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BEST PRACTICE

GUIDELINES

Health and Safety at Surface Mines,

Alluvial Mines and Quarries

November 2014


This best practice guideline ….

introductory sentence

summarising the content of the

guideline

ACKNOWLEDGEMENTS

Summary acknowledgement and thank you to key parties who contributed to the development of the guidelines.

DISCLAIMER

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TABLE OF CONTENTS

1 INTRODUCTION .................................................................................................................. 8

1.1 Purpose .............................................................................................................. 8

1.2 Scope ................................................................................................................. 8

1.2.1 What is a quarry? ................................................................................................. 8

1.2.2 What is an alluvial mine? ..................................................................................... 9

1.2.3 What is a surface mine? ....................................................................................... 9

1.2.4 Excavations associated with construction work .................................................. 9

2 INDENTIFY, ASSESS AND CONTROL HAZARDS .................................................................. 10

2.1 Hazard Management ........................................................................................... 10

2.2 Identify Hazards ................................................................................................ 10

2.3 Hazard Identification Methods .............................................................................. 10

2.4 Hazard Control ................................................................................................... 11

2.5 Hazard Monitoring .............................................................................................. 11

3 ROADS AND VEHICLE OPERATING AREAS ........................................................................ 12

3.1 Safe Site: Design, Layout, Construction and Maintenance ....................................... 12

3.1.1 Design and layout .............................................................................................. 12

3.1.2 Construction of roads and vehicle operating areas ........................................... 18

3.1.3 Maintenance and repair .................................................................................... 26

3.2 Safe Site - Operation .......................................................................................... 27

3.2.1 Reversing ............................................................................................................ 27

3.2.2 Signalling ............................................................................................................ 28

3.2.3 Parking ............................................................................................................... 28

3.2.4 Loading ............................................................................................................... 28

3.2.5 Overhead power lines ........................................................................................ 30

3.2.6 Other overhead structures ................................................................................ 31

3.2.7 Dust suppression ................................................................................................ 32

3.2.8 Fuelling vehicles ................................................................................................. 32

3.2.9 Railway sidings ................................................................................................... 33

3.3 Safe Driver ........................................................................................................ 33

3.3.1 Training and competency of drivers .................................................................. 33

3.3.2 Fitness to operate .............................................................................................. 33

3.4 Safe Vehicle ...................................................................................................... 33


3.4.1 Suitability ........................................................................................................... 33

3.4.2 Visibility .............................................................................................................. 34

3.4.3 Brake testing ...................................................................................................... 37

3.4.4 Inspecting and servicing vehicles ....................................................................... 39

3.4.5 Protection of drivers, operators or passengers ................................................. 40

4 TIPS (Including Stockpiles) ................................................................................................ 46

4.1.1 Stability of tips ................................................................................................... 46

4.1.2 Base preparation of tips and stockpiles ............................................................. 47

4.1.3 Access to tips and stockpiles .............................................................................. 47

4.1.4 Working a tip or stockpile .................................................................................. 47

4.1.5 Edge protection (berms) at tip points ................................................................ 51

4.1.6 Drainage of a tip ................................................................................................. 51

4.1.7 Evidence tip points may fail ............................................................................... 51

4.1.8 Other considerations ......................................................................................... 53

4.1.9 Training in tip safety .......................................................................................... 53

4.1.10 Reworking tips ................................................................................................... 53

5 PLANT, EQUIPMENT AND INSTALLATIONS ....................................................................... 54

5.1 Scope ............................................................................................................... 54

5.2 Siting of Plant .................................................................................................... 54

5.3 Dredges and Pontoons ........................................................................................ 55

5.4 Processing Plant and Equipment (Crushers, Conveyors and Screens) ........................ 55

5.4.1 Platforms, walkways, stairways and ladders ..................................................... 55

5.4.2 Guarding ............................................................................................................. 56

5.4.3 Conveyor guarding ............................................................................................. 67

5.4.4 Conveyor skirt boards ........................................................................................ 71

5.4.5 Feeding crushers ................................................................................................ 71

5.4.6 Blocked crushers ................................................................................................ 71

5.4.7 Slips and trips (spills) .......................................................................................... 73

5.5 Working Near Water ........................................................................................... 73

5.6 Prevention, Detection and Suppression of Fire and Explosion ................................... 74

5.6.1 Typical causes of fire .......................................................................................... 74

5.6.2 Hot work ............................................................................................................ 75

5.6.3 Control of explosive atmospheres ..................................................................... 75


5.7 Electricity .......................................................................................................... 76

5.8 Maintenance and Inspection ................................................................................ 76

5.8.1 Common hazards when undertaking maintenance .......................................... 77

5.9 Training and Supervision of Plant Operators .......................................................... 79

6 HANDLING AND STORAGE OF LARGE SHEET STONE SLABS ............................................. 80

7 GROUND CONTROL........................................................................................................... 81

7.1 Geotechnical Assessment .................................................................................... 81

7.2 Design of Excavations and Tips ............................................................................ 81

7.2.1 Drainage ............................................................................................................. 82

7.2.2 Shoring ............................................................................................................... 82

7.3 Working excavations, tips and stockpiles ............................................................... 82

7.3.1 Extraction methods ............................................................................................ 82

7.3.2 Historic underground workings ......................................................................... 82

7.3.3 Face heights ....................................................................................................... 82

7.3.4 Bench widths ...................................................................................................... 84

7.3.5 Extracting beneath water .................................................................................. 84

7.3.6 Stability of High Walls and Faces ....................................................................... 84

7.3.7 Undetonated explosives .................................................................................... 85

7.3.8 Stripping (removal and placement of overburden) ........................................... 85

7.4 Inspections........................................................................................................ 85

7.5 Falling from faces ............................................................................................... 86

7.6 Rehabilitation .................................................................................................... 87

7.7 Changes to the Excavation or Tip ......................................................................... 88

7.8 Lagoons, Ponds and Dams ................................................................................... 88

7.8.1 Wall stability ...................................................................................................... 88

7.8.2 Dewatering channels ......................................................................................... 89

8 EXPLOSIVES ....................................................................................................................... 91

9 WORKER HEALTH .............................................................................................................. 92

9.1 Respirable Dust.................................................................................................. 92

9.1.1 Drilling ................................................................................................................ 92

9.1.2 Crushing or milling ............................................................................................. 92

9.1.3 Screening ............................................................................................................ 93

9.1.4 Conveyors, feeders and loading ........................................................................ 94

9.1.5 Heating or drying ............................................................................................... 94


9.1.6 Bagging ............................................................................................................... 94

9.1.7 Sawing ................................................................................................................ 95

