FIT FOR WORK / FIT FOR LIFE

Our Charter states we have an overriding commitment to health, safety, environmental responsibility and sustainable development. Zero Harm is an important aspirational goal for all our HSEC initiatives - this initiative is part of our journey on the Road to Zero Harm, as shown in the diagram below


An Introduction to FIT FOR WORK / FIT FOR LIFE

1. Context
a. Guidelines and Toolkits should be read and used in conjunction with the Charter, HSEC Policy, HSEC Management Standards and Fatal Risk Control Protocols
b. Guidelines are advisory only and provide guidance on the effective implementation of the HSEC Management Standards
c. Toolkits provide a preferred method for meeting the requirements of the HSEC Management Standards and the Fit for Work / Fit for Life Guidelines

2. Application and Scope
a. Guidelines and Toolkits apply to all BHP Billiton controlled sites and controlled activities, and to all BHP Billiton employees, contractors and visitors, when involved in controlled activities.
b. This initiative seeks to promote a consistent approach to the management of health issues in the work environment.
c. Holistic approach which recognises the family as an important component of the initiative.
d. Initiative consists of eight Guidelines (and associated Toolkits) :
* Drug and Alcohol Programs
* Fatigue Management Programs
* Fatigue Management
* Fatigue Impairment Assessment and Intervention
* Fatigue Education
* Medical Assessment Programs
* Travel Health Programs
* Ergonomic Analysis
* Occupational Rehabilitation Programs
* Health Promotion Programs
* Employee Assistance Programs

Drug and Alcohol Programs
a. Diagnose, treat and, ideally, prevent substance abuse
b. Reduce the incidence of workplace accidents and injuries
c. Reduce the incidence of problems (e.g. low productivity, absenteeism, staff turnover) related to alcohol and drugs
d. Provide support and rehabilitation to affected employees
e. Reduce ill effects related to drugs and alcohol in the community and family
f. Include a written policy, outlining those substances which are covered by the program, testing circumstances, disciplinary actions

Fatigue Management Programs
a. Identify and assess fatigue-related risks
b. Implement a process for controlling fatigue-related risks and their potential to impact on health and wellbeing
c. Clearly defines responsibilities of the employer, management and supervisors, and employees
d. Toolkits covers the areas of :
* Fatigue Impairment Assessment and Intervention
* Fatigue Education Programs
* Fatigue Management and Checklist
- Structure and design of work-time arrangements
- Employee fitness for work
- Management processes for monitoring and controlling potential for fatigue
- Effects of activities carried out during rostered and overtime hours, and non-rostered hours

Medical Assessment Programs
a. Detect current and future health risks
b. Ensure ongoing fitness for work
c. Provide access to thorough medical and health consultations
d. Promote and encourage a healthy lifestyle
e. Include the elements of :
* Health surveillance
* General medical assessment
* Pre-placement assessment
* Functional capacity assessment
* Extended medical assessment
* Exit medicals
* Vaccination programs

Travel Health Programs
a. Address health and medical issues associated with international business travel and relocation
b. Manage the adverse health risks associated with international business travel and relocation
c. Promote health and wellbeing of travellers through pre-departure preparation
d. Recognise the psychosocial impact of travel, including frequent separation from family
e. Provide for 24-hour access to medical advice, assistance, and where necessary, medical emergency evacuation

Ergonomic Analysis
a. Identify the specific tasks which must be undertaken in order to complete a job
b. Assess the impact of these tasks on the health, safety and wellbeing of the individual performing the task
c. Health-oriented approach, using the principles of ergonomics to make recommendations
d. Conducted by suitably qualified personnel and involve the persons who actually perform the tasks being analysed
e. Examples of checklists are provided to assist in conducting ergonomic analysis of site-based jobs, workstations, and functional abilities screens

Occupational Rehabilitation Programs
a. Help injured or ill employees to remain at work or return to work as soon as safely possible
b. Restore injured or ill workers to the fullest capacity for employment of which they are capable
c. Obtain the support of the workers colleagues, supervisors and managers during the occupational rehabilitation process
d. Ensure individuals are proactively involved in the management of, and recovery from, their injury or illness
e. Clearly define the responsibilities of the employer, the employee, the supervisor/manager, and the occupational rehabilitation personnel
f. Include return-to-work plans
g. Outline a procedure for grievance and dispute resolution

