. Refuse to enter
conducted improperly or not dust inhalation, falls of ground,
working places that was not examined
conducted at all. presence of harmful gases.
and made safe.
Ensure early entry examination is
Bad Hanging and Sidewalls. Falls of Ground. thoroughly done. Constantly examine and
make safe.
Ensure early entry examination is
Unsupported areas after the blast. Falls of Ground. thoroughly done. Constantly examine and
make safe.
Dust inhalation, unidentified
Poorly watered down working Ensure workplaces are thoroughly
geological disturbances
places. watered down prior to doing any work.
resulting in FOGs.
Lashing of dry muck pile (broken Water down muck pile regularly as
Dust inhalation.
rock). lashing progresses.
Undermining of steeply piled Rolling rocks resulting in Bar down steeply piled broken rock to the
broken rock injuries. angle of repose.
Ensure safety platforms and / or swinging
Unprotected lashing opposite
Rolling / falling rocks from barricades are in place when loading
steeply inclined workings
steeply inclined workings. takes place opposite steeply inclined
(Boxholes etc.).
workings.
Not keeping the muck pile square Always keep the muck pile square and
Collapsing sides of muck pile.
as lashing progresses. thus keeping the sides clean.
Unexposed misfires and / or
Not lashing down to the footwall. Ensure to lash down to the footwall.
old explosives that could result
in explosions.
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Defective parts resulting in