9.1.8 Miscellaneous situations.................................................................................... 96

9.1.9 Respiratory protective equipment (RPE) ........................................................... 96

9.1.10 Maintenance, examination and testing of control measures ........................... 97

9.1.11 Information, instruction and training ................................................................ 99

9.2 Noise ............................................................................................................... 100

9.2.1 Blasting ............................................................................................................. 100

9.2.2 Drilling .............................................................................................................. 101

9.2.3 Compressors .................................................................................................... 102

9.2.4 Excavators or draglines .................................................................................... 102

9.2.5 Wheel loaders, dump trucks and other vehicles ............................................. 102

9.2.6 Crushing or milling ........................................................................................... 102

9.2.7 Screening .......................................................................................................... 103

9.2.8 Conveying and feeding..................................................................................... 103

9.2.9 Heating or drying ............................................................................................. 103

9.2.10 Saws ................................................................................................................. 103

9.2.11 Miscellaneous situations.................................................................................. 104

10 TRAINING REQUIREMENTS ......................................................................................... 105

11 EMERGENCY MANAGEMENT ...................................................................................... 106

11.1 Communications ............................................................................................... 106

11.2 Suitable Access and Egress for Emergency Services............................................... 107

11.3 Means of Escape ............................................................................................... 107

11.4 Rescue and Emergency Equipment ...................................................................... 107

11.5 Training in Emergency Procedures ....................................................................... 107

12 EMPLOYEE FACILITIES ................................................................................................. 108

12.1 Washing Facilities .............................................................................................. 108

12.2 Toilets ............................................................................................................. 108

12.3 Drinking Water ................................................................................................. 108

12.4 Facilities for Employees who become ill at work .................................................... 109

12.5 Facilities for changing and storing clothes............................................................. 109

12.6 Facilities for meals ............................................................................................ 109

13 SITE SECURITY AND PUBLIC SAFETY ............................................................................ 110

13.1 Barriers ........................................................................................................... 110

13.2 Signage ........................................................................................................... 110


1 INTRODUCTION

The Best Practice Guidelines for Health and Safety at Surface Mines, Alluvial Mines and Quarries provides health and safety guidance to operators of a surface mine, alluvial mine or quarry and those involved in the planning and preparatory stages of any surface mine, alluvial mine or quarry operation.

1.1 Purpose These guidelines outline how operators can meet their obligations under the Health and Safety in

Employment Act 1992 (HSEA), the Health and Safety in Employment Regulations 1995 (HSE

Regulations), and the Health and Safety in Employment (Mining Operations and Quarrying

Operations) Regulations 2013 (HSE (Mining and Quarrying) Regulations).

While primarily aimed at employers, engineers, geotechnical specialists and operators of mines or

quarries, workers, contractors and health and safety representatives working at mines or quarries

may also find the information in these guidelines helpful.

The precautions required in a specific situation will depend on the extent and nature of the

particular risks involved. High-risk situations require higher standards of precautions than low-risk

situations. The examples of hazard elimination and risk controls given do not cover every possible

situation and may not be relevant to all sites. Mine or quarry operators should complete their own

risk assessments and take competent advice when implementing health and safety management

systems.

1.2 Scope The HSEA requires duty holders to have effective ways of managing health and safety. Duty

holders are not legally required to use this Guide, but it will help them to comply with the intention

of the law.

‘Must’ is used in this guidance in places where there is a legal requirement to achieve the desired

result. It is used to alert the reader to the need for that recommendation to be implemented.

‘Should’ is used in this guideline as a way of indicating a preference. It does not indicate a

mandatory requirement as other alternatives may achieve a desired result.

The HSEA, HSE Regulations and the HSE (Mining and Quarrying) Regulations place responsibilities

on many different people. These people are called ‘duty holders’. Duty holders must take all

practicable steps to make sure the workplace is designed safely and is adequately maintained to

avoid risk of injuries or harm.

Throughout this document we have referred to people who have duties as ‘you’. Where the

guidance is addressed to some other duty holder, for example a competent person, the text makes

it clear who it is intended for.

1.2.1 What is a quarry? A quarry includes:

a) All the surface extraction workings including preparatory and abandonment works


b) Tips (even if they are outside the site boundary)

c) Storage of extracted materials, including stockpiles

d) Settling ponds (even if they are outside the site boundary)

e) Areas used for the processing of extracted materials (this includes washing, drying and

bagging) where the processing is carried out at the place where the extraction is

undertaken;

f) Areas used for crushing or screening extracted or processed materials regardless of

whether it is at the place the material was extracted

g) The buildings and structures at the quarry that are used for the working of the quarry

h) Common areas (for example quarry roadways and railways, but not public roads or

railways under the control of a rail company)

1.2.2 What is an alluvial mine? An alluvial mine includes:



c) Storage of extracted material, including stockpiles

d) Areas used for the preparation of extracted materials (including crushing, screening and

washing) where the processing is carried out at the place of extraction

e) The buildings and structures at the mine that are used for the working of the mine

f) Common areas (for example roadways and railways, but not public roads or railways under

the control of a rail company)

g) Includes the extraction of gold from river deposits of sand or gravel and the extraction of

iron sand from sand or gravel

1.2.3 What is a surface mine? A surface mine includes:



c) Storage of extracted materials, including stockpiles

d) Settling ponds (even if they are outside the site boundary)

e) Areas used for the processing of extracted materials (including crushing, screening,

washing, drying, bagging and ore processing)

f) The buildings and structures at the mine that are used for the working of the mine

g) Common areas (for example roadways and railways, but not public roads or railways under

the control of a rail company)

h) Exploring for coal

i) Tourist mining operations (excluding alluvial mines)

1.2.4 Excavations associated with construction work These guidelines are not intended to cover excavations made solely for the purpose of carrying out

any building, civil engineering or engineering construction work where the extracted material is

used on the site at which the extraction has taken place (e.g. extracting rock from a face adjacent

to a road where the rock is used for embankment stability on that road). However people may find

sections of this guidance helpful when assessing and mitigating hazards in those situations e.g.

slope stability, bench widths etc.

For guidance on building, civil engineering or engineering construction refer the WorkSafe New

Zealand Approved Code of Practice for Excavations for Shafts and Foundations.


2 INDENTIFY, ASSESS AND

CONTROL HAZARDS

Making sure hazards do not cause harm or injury is the basis of health and safety in any workplace. This section covers the basics of hazard management.

For further information on hazard management systems for principal hazards, refer to the

WorkSafe New Zealand Guidance for a Hazard Management System for mines. For further

information on developing safety management systems for small operations refer to the WorkSafe

New Zealand Guide to developing Safety Management Systems for the extractives industry.