Health Promotion Programs
a. Help people change their lifestyles to move towards a state of optimal health – a balance of physical, emotional, social, spiritual and intellectual health
b. Fit with the culture, understandings, legal and socio-economics of the location
c. Motivate the adoption of better health habits, provide information and develop skills that enable behaviour change
d. Improve wellbeing, morale, productivity and the health of the local community
e. Reduce workplace injuries and absenteeism

Employee Assistance Programs
a. Promote wellbeing through pro-active awareness programs
b. Provide short-term, confidential and independent assistance to employees and their immediate family members who may be experiencing personal or work-related problems
c. Provide assistance to managers and supervisors in dealing with difficult or sensitive work situations or employee issues

Fit for Work / Fit for Life
The Fit for Work/Fit for Life initiative :
a. will be linked to a Community of Practice
b. has Champions who will
* work to enhance understanding and dissemination of the initiative, and
* continue to develop operational understanding on managing these issues

FIT FOR WORK / FIT FOR LIFE

Our Charter states we have an overriding commitment to health, safety, environmental responsibility and sustainable development. Zero Harm is an important aspirational goal for all our HSEC initiatives - this initiative is part of our journey on the Road to Zero Harm, as shown in the diagram below


An Introduction to FIT FOR WORK / FIT FOR LIFE

1. Context
a. Guidelines and Toolkits should be read and used in conjunction with the Charter, HSEC Policy, HSEC Management Standards and Fatal Risk Control Protocols
b. Guidelines are advisory only and provide guidance on the effective implementation of the HSEC Management Standards
c. Toolkits provide a preferred method for meeting the requirements of the HSEC Management Standards and the Fit for Work / Fit for Life Guidelines

2. Application and Scope
a. Guidelines and Toolkits apply to all BHP Billiton controlled sites and controlled activities, and to all BHP Billiton employees, contractors and visitors, when involved in controlled activities.
b. This initiative seeks to promote a consistent approach to the management of health issues in the work environment.
c. Holistic approach which recognises the family as an important component of the initiative.
d. Initiative consists of eight Guidelines (and associated Toolkits) :
* Drug and Alcohol Programs
* Fatigue Management Programs
* Fatigue Management
* Fatigue Impairment Assessment and Intervention
* Fatigue Education
* Medical Assessment Programs
* Travel Health Programs
* Ergonomic Analysis
* Occupational Rehabilitation Programs
* Health Promotion Programs
* Employee Assistance Programs

Drug and Alcohol Programs
a. Diagnose, treat and, ideally, prevent substance abuse
b. Reduce the incidence of workplace accidents and injuries
c. Reduce the incidence of problems (e.g. low productivity, absenteeism, staff turnover) related to alcohol and drugs
d. Provide support and rehabilitation to affected employees
e. Reduce ill effects related to drugs and alcohol in the community and family
f. Include a written policy, outlining those substances which are covered by the program, testing circumstances, disciplinary actions

Fatigue Management Programs
a. Identify and assess fatigue-related risks
b. Implement a process for controlling fatigue-related risks and their potential to impact on health and wellbeing
c. Clearly defines responsibilities of the employer, management and supervisors, and employees
d. Toolkits covers the areas of :
* Fatigue Impairment Assessment and Intervention
* Fatigue Education Programs
* Fatigue Management and Checklist
- Structure and design of work-time arrangements
- Employee fitness for work
- Management processes for monitoring and controlling potential for fatigue
- Effects of activities carried out during rostered and overtime hours, and non-rostered hours

Medical Assessment Programs
a. Detect current and future health risks
b. Ensure ongoing fitness for work
c. Provide access to thorough medical and health consultations
d. Promote and encourage a healthy lifestyle
e. Include the elements of :
* Health surveillance
* General medical assessment
* Pre-placement assessment
* Functional capacity assessment
* Extended medical assessment
* Exit medicals
* Vaccination programs

Travel Health Programs
a. Address health and medical issues associated with international business travel and relocation
b. Manage the adverse health risks associated with international business travel and relocation
c. Promote health and wellbeing of travellers through pre-departure preparation
d. Recognise the psychosocial impact of travel, including frequent separation from family
e. Provide for 24-hour access to medical advice, assistance, and where necessary, medical emergency evacuation

Ergonomic Analysis
a. Identify the specific tasks which must be undertaken in order to complete a job
b. Assess the impact of these tasks on the health, safety and wellbeing of the individual performing the task
c. Health-oriented approach, using the principles of ergonomics to make recommendations
d. Conducted by suitably qualified personnel and involve the persons who actually perform the tasks being analysed
e. Examples of checklists are provided to assist in conducting ergonomic analysis of site-based jobs, workstations, and functional abilities screens