Neglecting to conduct a pre-use Ensure the pre-use examination is
breakdowns, property damage,
inspection and not completing conducted and the checklist completed
production loss and / or injuries
Pre-use checklist. and signed.
to persons.
Not lashing the fly-dirt between Congestion, derailments, slip
Ensure all flydirt is lashed prior to lashing
and on the sides of the rails prior and fall injuries, persons being
the muck pile.
to lashing the muck pile. struck by moving machinery.
Not removing big rocks, material, Congestion, derailments, slip
Ensure all obstructions are cleared and
equipment and other obstructions and fall injuries, persons being
moved from the area where lashing must
from area where lashing must struck by moving machinery
take place.
take place. against obstructions.
Persons other than the loader Persons being struck by Ensure no persons other than the loader
operator between the face and moving machinery or by operator is positioned between the face
the second hopper from the face spillage when tipping into the and the second hopper from the face
whilst lashing. hopper takes place. whilst lashing.
Sub-standard sliding rails, Derailments and consequently Adhere to sliding rail, jumpset and track
jumpsets or track installation injuries and production loss. installation standards.
Attempting to break up big rocks Derailments, property damage Use a 6,8kg hammer and not the loader
with the loader bucket. and injuries to persons. bucket to break up big rocks.
Big rocks falling from loader
Attempting to pick up or lash big Big rocks must be broken up with a
bucket or hopper resulting in
rocks with the loader bucket hammer and not be lashed.
injuries to persons
Damage to air hose by the
Failure to use a hanger to Support the air hose by means of a
loader or hopper wheels
support the air hose. hanger/s against the sidewall.
resulting in injuries.
Unauthorised operation,
Neglecting to shut off the air and
inadvertent activation of Ensure the loader is locked out when not
release the pressure when the
controls resulting in injuries to in use.
loader is not in use (Lock-out)
persons
Attempting to re-rail the loader by Loader falling / striking Re-rail the loader using a loco jack as per
using the controls. persons standard procedures.
Bucket dropping to the rails
Transporting the loader without
during transportation causing Ensure the bucket is securely locked prior
securely locking the bucket with
derailments that could result in to transportation.
the bucket pins.
injuries.
Transporting the loader without Persons / pedestrians being Centralise and securely lock the upper
securely locking the upper struck by the swaying upper carriage to the chassis prior to
carriage to the chassis. carriage transportation.
Neglecting to disengage and lock Damage to property. Loader Ensure the loader clutch is locked in
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the loader clutch in neutral prior to derailing causing injuries to neutral prior to transportation.
transportation. persons.
Transporting the loader with the Derailments, collisions causing Do not exceed normal walking speed
loco at excessive speeds. injuries and property damage. when transporting the loader.
Inadequate warning, collisions
No guard on foot preceding the Ensure a guard precedes the loader
with oncoming traffic /
loader whilst being transported. during transportation.
pedestrians.
Neglecting to use an approved Use only the approved 500mm towbar to
Derailments around curves
500mm Towbar to attach the couple the loader securely to the hopper
resulting in injuries and / or
loader to the loco or hopper for or loco. Do not use hopper shackles,
property damage.
transportation. slings or chain.
Use only the approved Pushbar to push
Not using the approved 50mm X
sliding rails forward. Do not use sleepers,
1.5m Pushbar to push sliding rails Injuries to persons.
pieces of rail, temporary support props or
forward into the muck pile.
mine poles.
Neglecting to always close the
Inadvertent operation of the
compressed air valve on the Ensure the compressed air is always shut
loader controls resulting in
loader when the loader is not in off when the loader is not in use.
injuries to persons.
use.
Not lowering the bucket and When the loader is not in use ensure the
Bucket dropping to the rails
locking it with the locking pins bucket is lowered and locked with the
causing injuries to persons.
when the loader is not in use. locking pins.
Not locking the safety catches on Inadvertent operation of the
Ensure safety catches are in the locked
the controls when the loader is loader controls resulting in
position when loader is not in use.
not in use. injuries to persons.
50mm air hose disengaging Secure all hose connections and joints
Not securing all 50mm air hose
under pressure at hose with safety chains and bolts and nuts. Do
connections and joints with safety
connections and joints not use 8 gauge wire, slings or other
chain and bolts and nuts.
resulting in injuries to persons. material.
50mm air hose disengaging Use only the approved clamps with bolts
Using wire or other unsafe under pressure at hose and nuts to join 50mm air hoses. Ensure
materials to join 50mm air hose connections resulting in nuts are tightly secured. Never use any
injuries to persons. other material to join hoses.
Inadequate strength to
One person only holding 50mm At least two persons must hold the 50mm
securely hold the 50mm air
air hose when blowing hose out. hose when blowing it out.
hose.
Injuries to persons as a result Warn and ensure all persons are clear
Pointing the 50mm hose at other
of being struck by grit and fines and in a safe place prior to blowing out
persons whilst blowing it out.
emerging under pressure from the 50mm air hose. Do not direct the hose
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hose. to persons during blowing out.

Neglecting to close the air valve
Persons being struck by the
and releasing the pressure inside Ensure all pressure inside the hose has
hose / tail when disconnecting
the hose prior to disconnecting been released prior to disconnecting it.
hose under pressure.
the hose.
Neglecting to remove kinks in air Ensure all kinks are removed and all
Trapped air (stored energy)
hose prior to releasing the pressure inside the hose released prior to
inside the hose.
pressure. disconnecting.
Removing the safety chain Persons being struck by the Never remove safety chain completely.
completely whilst disconnecting hose / tail when disconnecting Supply enough slack only to be able to
the air hose. hose under pressure. disconnect the hose.
Not removing other persons to a Persons being struck by the
Ensure all persons are removed to a safe
safe position prior to hose / tail when hose is
place prior to disconnecting the hose.
disconnecting the hose. disconnected.
Bursting hose, hose
Pressurising air hose by suddenly disengaging at joints / Open the air valve slowly to pressurise
opening the air valve to the full. connections resulting in the hose.
injuries.
MACHINERY
Question 1
Who may drive a locomotive?
Answer 1
Question 2
Who may ride on any car or truck underground?
Answer 2
Question 3
Who may ride on the buffer of a loco or hopper?
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Answer 3
Question 4
When may a person board or alight from a locomotive or any other vehicle whilst it is still in motion?
Answer 4
Question 5
Must all trains have a light underground?
Answer 5
Question 6
Where must batteries be changed underground?
Answer 6
Question 7
Why must moving parts of machinery be provided with guards?
Answer 7
Question 8
Why are electrical sub-stations to be kept locked? 1
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Answer 8
Question 9
Why must plastic electric cables be suspended?
Answer 9
Question 10
When using machinery, what precautions should be taken for the safety of persons?
Answer 10
Question 11
Why must moving machinery be illuminated?
Answer 11
Exercise
Load and remove a battery
Transport Material
Transport Rock
Re-Railing as part of loco operating