2.1 Hazard Management Planning a safe approach to a job can help identify the hazards of working at a site. The hazard

management process includes:

Hazard identification

Hazard assessment – decide if the identified hazards are significant

Hazard control – whether by eliminating, isolating or minimising the hazard

A safety plan or hazard register documenting this information

Hazard monitoring, including workplace exposure monitoring or health monitoring of

workers

A schedule to update the safety plan or hazard register

2.2 Identify Hazards The first step in the hazard management process is to identify hazards – anything that could injure

or harm someone.

Sections 7-10 of the HSE Act outline the process to identify, assess and control hazards.

2.3 Hazard Identification Methods A good hazard identification process is key to hazard management. You can identify hazards using:

Physical inspections: inspect the workplace and assess where someone could get injured

Task analysis: identify the hazards involved in each task. This should include what

happens when intervention is required e.g. breakdowns of equipment.

Process analysis: identify hazards at each stage of the production process

Best practice guidelines and standards

A hazard and operability study (HAZOP)

Accident investigation analysis: identify hazards and causes of harm from investigations

involving similar types of work

Hazard identification and management must be completed and monitored regularly to make sure

control measures are working and no new hazards have been introduced.


2.4 Hazard Control There is a hierarchy of controls or preferred order of control measures, which range from the most

effective to the least effective. The hierarchy of control measures is:

1. Elimination – removing the hazard or hazardous work practice from the operation. This is

the most effective control measure;

2. Isolation – preventing people from interacting with the hazard e.g. machine guarding,

remote handling;

3. Minimisation – if the hazard cannot be removed, replaced or isolated, a minimizing

control is the next preferred measure. This may include changes to tools or equipment,

introducing work practices that reduce the risk, limiting the amount of time a person is

exposed to a particular hazard and providing Personal Protective Equipment (PPE) where

appropriate.

There may be circumstances where more than one control measure could be used to reduce

exposure to hazards.

By using these controls you will be able to remove or reduce the exposure of the hazard to

workers. When setting up these controls it is always better to remove the risk rather than just

issue workers with PPE.

2.5 Hazard Monitoring Constantly reviewing hazards and control measures is important to ensure they continue to be

relevant and stop or control exposure to hazards or hazardous work practices. This includes

monitoring the health of those workers exposed.


3 ROADS AND VEHICLE

OPERATING AREAS

Roads and vehicle operating areas can pose significant risk at mines and quarries due to the size of the equipment used, the environment in which people work and the loads that are carried by some vehicles.

Key elements in improving vehicle safety are:

1. Designing the workplace to eliminate, isolate or minimise the hazards; 2. Using vehicles which are suitable and well-maintained; 3. Establishing and following safe driving and working practices.

These issues can only be addressed if all parties co-operate in identifying and controlling the

hazards involved.

This guidance is organised into three key areas to consider when carrying out a risk assessment:

1. Safe site (design and operation) 2. Safe vehicle

3. Safe driver

3.1 Safe Site: Design, Layout, Construction and

Maintenance

3.1.1 Design and layout Every site is different and likely to present different hazards and risks. However, a well-designed

and maintained site with suitable separation of vehicles and people will make workplace vehicle

accidents less likely.

The primary purpose of roads at mines or quarries is to get the mineral and non-mineral from the

mine or quarry floor to the processing plant, tips and stockpiles, and from there to the site

entrance. Roads may also service maintenance areas, offices, worker facilities, worker and visitor

parking areas and rehabilitation areas under maintenance.

The overall message is simple – safe workplaces are achieved by separating pedestrians and

vehicles and providing hazard-free vehicle routes.

3.1.1.1 Vehicle routes The most effective way of ensuring pedestrians and vehicles move safety around a workplace is to

provide separate pedestrian and vehicle routes.

Circumstances at the site might mean complete separation is not possible, so you should have

clearly marked pedestrian and vehicle routes, using measures such as barriers or signs.

Some of the considerations when deciding on the route include:

Slope stability and rock fall risk


What the road is used for and in particular avoiding potentially dangerous crossing points e.g.

intersections, railways, travel under overhead power lines etc.

Whether to have one-way or two-way routes Minimising the need for reversing with one-way systems and turning points Access to the site including weight restrictions on bridges, narrow roads etc. Ability to separate heavy and light vehicles Where distribution points will be (processing areas, weighbridge location, sheeting areas,

loading areas, points of sale to the public etc.) Impacts of land adjacent to the road Ability to separate pedestrians Avoiding hazards such as excavations, structures, fuel or chemical storage areas, overhead

power lines etc. Avoiding steep gradients and tight bends

Roads should:

Be adequate for the number, type and size of the largest vehicles that may use them Have firm surfaces, adequate drainage and safe profiles to allow safe vehicle movements

Be clearly signed with signposts and, where appropriate, road markings (e.g. on sealed roads) showing the right of way

Have speed limits and speed control measures specific to site conditions and the types of

vehicles using the route. It may be necessary to engage a specialist Traffic Engineer for complex traffic flows, especially at

sites with large processing operations, as they have the background and expertise regarding

potential engineering solutions.

Place holder for diagrams or photos similar to below but in a mine/quarry context

Figure 1: Example of traffic routes on complex site Figure 2: Example of traffic routes at a simple site

At sites where one-way systems are not practical, it may be appropriate to use cul-de-sacs or

other arrangements to allow vehicles to turn and drive forwards for most of the time. Turning

arrangements should ideally be a roundabout or a ‘banjo’ type, although ‘hammerhead’ and ‘stub’

arrangements may be acceptable.

Placeholder for diagram similar to below


Figure 3: Turning arrangements

3.1.1.2 Haul road considerations In addition to the carriageway, the haul roads may also need to accommodate:

Minor debris falling from the face immediately above the road and collecting at the base of the

face Rockfall protection measures may be required including a rockfall catch ditch, although risk

from rockfall should be minimised by considering alternative routes Drainage Edge protection Allowance for breakback of the bench crest during the life of the road. The amount of

breakback will depend on the geotechnical character of the face. Additional width on bends to accommodate the circular clearance diameter of the vehicles Additional allowance on busy roads for pedestrian routes. Pedestrians should, where possible,

use different routes or be separated from the carriageway by a barrier. Figure 4: Design principles for haul roads incorporated in benched quarry slopes illustrates how the

width of the bench carrying a haul road suitable for dump trucks might be determined as part of

an overall slope design by the mine or quarry designer.