Occupational Rehabilitation Programs
a. Help injured or ill employees to remain at work or return to work as soon as safely possible
b. Restore injured or ill workers to the fullest capacity for employment of which they are capable
c. Obtain the support of the workers colleagues, supervisors and managers during the occupational rehabilitation process
d. Ensure individuals are proactively involved in the management of, and recovery from, their injury or illness
e. Clearly define the responsibilities of the employer, the employee, the supervisor/manager, and the occupational rehabilitation personnel
f. Include return-to-work plans
g. Outline a procedure for grievance and dispute resolution

Health Promotion Programs
a. Help people change their lifestyles to move towards a state of optimal health – a balance of physical, emotional, social, spiritual and intellectual health
b. Fit with the culture, understandings, legal and socio-economics of the location
c. Motivate the adoption of better health habits, provide information and develop skills that enable behaviour change
d. Improve wellbeing, morale, productivity and the health of the local community
e. Reduce workplace injuries and absenteeism

Employee Assistance Programs
a. Promote wellbeing through pro-active awareness programs
b. Provide short-term, confidential and independent assistance to employees and their immediate family members who may be experiencing personal or work-related problems
c. Provide assistance to managers and supervisors in dealing with difficult or sensitive work situations or employee issues

Fit for Work / Fit for Life
The Fit for Work/Fit for Life initiative :
a. will be linked to a Community of Practice
b. has Champions who will
* work to enhance understanding and dissemination of the initiative, and
* continue to develop operational understanding on managing these issues

FIT FOR WORK / FIT FOR LIFE

Our Charter states we have an overriding commitment to health, safety, environmental responsibility and sustainable development. Zero Harm is an important aspirational goal for all our HSEC initiatives - this initiative is part of our journey on the Road to Zero Harm, as shown in the diagram below


An Introduction to FIT FOR WORK / FIT FOR LIFE

1. Context
a. Guidelines and Toolkits should be read and used in conjunction with the Charter, HSEC Policy, HSEC Management Standards and Fatal Risk Control Protocols
b. Guidelines are advisory only and provide guidance on the effective implementation of the HSEC Management Standards
c. Toolkits provide a preferred method for meeting the requirements of the HSEC Management Standards and the Fit for Work / Fit for Life Guidelines

2. Application and Scope
a. Guidelines and Toolkits apply to all BHP Billiton controlled sites and controlled activities, and to all BHP Billiton employees, contractors and visitors, when involved in controlled activities.
b. This initiative seeks to promote a consistent approach to the management of health issues in the work environment.
c. Holistic approach which recognises the family as an important component of the initiative.
d. Initiative consists of eight Guidelines (and associated Toolkits) :
* Drug and Alcohol Programs
* Fatigue Management Programs
* Fatigue Management
* Fatigue Impairment Assessment and Intervention
* Fatigue Education
* Medical Assessment Programs
* Travel Health Programs
* Ergonomic Analysis
* Occupational Rehabilitation Programs
* Health Promotion Programs
* Employee Assistance Programs

Drug and Alcohol Programs
a. Diagnose, treat and, ideally, prevent substance abuse
b. Reduce the incidence of workplace accidents and injuries
c. Reduce the incidence of problems (e.g. low productivity, absenteeism, staff turnover) related to alcohol and drugs
d. Provide support and rehabilitation to affected employees
e. Reduce ill effects related to drugs and alcohol in the community and family
f. Include a written policy, outlining those substances which are covered by the program, testing circumstances, disciplinary actions

Fatigue Management Programs
a. Identify and assess fatigue-related risks
b. Implement a process for controlling fatigue-related risks and their potential to impact on health and wellbeing
c. Clearly defines responsibilities of the employer, management and supervisors, and employees
d. Toolkits covers the areas of :
* Fatigue Impairment Assessment and Intervention
* Fatigue Education Programs
* Fatigue Management and Checklist
- Structure and design of work-time arrangements
- Employee fitness for work
- Management processes for monitoring and controlling potential for fatigue
- Effects of activities carried out during rostered and overtime hours, and non-rostered hours