1. Front wheels off tracks
2. Back wheels off tracks
3. All four wheels off tracks
Operating loco & and Operating a Spilminator after load and remove a battery (Ensure to address all
the loco unit stds w.r.t transportation)
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HRD Officer to ensure that learners physically exercise and practise the following with Loader
Transportation
Operate a Loader
Re railing
1. Front wheels off tracks
2. Back wheels off tracks
3. All four wheels off tracks
Your National Certificate in Mining Operations Development is now completed HRD Officer to
arrange for the Development Operator phase, where Learners will be exposed to all the phases of a
Development Operator

HRD - SOM - LNR - TRM - 013 - National Certificate Mining Operations NQF 2 - Development

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PLATINUM

NATIONAL CERTIFICATE MINING OPERATIONS NQF 2 -

This manual has been revised with the following in mind:

OcS-F008 Control workplace hazardous substances

MnH-G589 Analyse and solve problems

2. IN STOPE DEVELOPMENT / RE - DEVELOPMENT

National Certificate Mining Operations NQF Level 2 - Development Page 3 of 276

12. MULTI BLAST

13. PRIMARY DEVELOPMENT

14. SECONDARY DEVELOPMENT

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16. OFF SETS

18. FOOTWALL DRIVES

19. TIME BLAST

National Certificate Mining Operations NQF Level 2 - Development Page 5 of 276

SELF-PROPELLED MOBILE MACHINE

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FLAMMABLE GAS WARNING DEVICE

4 Underground waiting places

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IDENTIFIED HAZARDS PERTAINING PERFORMINIG OF WAITING PLACE PROCEDURES

HAZARDS POSSIBLE RESULTS CONTROLS

Rock drill Operator

National Certificate Mining Operations NQF Level 2 - Development Page 10 of 276

PTV (Pipes, Tracks and Ventilation)

5 Emergency Preparedness and Refuge Bays

National Certificate Mining Operations NQF Level 2 - Development Page 11 of 276

2. Compressed air column 50 mm diameters. Noise reduction installed to back of chamber.

3. Potable, wholesome drinking water must be available.

5. Internal telephone where possible.

6. Adequate number of benches provided.

7. Drain for water to be led out of chamber.

8. Portable toilets (Male/Female).

9. The necessary notices as required by the standard.

National Certificate Mining Operations NQF Level 2 - Development Page 14 of 276

IDENTIFIED HAZARDS PERTAINING THE REFUGE CHAMBER REQUIREMENTS

HAZARDS POSSIBLE RESULT CONTROL

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National Certificate Mining Operations NQF Level 2 - Development Page 16 of 276

National Certificate Mining Operations NQF Level 2 - Development Page 19 of 276

Learners to write Dust examination

Gases Encountered in Mines

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Their Properties and Means of Detection

Note: The density of gasses is relative to normal air.

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7.1 Oxygen (O2)

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7.2 Carbon Monoxide (CO)

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7.3 Carbon Dioxide (CO2)

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7.4 Nitrous Fumes

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7.5 Hydrogen Sulphide (H2S)

3. Heavier than air (RD 1,18).

7.6 Hydrogen (H2)

Procedure To Rescue and Revive Gassed Persons

2. Send word to nearest senior supervisor.

Banksman / control room to be notified from underground to organise an ambulance.