A comprehensive design manual published by the US Bureau of Mines in 1977 (Design of Surface

Mine Haulage Roads – A Manual) includes recommendations for the design of all aspects of surface

mine and quarry haul roads, much of which is still very relevant today.



Figure 4: Design principles for haul roads incorporated in benched quarry slopes

3.1.1.3 Traffic management plan (TMP) Regardless of the size of the site, producing a site specific TMP is helpful in determining where and

what risks are present. Usually TMPs are visual in nature and identify vehicle routes, flow, access

points, parking areas and other vehicle control areas.

When using TMPs they should be updated to reflect any changes within the operation and

communicated to all site workers and visitors as required. This may be effectively achieved via

induction or signage.


Figure 5: Example of Traffic Management Plan

3.1.1.4 Site access Access to mines and quarries should be controlled to ensure unauthorised persons cannot progress

to a location where they may be at risk from site operations. This is particularly important for sites

where there are sales to the public or in residential areas. Control measures may include signage,

automated barrier arms or worker controlled areas (e.g. a weighbridge operator).

Once through the site entrance, direct vehicles and pedestrians to a safe area depending on the

nature of their visit. This is usually achieved effectively by signage but may also include road


marking, footpaths or barriers. Sufficient parking spaces to allow workers and visitors safe access

should be allowed for.

Where site vehicles cross a footpath or turn on to a public road, particular consideration should be

given to safeguarding the public. This may involve discussions with the local council or New

Zealand Transport Agency as part of the planning process.

3.1.1.5 Contractors and visiting drivers Careful consideration should be given to contractors and visiting drivers who are required to

access operational areas. Their needs should be assessed and where applicable, they should be

inducted to ensure they are aware of the site rules and procedures and what is expected of them.

For example light vehicles, such as maintenance vans, are invariably required to attend

breakdowns in operational areas. Consider issuing the visiting driver with the traffic management

plan or escorting them so their movements and operations are strictly controlled. For smaller sites,

a simpler system may be more appropriate (e.g. contacting on-site workers before entry).

Regardless of the size of the site you must establish safe systems of work which could include

vehicle visibility standards (refer 3.4.2.5) as required.

3.1.1.6 Pedestrian separation Pedestrian activity in operational areas should, wherever possible be restricted, particularly in the

hours of darkness. For certain operations (e.g. using explosives, working near a face etc.)

prohibited zones should be identified and clearly marked by signs, barriers, cones etc. Workers

should not enter operational areas as a pedestrian unless authorised to do so.

Pedestrians need to be kept away from vehicles, particularly where they have to reverse. They

should use separate routes wherever possible, for example pedestrian only areas and safe,

designated pedestrian routes. Where this is not possible, high visibility clothing and good lighting

reduce the risk, as do the other requirements relating to speed, reversing and visibility referred to

in this guidance.

Pedestrian and vehicle interactions can also be controlled by time. For example pedestrians only

allowed to enter areas when vehicles are stationary (e.g. lunch breaks) or vice versa. Where

separation by time is used as a control, check pedestrians have moved out of the area before

operations recommence.

For smaller sites, or where only a few people are working, holding areas may be more appropriate

than physical separation e.g. signage stating visitors are to remain at site hut until authorised to

proceed. Prohibited zones should be established and clearly signed.

Placeholder for diagram similar to below (changed to represent quarry/mine context)

Figure 6: Example of signage for small sites Figure 7: Example of pedestrian route


3.1.1.7 Traffic signage and markings Signage and line marking for drivers and pedestrians should be consistent with those used on

public roads (where a suitable sign or marking exists) to ensure instructions are easily

recognizable to drivers and pedestrians. Refer to the New Zealand Transport Agency manuals

Ministry of Transport Signs and Markings (MOTSAM) and Traffic Control Devices (TCDM) for further

information.

Keep signs clean to ensure their continued effectiveness.

Where driving is likely to be carried out in the dark, use illuminated or reflective signs or markings.

Signs could be used to inform drivers or pedestrians about the routes to use and also to instruct

people how to behave safely (e.g. whether they should use protective equipment, and how).

Warning signs to show hazards along the way could also be appropriate.

Placeholder for diagram similar to below (changed to represent mine/quarry context and NZ signs)

Figure 8: Weight restriction sign Figure 9: Sign helping arriving drivers know what to expect

3.1.1.8 Speed limits Site conditions can vary considerably over a relatively short period of time, either because of

changing weather conditions reducing visibility or by road conditions deteriorating; reducing

traction or becoming more slippery or because of the volume of vehicles which accelerates wear

and tear on bends and other areas where braking takes place.

Speed limits should be established based on the layout and condition of the roads and the

capabilities of the vehicles using the roads. For a given segment of a road, the speed limit should

be the speed at which, under normal conditions, sight distances are adequate, the curves can be

safely negotiated and any downgrades can be travelled without exceeding the braking capabilities

of the vehicles. Additionally the speed should be consistent with the width and smoothness of the

road so the driver can operator the vehicle with a reasonable margin for error and a reasonable

level of comfort and control.

Any such speed limits should be regularly monitored and reviewed to ensure they are still

appropriate. Where speed limits are set install adequate signage.

Emphasize to drivers the speed limit only applies under ideal driving conditions, and they are

responsible for reducing their speed to a safe level when road, weather or other traffic conditions

are less than ideal.

Further information on setting speed limits for on-road heavy vehicles is available in the New

Zealand Transport Agency publication Heavy Vehicle Stability Guide.

3.1.1.8.1 Speed on downgrades The speed limit posted on downgrades should take into account the braking capabilities of the

vehicles using the road. On haul roads speed limits need to be reduced in advance of a downgrade


to account for the lag time involved before retarders are engaged. Vehicle operator manuals

should be consulted to determine retarder lag time requirements.

3.1.1.8.2 Speed around a curve A vehicle travelling around a curve is held on the curved path by the friction between the tyres and

the road surface and, if the curve is banked, by the inward tilt of the vehicle. If the friction and

banking forces are exceeded, the vehicle will slide or have a tendency to overturn as it rounds the

curve.

The chances of sliding or overturning are increased the higher the speed and weight of the vehicle

and the sharper the curve. So for a given speed, there is a limit to the sharpness of a curve that

can be safely negotiated.

Limit the speed on curves to allow adequate traction.

3.1.1.9 Following distances If a vehicle follows another vehicle too closely, an accident can occur if the driver in the trailing

vehicle doesn’t react as fast as the lead driver to an emergency stop situation, or if the trailing

vehicle cannot stop as effectively as the lead vehicle. For these reasons, vehicles should follow one

another at a distance that provides a cushion or margin for error.