Medical Assessment Programs
a. Detect current and future health risks
b. Ensure ongoing fitness for work
c. Provide access to thorough medical and health consultations
d. Promote and encourage a healthy lifestyle
e. Include the elements of :
* Health surveillance
* General medical assessment
* Pre-placement assessment
* Functional capacity assessment
* Extended medical assessment
* Exit medicals
* Vaccination programs

Travel Health Programs
a. Address health and medical issues associated with international business travel and relocation
b. Manage the adverse health risks associated with international business travel and relocation
c. Promote health and wellbeing of travellers through pre-departure preparation
d. Recognise the psychosocial impact of travel, including frequent separation from family
e. Provide for 24-hour access to medical advice, assistance, and where necessary, medical emergency evacuation

Ergonomic Analysis
a. Identify the specific tasks which must be undertaken in order to complete a job
b. Assess the impact of these tasks on the health, safety and wellbeing of the individual performing the task
c. Health-oriented approach, using the principles of ergonomics to make recommendations
d. Conducted by suitably qualified personnel and involve the persons who actually perform the tasks being analysed
e. Examples of checklists are provided to assist in conducting ergonomic analysis of site-based jobs, workstations, and functional abilities screens

Occupational Rehabilitation Programs
a. Help injured or ill employees to remain at work or return to work as soon as safely possible
b. Restore injured or ill workers to the fullest capacity for employment of which they are capable
c. Obtain the support of the workers colleagues, supervisors and managers during the occupational rehabilitation process
d. Ensure individuals are proactively involved in the management of, and recovery from, their injury or illness
e. Clearly define the responsibilities of the employer, the employee, the supervisor/manager, and the occupational rehabilitation personnel
f. Include return-to-work plans
g. Outline a procedure for grievance and dispute resolution

Health Promotion Programs
a. Help people change their lifestyles to move towards a state of optimal health – a balance of physical, emotional, social, spiritual and intellectual health
b. Fit with the culture, understandings, legal and socio-economics of the location
c. Motivate the adoption of better health habits, provide information and develop skills that enable behaviour change
d. Improve wellbeing, morale, productivity and the health of the local community
e. Reduce workplace injuries and absenteeism

Employee Assistance Programs
a. Promote wellbeing through pro-active awareness programs
b. Provide short-term, confidential and independent assistance to employees and their immediate family members who may be experiencing personal or work-related problems
c. Provide assistance to managers and supervisors in dealing with difficult or sensitive work situations or employee issues

Fit for Work / Fit for Life
The Fit for Work/Fit for Life initiative :
a. will be linked to a Community of Practice
b. has Champions who will
* work to enhance understanding and dissemination of the initiative, and
* continue to develop operational understanding on managing these issues

FIT FOR WORK / FIT FOR LIFE

Our Charter states we have an overriding commitment to health, safety, environmental responsibility and sustainable development. Zero Harm is an important aspirational goal for all our HSEC initiatives - this initiative is part of our journey on the Road to Zero Harm, as shown in the diagram below


An Introduction to FIT FOR WORK / FIT FOR LIFE

1. Context
a. Guidelines and Toolkits should be read and used in conjunction with the Charter, HSEC Policy, HSEC Management Standards and Fatal Risk Control Protocols
b. Guidelines are advisory only and provide guidance on the effective implementation of the HSEC Management Standards
c. Toolkits provide a preferred method for meeting the requirements of the HSEC Management Standards and the Fit for Work / Fit for Life Guidelines

2. Application and Scope
a. Guidelines and Toolkits apply to all BHP Billiton controlled sites and controlled activities, and to all BHP Billiton employees, contractors and visitors, when involved in controlled activities.
b. This initiative seeks to promote a consistent approach to the management of health issues in the work environment.
c. Holistic approach which recognises the family as an important component of the initiative.
d. Initiative consists of eight Guidelines (and associated Toolkits) :
* Drug and Alcohol Programs
* Fatigue Management Programs
* Fatigue Management
* Fatigue Impairment Assessment and Intervention
* Fatigue Education
* Medical Assessment Programs
* Travel Health Programs
* Ergonomic Analysis
* Occupational Rehabilitation Programs
* Health Promotion Programs
* Employee Assistance Programs

Drug and Alcohol Programs
a. Diagnose, treat and, ideally, prevent substance abuse
b. Reduce the incidence of workplace accidents and injuries
c. Reduce the incidence of problems (e.g. low productivity, absenteeism, staff turnover) related to alcohol and drugs
d. Provide support and rehabilitation to affected employees
e. Reduce ill effects related to drugs and alcohol in the community and family
f. Include a written policy, outlining those substances which are covered by the program, testing circumstances, disciplinary actions