As vehicle speeds increase, the following distance should be lengthened to provide the necessary

level of safety. Drivers should increase their following distance in any conditions where the sight

distance is reduced (e.g. foggy conditions) or when road conditions may result in a longer stopping

distance (e.g. wet weather).

You should consider the speeds on both level roads and grades, and establish following distance

rules that provide for safe distances in all situations.

3.1.1.10 Lighting Lighting a mine or quarry site is much more difficult than lighting a flat area because of the

uneven surfaces and the consequential deceptive effects of shadows.

You must1 provide adequate lighting to all areas and especially to those areas used in hours of

darkness or in poor visibility or diminished lighting conditions. As a minimum, consider lighting at:

Junctions Around plant and buildings Pedestrian routes Where loading and unloading takes place

Lights provided on vehicles must be sufficient to enable them to be driven safely, but additional

lighting may be required for manoeuvring operations such as reversing or tipping.

The safety of security staff and others who have to move around the site at night must be

ensured. An appropriate combination of torches and floodlights could be appropriate.

3.1.2 Construction of roads and vehicle operating areas Roads and vehicle operating areas should be adequately constructed and suitable for the type and

size of vehicles using them. They should be surfaced with suitable materials and be well drained to

prevent a slippery surface. Vehicles should be able to move safely and without risk of accidentally

leaving the road or vehicle operating area or from any instability of the road or vehicle operating

area. The effects of vibration on the road or vehicle operating area from any use of explosives

should be considered.

1 HSE Regulation 4


For information on designing and maintaining driving surfaces in a way that is suitable for the

vehicles that use them you should consider the services of a qualified engineer with road

construction experience.

3.1.2.1 Road widths Road widths should be sufficient to allow two of the largest vehicles using the road to pass safely

unless adequate passing bays and turning points are provided (turning points are not

recommended on haul roads). Lanes should provide clearance, left and right of the widest vehicle

in use, which is equivalent to one-half the vehicle width. Provide separate roads for light vehicles

where possible.

Corners on haul roads should be designed wider than the straight stretch to allow for overhang of

vehicles on the corner. Switchbacks or other areas on haul roads requiring sharp curves should be

designed to take into account the minimum turning radius of the haul trucks.


Figure 10: Recommended minimum road width

3.1.2.2 Road gradient The steepness or grade of a roadway can have a significant effect on the driver’s ability to control

a vehicle. Two important aspects are:

1. The grade needs to be compatible with the braking capabilities of the vehicle; and

2. The grade will affect a vehicle’s stopping distance.

3.1.2.2.1 Determining the grade of a road The steepness of a road is normally expressed as “percent grade”. Information in vehicle manuals

about braking capabilities, for example, is normally given in terms of the grade in percent. The

grade in percent is determined by dividing the roads vertical rise by its horizontal run and

multiplying this value by 100. An easier way to remember this is the grade (in percent) is equal to

the number of metres the road rises (vertically) over a horizontal distance of 100 metres. For

example, a road that rises 10 metres over a horizontal distance of 100 metres is a 10% grade.



Figure 11: Road Gradient

The steepness of a road can be measured using surveying equipment or calculated using an

accurate topographic map. Regardless which method is used, the grade should be determined over

a portion of the road where the grade is constant. Where the steepness of the road varies, the

grades should be determined for different segments.

On a haul road it is recommended the maximum overall grade is restricted to 10%, with grades to

15% permitted for short distances. On any grade over 10%, it is especially important the vehicle

manual be checked to ensure the vehicle can be safely driven and to know what precautions need

to be taken.

3.1.2.2.2 Grade and vehicle compatibility The grade or steepness of a road is an area where you should have compatibility between road

conditions and vehicle capability. A critical safety concern is the brakes can handle the downgrades

without leading to loss of control of the vehicle. Different vehicles, having different performance

characteristics, will use the roads. The roads should be designed to accommodate the vehicles with

the least, or the most critical, braking capability, which is usually large haul trucks.

It is important vehicles are not overloaded as brake or retarder performances depend on the

steepness of the grade and on the vehicle’s weight (also refer 3.2.4.3).

3.1.2.2.3 Effect of grade on stopping distances On a downgrade, all other conditions being equal the stopping distance will be greater than on

level ground. On an upgrade the stopping distance will be shorter than on level ground.

3.1.2.2.4 Grade situations to avoid Avoid haul road alignments that result in a sharp curve near the top of a grade. Such a curve is

difficult to perceive at night, when headlights would tend to shine up into the darkness. If this

situation cannot be avoided, measures should be taken to define the curve, such as using

reflective markers.

Also avoid sharp curves near the bottom of a grade. Here, a vehicle may tend to pick up

momentum, making it more difficult to maintain control around the curve. If this situation cannot

be avoided, a safe speed for descending the grade should be posted and adequate restraining

measures, such as large berms or runaway provisions should be used as a precaution (refer

3.1.2.6 and 3.1.2.7).

3.1.2.3 Drainage Poor drainage control jeopardises the safety of a road by allowing:

Muddy and slick road surface material

Erosion to cause washouts and rutting

Standing water to soak and soften the road base

Fill sections and slopes to become saturated and unstable

Proper drainage is normally provided by the use of:

Vertical rise

Horizontal run


Cross slope. The purpose of surface drainage is to cause the water to leave the road as shallow,

non-erosive sheet flow in a direction and pattern chosen to suit various combinations of road

material, slope and terrain. To promote drainage either the road surface should be sloped from

one side to the other, or the road should be crowned, or raised, in the centre.

Unpaved roads normally have a cross-slope between 4% and 6% and paved roads normally have a

cross-slope of 2%. On haul roads a crown between 2% and 4% is preferred as steeper crowns can

increase tyre wear and metal fatigue in trucks. Avoid carrying crowns around curves (or bends).

Instead bank the road to the inside of the curve.

Free-draining road materials allow water on the road surface to drain down and out.

Roadside ditches collect drainage from the road surface and intercept runoff from adjacent

hillsides, keeping it off the road surface.

Culverts carry runoff under the road surface to a drainage course. Where using culverts they

should be buried deep enough to prevent being crushed by vehicles passing over them. Unless the

culverts lead to additional diversionary ditching, provide water run-outs to reduce the velocity to

the point where the water is non-erosive. On shallow slopes (less than 10%) with limited water

flows (<0.5m/s), this can be done with vegetated outflow areas. Energy dissipaters (riprap or

dumped rock) may be required where flow rates are higher.

In areas of naturally occurring high water table, such as swamps or watercourses, good drainage

should be provided and maintained to ensure low water levels in the road fill.

Temporary in pit roads with high ground water levels can be improved by placing gravel or rockfill

over the area or by installing pumping wells to lower the water table. Pumping wells may be cost

effective if it also reduces the water level in, and improves the stability of, the working face.

Drainage features should be large enough, and spaced apart, so they can deal with the greatest

expected demands on them.

While it is raining, or right after it rains, is a good time to check drainage is working properly.

3.1.2.4 Rock fall protection If roads are in use along the bottom of a face or below a tipping area, you should ensure any

vehicles using the road are a suitable distance from the face or tip to protect them from potential

rock falls. Where appropriate install catch bunds (or berms) to catch any falling materials. Berms

may need to be designed by a Geotechnical Specialist.

Determine a suitable inspection and maintenance regime to ensure the berms continued

effectiveness. Maintenance regimes should include clearing of slips or rock falls which will reduce

the catchment area if left to accumulate.

Placeholder for diagram of rock fall protection

3.1.2.5 Sight distance for stopping Design roads with viewing distances and alignments that ensure a vehicle rounding a curve,

cresting a hill, descending a grade, or approaching a junction can stop in time to avoid an object in

the road or a vehicle pulling onto the road.

Placeholder for more information on sight distances



Figure 12: Road alignment

3.1.2.6 Edge protection (berms or stop blocks) The failure to provide adequate edge protection is the cause of many vehicle incidents. Adequate

edge protection should be provided where there is a drop, lagoon or other hazards which would

put the driver, or others, at risk if the vehicle left the road or vehicle operating area (e.g. tip point,

ramp etc.).

3.1.2.6.1 Purpose of edge protection The purpose of edge protection is to warn the driver that the edge is there. It works by catching

the vehicle or by overturning it back on to the road. To do this it has to be well constructed and

sufficiently large to absorb the momentum of the vehicle. Part of the site tip and excavation rules

should determine the size and type of edge protection you intend to use and where.

3.1.2.6.2 Height of edge protection On roads, tip points or ramps used by heavy vehicles, the minimum acceptable height of the edge

protection is 1.5 metres or the radius of the largest wheel or tyre – whichever is greater. For the

majority of cases 1.5 metres will be adequate as they are sufficient to overturn the vehicle back

onto the road (another reason to wear seat belts).

However in some cases the edge protection may need to be higher to stop a vehicle going over an

edge. For an eighty five tonne vehicle or less tests have shown that you need a berm of three

times axle height. For vehicles of greater capacity than 85 tonnes a height of four times axle

height would be required. When designing roads a higher edge protection should be considered for

areas where the vehicles are more likely to run through edge protection.

Placeholder for diagrams similar to below

Figure 13: Edge Protection for large vehicles

3.1.2.6.3 Construction of edge protection Edge protection may consist of purpose made crash barriers or suitable berms made from

excavated material, for example scalpings. Edge protection should be built on a good foundation.

Sand pushed off the edge of the road will be too soft to work and gives a false sense of security.


Additional protection may be needed in high-risk areas, such as sharp bends or steep haul roads,

where runaway provisions could also be considered (refer 3.1.2.7).

Edge protection less than 1.5 metres, or the radius of the vehicle wheel, or with sloping slides,

makes an ideal ramp for the vehicle to run over, and is totally ineffective (refer Figure 14).

Blocks of stone or tyres placed along the edge of a road, tip head, ramp or bench, which can be

easily pushed out of the way by a vehicle are not suitable for edge protection (refer Figure 15).

A bank of unconsolidated material (e.g. scalpings) is suitable if it is big enough to allow the

vehicles momentum to be absorbed. The impact face should be as nearly vertical as possible and

the height as described above (refer Figure 16). When cutting the inside slope to steepen the

berm, make sure enough material is initially placed so once the berm is cut, the base width will

still be adequate. The base width should be at least the width the berm would have, if both its

outside and inside slopes were at the material’s angle of repose. It is important that a full base

width be maintained to serve the function of keeping trucks back from the edge of a pile (refer

Figure 17).

Rocks can be used if they can safely absorb the impact, for example by heaping materials like

scalpings between and behind the rocks to provide an adequate barrier. A violent stop due to

impact with large rocks would increase the risk of injury to the driver, and of damage to the

vehicle, and should be avoided (refer Figure 18).

Where necessary to ensure the drainage of surface water, gaps may be left in the windrow, or

other drainage systems provided. Any gaps should not be wide enough for a vehicle to pass

through. Any gaps should be designed so a vehicles wheel cannot be trapped i.e. at an angle

leading away from the travelling direction (see figure 19).


Figure 14: Ineffective edge protection – sloping sides

Figure 15: Unsuitable edge protection – blocks of stone can be pushed out of the way

Figure 16: Suitable edge protection - a bank of scalpings big enough to absorb the vehicle's momentum

Figure 17: Suitable edge protection - the width of the berm is as wide as the normal angle of repose

Angle of

repose


Figure 18: Suitable edge protection - a rock which can safely absorb the impact

Placeholder for diagram showing gaps in

windrow for drainage

Figure 19: Gaps in windrow for drainage

3.1.2.6.4 Maintenance of edge protection Windrows can deteriorate due to weathering, and should be regularly inspected and maintained to

ensure their continued effectiveness.

3.1.2.6.5 Stop-blocks When a truck tips off a ramp or into a hopper adequate stop-blocks (or wheel stops) should be in

place. The block should be designed, installed and of sufficient height to offer definite restraint.

The stop-block should be adequate for the largest vehicles that will use the tip point. Clear spills

that accumulate in front of the stop-block as these effectively reduce the height of the block.

3.1.2.7 Runaway provisions Safety provisions to mitigate hazards caused by runaway vehicles can be provided as part of the

road design. One method is to use piles of loose granular material known as collision berms placed

strategically along the centreline of the road. In the case of brake or retarder failure, the driver

manoeuvres the vehicle into the line with the pile so the vehicle straddles the pile and is brought

to a halt.

Runaway or escape lanes are another method that can be used where space is available. Where

zigzag haul roads are used, the escape lanes are usually conveniently located at the beginning of

each sharp curve. The escape lane has a reverse grade (up to 20%) and is covered in a bed of

loose gravel or coarse sand. Collision berms, while usually less expensive than escape lanes, can

result in overturning of runaway vehicles.



Figure 20: Runaway-vehicle collision berms

3.1.2.8 Surface material The type of surface will depend on the volume and type of vehicles using the road and on the

specific site conditions, the anticipated life of the road and environmental considerations including

proximity to residential properties.

All roads should be adequately surfaced and drained to ensure vehicles can be driven safely. If

necessary, materials may need to be imported to the site.