Fatigue Management Programs
a. Identify and assess fatigue-related risks
b. Implement a process for controlling fatigue-related risks and their potential to impact on health and wellbeing
c. Clearly defines responsibilities of the employer, management and supervisors, and employees
d. Toolkits covers the areas of :
* Fatigue Impairment Assessment and Intervention
* Fatigue Education Programs
* Fatigue Management and Checklist
- Structure and design of work-time arrangements
- Employee fitness for work
- Management processes for monitoring and controlling potential for fatigue
- Effects of activities carried out during rostered and overtime hours, and non-rostered hours

Medical Assessment Programs
a. Detect current and future health risks
b. Ensure ongoing fitness for work
c. Provide access to thorough medical and health consultations
d. Promote and encourage a healthy lifestyle
e. Include the elements of :
* Health surveillance
* General medical assessment
* Pre-placement assessment
* Functional capacity assessment
* Extended medical assessment
* Exit medicals
* Vaccination programs

Travel Health Programs
a. Address health and medical issues associated with international business travel and relocation
b. Manage the adverse health risks associated with international business travel and relocation
c. Promote health and wellbeing of travellers through pre-departure preparation
d. Recognise the psychosocial impact of travel, including frequent separation from family
e. Provide for 24-hour access to medical advice, assistance, and where necessary, medical emergency evacuation

Ergonomic Analysis
a. Identify the specific tasks which must be undertaken in order to complete a job
b. Assess the impact of these tasks on the health, safety and wellbeing of the individual performing the task
c. Health-oriented approach, using the principles of ergonomics to make recommendations
d. Conducted by suitably qualified personnel and involve the persons who actually perform the tasks being analysed
e. Examples of checklists are provided to assist in conducting ergonomic analysis of site-based jobs, workstations, and functional abilities screens

Occupational Rehabilitation Programs
a. Help injured or ill employees to remain at work or return to work as soon as safely possible
b. Restore injured or ill workers to the fullest capacity for employment of which they are capable
c. Obtain the support of the workers colleagues, supervisors and managers during the occupational rehabilitation process
d. Ensure individuals are proactively involved in the management of, and recovery from, their injury or illness
e. Clearly define the responsibilities of the employer, the employee, the supervisor/manager, and the occupational rehabilitation personnel
f. Include return-to-work plans
g. Outline a procedure for grievance and dispute resolution

Health Promotion Programs
a. Help people change their lifestyles to move towards a state of optimal health – a balance of physical, emotional, social, spiritual and intellectual health
b. Fit with the culture, understandings, legal and socio-economics of the location
c. Motivate the adoption of better health habits, provide information and develop skills that enable behaviour change
d. Improve wellbeing, morale, productivity and the health of the local community
e. Reduce workplace injuries and absenteeism

Employee Assistance Programs
a. Promote wellbeing through pro-active awareness programs
b. Provide short-term, confidential and independent assistance to employees and their immediate family members who may be experiencing personal or work-related problems
c. Provide assistance to managers and supervisors in dealing with difficult or sensitive work situations or employee issues

Fit for Work / Fit for Life
The Fit for Work/Fit for Life initiative :
a. will be linked to a Community of Practice
b. has Champions who will
* work to enhance understanding and dissemination of the initiative, and
* continue to develop operational understanding on managing these issues

Efficiency Blasting Techniques

Drilling Blasting Foreman profile ……



Efficiency Blasting Technology



Why do we blast…??????!!!

1. Mine is usually required simply to lossen the rock so that it can be excavated and transported
2. Result muckpile must simply be able to be efficiency and economically excavated, transported and placed
3. The blasting task is to convert the insitu rock mass into a muckpile of an appropriate fragment size distribution and suitable shape and loosness to suit the available excavation equipment
- withouth causing excesive damage
- noise
- vibration
- fly rock.

“To minimise the overal mining cost and maximise the value of the resulting product”.