The materials that make up the road surface and road base need to serve two functions:

Provide adequate traction

Provide support for the vehicles without excessive sinking in or rutting

3.1.2.8.1 Traction The forces required for accelerating, turning, or stopping vehicles are developed by the friction

generated between the tyres and the road surface. The amount of friction available varies with

different road surfaces and is indicated by a friction coefficient, which is a measure of how well the

tyre grips the road surface. The friction coefficient indicates how much of the total weight of the

vehicle can be generated as a force between the tyre and the road surface. The higher this force,

the better the grip on the road and the more control the driver has in climbing, steering, and

stopping.

Table 1 shows some typical friction coefficients for a variety of road surfaces. Notice the significant

differences in values varying from concrete (0.9) down to ice, which can be practically zero. The

value of 0.9 for rubber tyres on concrete means 90% of the weight on a tyre is available as

braking force (presuming that the brake components themselves can provide this much braking

force).


Table 1: Typical values for the coefficient of friction between rubber tyres and various road surfaces

Material Dry Wet

Clay 0.60 – 0.90 0.10 – 0.30

Concrete 0.90 0.60 – 0.80

Gravel road, firm 0.50 – 0.80 0.30 – 0.60

Gravel road, loose 0.20 – 0.40 0.30 – 0.50

Ice 0.00 0.00

Sand, loose 0.10 – 0.20 0.10 – 0.40

Snow, packed 0.10 – 0.40 0.00

These different values show why it is so important drivers adjust their speed to suit the road

conditions. All other factors being equal, it will take a longer distance to stop when the traction

values are low. If the friction coefficient is reduced by half, once the brakes are applied the

stopping distance is doubled. Friction values also affect steering ability. When traction is low, the

defensive driving measure is to reduce speed.

The road surface coefficients given in Table 1 are the maximum values for the conditions indicated.

Maximum tyre grip occurs when the tyre is still rolling and just before the tyre would lockup and

slide. Once a tyre locks up and goes into a skid, the available friction is reduced. This reduction

can be as much as 50% under poor road conditions. This is why antilock brakes are of such

benefit. They help prevent tyres from locking up, so the available friction stays at the higher

values. Brakes stop the wheel, but it's the grip between tyre and road surface that stops the

vehicle.

A road surface of gravel or crushed stone is preferred for roads. While some other materials

provide better traction when dry, a gravel road surface offers good traction values in both wet and

dry conditions.

3.1.2.8.2 Support Rutting of a soft road surface can create a safety hazard by affecting a driver’s ability to control

the vehicle and by subjecting the driver to rough or jarring conditions. Rutting occurs when tyres

sink into the road surface because the road material doesn’t offer adequate support. Fine-grained

soils, even when well-compacted, may not support the tyre loads imposed by large haul trucks,

especially during wet conditions.

To prevent or minimize rutting of the road surface, a road base material with sufficient strength to

support the tyre loadings needs to be provided. A layer of gravel or crushed stone, for example,

has higher bearing strength and will distribute the tyre loadings over a larger area. The use of a

layer of geotextile can assist in providing a road base that will better support the tyre loadings. In

general, when well-constructed and properly maintained, gravel or crushed stone offers a roadway

that, in a variety of weather conditions, resists deformation and provides a relatively high

coefficient of friction. Where road base material has inadequate support strength, a great deal of

maintenance work will be necessary to keep the road in good condition.

3.1.3 Maintenance and repair Roads or vehicle operating areas should be regularly maintained so they do not develop bumps,

ruts or potholes which may make control of vehicles difficult or cause health problems due to

whole body vibration. In addition excess mud and slurry can seriously affect the manoeuvrability

and braking potential of the vehicles using the road.

You should suppress dust to ensure adequate visibility for drivers and pedestrians. Refer Section

3.2.7 for more information on dust suppression.


3.2 Safe Site - Operation

3.2.1 Reversing Reversing is notoriously hazardous, especially in confined areas such as around hoppers and other

plant, coaling sites, on benches and tips.

The most effective way of reducing reversing incidents is to remove the need to reverse by, for

example, using one-way systems and turning bays. Where this is not possible, organise sites so

reversing is kept to a minimum. Where reversing is necessary, consider the following:

Ensuring adequate visibility of the driver

Providing safe systems of work Providing adequate supervision and training

In areas where reversing is unavoidable, there should be effective arrangements to ensure it is

safe to reverse every time. To reverse safely the driver needs to be able to see the danger area at

the rear of the vehicle, or receive automatic warnings of any obstruction. The area should be clear

of pedestrians and other vehicles when reversing takes place.

Where safe reversing relies on reversing aids, for example closed circuit television (CCTV), the

vehicle should not be used if the devices are defective.

When it is dark, the site lighting and vehicle lights must provide sufficient illumination for the

driver to see clearly when reversing.

No single safeguard is likely to be sufficient on its own during reversing. All the relevant

precautions should be considered together. See Table 2 below.

Table 2: Control measures for reversing options

Type of Control Examples of Controls

Eliminate need to reverse Implement one-way systems around site and in loading and

unloading areas

Provide designated turning areas

Reduce reversing operations Reduce the number of vehicle movements as far as possible

Instruct drivers not to reverse, unless absolutely necessary

Ensure adequate visibility and

proximity devices for drivers

Fit CCTV, radar, convex mirrors etc. to overcome restrictions to

visibility from the driver’s seat, particularly at the sides and rear

of vehicles. Fit proximity devices to warn the driver of possible

collision with an object or person.

Ensure safe systems of work

are followed

Design vehicle reversing areas which:

o Allow adequate space for vehicles to manoeuvre safely

o Exclude pedestrians

o Are clearly signed o Have suitable physical stops, e.g. bunds of material or

buffers, to warn drivers that they have reached the limit of the safe reversing area

Ensure everyone on site understands the vehicle rules

Ensure all vehicles on site are fitted with appropriate

warning devices

Check that procedures work in practice and are

actually being followed


3.2.2 Signalling The job of signallers (or spotters) is to guide drivers and make sure reversing areas are free of

pedestrians or other hazards.

If you are using signallers, make sure:

Only trained signallers are used;

They are clearly visible to drivers at all times; A clear and recognised system of communication is adopted; They stand in a safe position throughout the reversing operation.

3.2.3 Parking Park vehicles on level ground wherever possible to minimise the possibility of them being set in

motion. Vehicles stopped or parked on slopes should never be left unattended unless the wheels

are secured, chocked, blocked or angled against a suitable berm so the vehicle cannot move

accidentally. Good practice for heavy vehicles is to reverse park into wheel drains (or spoon

drains).