Major factor in Fluencing Blast Efficiency
1. Paying attention to Detail
(is the key to safe, efficient blasting)
2. Each operation must be completed as precisely as possible
3. Efficient blast design require a Group Effort
4. Each operation controls the performance of the next

Optimum Blast Performance



Communication
1. Safe blasting Pactice require Good Communication between members of the same group and between groups.
2. Optimum blast design depend on Input from each group

Three key to Optimum Explosive Performance


Explosive Energy Distribution
1. Evenly distributed
2. Hole diameter to bench high Relationship
3. Angel drill
4. Appropriate pattern
5. Accurate drill

Evenly distributed Hole diameter to bench high



Angel drill Accurate drill



Appropriate pattern



Explosive Energy Confinement
1. Confined long enough after detonation
2. The Explosive path of least resistance must be controlled
3. Loaded according to geology
4. Stemming length and material type
5. Timming configuration
6. Accurate delay

Loaded according to geology


Explosive Energy Level
1. Sufficient to overcome the structure strength of the rock and permit controlled displacement
2. Base on the degree of fragmentation & displacement required
3. Account for site sensitivity
4. Evaluate high energy explosive for special site condition
5. Maintain explosive quality control with routine testing

Geological effect
1. Blasting result are in influenced “more by rock properties” than explosive properties
2. Rock properties
3. Rock strukture
4. Rock hardness

Rock stucture



Rock structure and hardness



Blast performance
1. Fragmentation
Factor affecting blasting performance in terms of fragmentation include:
a. oversize fragment
b. Fine
c. Easy of excavation
d. Issues detail to the transport of the muck
e. Mine customer requirement

2. Muckpile shape & digability
a. Muckpile shape and The mine Plan
b. Distribution of sweel and diggablility (pragmentation and swell together define diggabbility or the easy with wich a muckpile can be excavated)
c. Characteristics of excavation equipment

3. Grade movement



4. Damage
a. Wall Damage
b. Slope Damage
c. Coal Roof and edge damage
- Fracturing the top of coal
- Breackage and displacement of the coal edge
- Pushing coal in to the spoil together with overburden
- Mixing dilution material with the coal

5. Enviromental impact
a. Ground Vibration
b. Air blast

6. Downstream handling and processing

7. Cost

Timming



Blasting process



Drilling for multi bench

Efficient Haul Roads

A Design and Maintenance Guide

Haulroad Design and Maintenance


Major Factors in Haul Road Design



Many factors need to be considered in the design and maintenance of efficient haul roads. Unfortunately there is no single simple rule to follow, however this manual will highlight areas of focus and possible solutions.

“A haul road begins at the load face and ends at the tip head”

Road Geometry

The following criteria needs to be taken into consideration in haul road design:
Equipment size and performance capabilities
a. Safety
b. Topography
c. Mine Life
d. Rolling Resistance
e. Future Plans

Haul Road Design



a. Haul road geometry should provide for the smooth and cost-efficient operation of a haulage truck fleet at the designed operating speed and payload.
b. The road construction should be such that the above criteria is maintained throughout normal mining conditions

Road Width



a. One way - 3 truck widths.
b. Two-way straights - 3.5 truck widths.
c. Two way corners - 4 truck widths.



Grade

a. Maintain smooth grade.
b. Maintain consistent percentage.





Grade


Haul roads should be of constant grade with minimum transitions to ensure optimum performance. The selection of grade should be based on the capabilities of the machine and the expected rolling resistance

Rolling Resistance


For Off-Highway Trucks running radial-ply tyres, assume a minimum RR (rolling resistance) of:

a. Hard, well-maintained road . . . . . . . 1.5%
b. Well-maintained road with flex . . . . . . 3%
c. 25 mm/1” tyre penetration . . . . . . . . .4%
d. 50 mm/2” tyre penetration . . . . . . . . .5%
e. 100 mm/4” tyre penetration . . . . . . . .8%
f. 200 mm/8” tyre penetration . . . . . . .14%

In practice, a 5% increase in rolling resistance can result in up to a 10% decrease in production and a 35% increase in production costs.

Haul Road Alignment:

Geometric elements for operation at normal speeds
Equipment operator sees ahead a distance equal to or greater than the stopping distance.



a. Speed
b. Weight
c. Slope



Design criteria for vertical and horizontal alignment.

Sight distance
Distance from driver’s eye to hazard must equal or exceed required stopping distance.

Vertical. curve crests
Horizontal. curves

Grades
Flatter grades incur greater costs.
Traditional optimum 7%-9%
Reasonable to accept 10% max. sustained

What do you think grades should be?

Horizontal and Vertical Alignment



Design corners and crests that allow excellent visibility at normal travel speeds.
Use worst-case scenarios.

Corners


a. Use maximum practical radii.
b. Employ super elevation for higher speed operations.
c. Use super elevation >10% with caution.

Vertical Curves



To maximise safe working, corners and crests must be designed such that machine operators are capable of seeing and avoiding hazards when travelling at normal operating speeds.

Super elevation of Curves

Negotiating curves can generate high lateral tyre forces. These forces contribute to high tyre wear and ply separation. Super elevating the curve helps eliminate these forces. The amount of superelevation depends on the curve’s radius and the speed at which it is negotiated. The following table is a guide for providing the superelevation necessary to eliminate lateral forces.



Super elevated turns present a danger when slippery. For this reason, curves super elevated over 10% should be used with caution. Unless the proper speed is maintained, matching the elevation of the curve, a vehicle may slide off of the lower edge of the roadway. Super elevated curves should be maintained in good tractive conditions.





Super Elevation Run out



“Correctly designed transitions properly load truck frame, suspension and tyres, as well as prevent spillage.”

Constant Crossfall

To facilitate effective drainage of a haul road, it is necessary to elevate one side of the haul road from the opposite side.

Recommended Crossfall = 1% - 4%

The limiting criteria for maximum crossfall, is as the slope increases, so does the potential for uneven tyre / bearing wear.



One-Way Crossfall





Two-Way Crossfall



Cross-slope


a. Flats
Apply minimum slope to maintain drainage
Use constant crossfall when possible
b. Grades
Minimal cross-slope required

Bench Width



Truck must clear loader under full acceleration.
Minimum width = machine turning radius + width of safety berm.


Drainage and Safety Berms



Drainage system - sized to accommodate maximum rainfall.
Berm size - at least one-half wheel height.

Drainage



Any haul road design is only as good as the drainage capabilities of the design.
The key to maintaining a haul road in the best structural condition, is to limit the exposure of the surface water and to remove any surface water quickly.

If the construction of complex drainage is not feasible or economic, the simplest way to reduce water damage to a haul road is to elevate the haul road above the lay of the land.

Safety Berms (Windrows)



Berms are an effective way of preventing vehicles from straying into dangerous areas. They can be placed at intersections to control traffic and on the edges of steep slide slopes.
A berm should be a minimum ½ wheel height of the largest wheeled machine on site.

Pavement Cross Sections

A well structured and drained haul road is critical to the efficient operation of haul trucks.
The road base geometry is dependent on the capacity of the truck and the materials available.
Not all mines have the same base material properties….. But as long as the CBR (Californian Bearing Ratio) value is know, the depth of the base can easily be determined for a particular load.
The attached table, demonstrates a typical pavement cross section for the range of Cat Mining Trucks.

Summary:

a. Haulage way width
b. Max., sustained grades
c. Rolling Resistances
d. Stopping distance
e. Sight distance
f. Vertical curves
g. Super elevation rate, run out
h. Sub base
i. Surface materials
j. Sharp curves
k. Combined horizontal, vertical alignment
l. Cross slope
m. Typical cross sections

Electric Hazards

Safety and Accident Prevention

1. Static Electricity
a. Can build up on equipment or people
b. Use anti-static footwear
c. Use anti-static hoses

Static Charge
a. Type of clothing
* Synthetic is bad
b. Conductivity of footwear
* Rubber soles are bad
c. Dryness of skin
* Dry skin is bad
d. Humidity of air
* Low humidity (<60%) is bad Static and ANFO

Pneumatically conveyed ANFO can build up a static charge if the humidity of the compressed air is low

2. Stray Currents
a. Faulty or damaged cable insulation
b. Conductive ground
c. Wet conditions

Minimising Stray Currents
a. Use a low resistance Earth
b. Electrically bond all rails, cables, pipes, etc.
c. Check cable insulation
d. Insulate firing lines and detonating cables from any stray currents and earths
e. Short and insulate all detonator wires until contact has to be made

3. Lightning
a. Use a lightning monitoring system
b. Devise a standard lightning warning signal
c. Stop blasting operations and evacuate the area when a storm is approaching

4. Radio Frequency Energy
Detonator wires can act as aerials and generate a current from sufficient radio energy
a. No walkie talkies
b. No cell phones
c. No mobile radios
d. All of these must be switched off, if not barred, from the blast area

General Recommendations
a. Leave detonators in their original containers, coiled and shorted, until required
b. Earth yourself and any equipment before coming into contact with explosives
c. Strive for a blast area free of stray currents