When leaving a vehicle unattended, switch off the engine, remove the ignition key, apply all

brakes and select the appropriate gear to suit any gradient. Keep the key or any other device for

starting vehicles in a secure place to prevent unauthorised starting of vehicles.

Lower ground engaging equipment i.e. excavator buckets, dozer blades, ripper teeth and scraper

bowls to the ground when parking and if stopping to be serviced, inspected or fuelled.

Vehicles should never be parked in the swing radius of an excavator or the manoeuvring zone of

other operational vehicles unless in accordance with a safe system of work that involves the

immobilisation of the other vehicles. When it is necessary to park light vehicle close to non-

operational heavy vehicles e.g. for maintenance purposes, prevent the heavy vehicles from moving

before entering the area and ensure it remains immobilised throughout the operation.

You must establish a safe system of work to ensure anyone leaving a vehicle does not enter a

hazardous area. This includes when operators are undertaking daily start-up inspections.

3.2.4 Loading Loading for the purposes of this guidance refers to the loading of vehicles with excavated material.

Information on safety when loading mobile plant or equipment (or other loads) from transporters

or trucks is available from the New Zealand Transport Agency (The Truck Loading Code).

Depending on the nature of the site, loading may be into haul trucks, truck and trailer units, utility

vehicles or car trailers (e.g. where selling of product is directly to the public).

Where loading light vehicles (utilities or car trailers) select suitable mobile plant or purpose built

devices (hoppers) that reduce the risks to other vehicles or pedestrians e.g. using a bobcat rather

than an excavator. While the principles of the information below will apply in these situations,

some specific instructions may not. You should complete a risk assessment to determine this.

The loading zone is defined by the manoeuvring of the mobile plant and the manoeuvring zone of

the vehicles being loaded.

3.2.4.1 Entering a loading zone Prohibit the entry of any vehicle (other than those being loaded) or pedestrian into a loading zone

while excavation and loading operations are active.

Where vehicles or pedestrians are required to enter loading zones determine a safe system of work

which specifies communication protocols. For example the system could specify contact is made

with the mobile plant operator to request permission to proceed. On larger sites this may be co-

ordinated by a supervisor or other designated person in control of traffic movements.


The safe system of work should also specify steps to be taken, including the immediate suspension

of works, if a vehicle or pedestrian enters the loading zone without prior permission.

Placeholder for diagram of a loading zone showing prohibited zones (swing radius of an excavator,

travel path of a loader) and possibly something like the restricted area diagrams from the Coalpro

document as shown below.

Figure 21: Restricted zones when loading

3.2.4.2 Loading operations The vehicle should be as level, stable and stationary as possible. Apply all vehicle and trailer

brakes.

Follow these principles:

Spread loads as evenly as possible during loading. Unbalanced loads can make the vehicle or trailer unstable, or overload individual axles.

Rest loads as close as possible to the bulkhead. However, avoid loading drawbar trailers too far forwards as this can lead to a snaking effect as the combination moves forwards.

Avoid loading to the back of the trailer as this can cause the trailer to tip backwards

(especially for single-axle trailers). This can reduce the grip the vehicle has on the road surface, as the wheels are lifted away from the ground.

Arrange loads close to the middle of the trailer and slightly forward of it to place enough downward force on the tow bar to keep the trailer coupled, but not enough to put too much pressure on the tow vehicle suspension or hitch

Balance loads across the axle (or axles) of a drawbar so that coupling or uncoupling can be managed easily and safely, and so the trailer is stable when being transported

Wherever possible, couple (or uncouple) drawbar trailers unloaded as this makes them easier to handle and generally safer to work with

Loose bulk loads being transported in a vehicle on a public road without a tarpaulin fitted should at no time reach higher than 100mm below any side of the vehicle

Doors to bulk bins must be closed to avoid loose bulk loads from being blown out As loose loads normally rely on the vehicle body for restraint it is extremely important to

ensure all body to chassis attachment points (e.g. ‘U’ bolts, hinge pins, hinge pin brackets etc.) are secure and these and the body are in sound condition.

When travelling on a public road, loose bulk loads should be tarped, netted or sheeted as

appropriate whenever there is a risk of load shedding due to wind action or movement. Body work

should be kept in good condition in order to minimise the hazards during transportation. This

applies particularly to badly fitted tail gates that permit gravel and stones to fall to the roadway.

If the load is to be sheeted, an on-vehicle sheeting device that can be worked from ground level or

a safe place higher up should be provided, or a sheeting platform or gantry should be available on

site. Refer section 3.4.5.4.1 for more information on sheeting.



Figure 22: Loads should be spread evenly across the vehicle

Figure 23: Cover loose bulk loads when travelling on a public road

Body height extensions (topper boards) should only be used where conditions and type of load

permit. In these circumstances, their supports should be adequately fixed to the existing body. It

is not considered adequate to rely on the load within the parent body of the vehicle for support.

Where necessary, tie-chains should be used transversely at the top of body extensions to prevent

sideways spread.

3.2.4.3 Weight The vehicle should be able to take the full weight of everything it is asked to carry. No vehicle

should ever be loaded beyond its ‘rated capacity’ (the original vehicle manufacturer should provide

this information) or its legal limit of gross weight if it is to be used on public roads. Overloaded

vehicles can become unstable and difficult to steer, or be less able to brake.

3.2.5 Overhead power lines Overhead power lines on a site are likely to pose a significant risk, unless vehicles cannot approach

them. Vehicles do not need to strike the overhead lines for injury to occur – electricity can arc

through a surprising distance depending on the voltage and conditions.

Precautions such as those illustrated in Figure 23 are required if it is possible for a vehicle to reach

the danger zone around the cables. Assessment of the risk should take account of the possibility of

vehicles travelling when tipped.

The most effective way to prevent contact with overhead lines is by not carrying out work where

there is a risk of contact with, or close approach to, the wires. If you cannot avoid working near an

overhead line and there is a risk of contact or close approach to the wires, you should consult its

owner to find out if the line can be permanently diverted away from the work area or replaced with

underground cables. This will often be inappropriate for infrequent, short-duration or transitory

work.

No vehicle or its load can approach or work within at least 4 metres of an overhead power line

unless written consent is given by the lines owner.

Where vehicles are likely to be used at any time in the proximity of overhead power lines, a sign

must2 be installed in a conspicuous place as near as practicable to the driver’s position. The sign

should be maintained in a legible condition and must state “Warning: Keep clear of power lines”.

If work needs to be carried out below power lines and it is possible that vehicles could reach into

the danger zone, the lines should normally be isolated and earthed before work begins. If this is

not feasible, physical safeguards such as chains on the booms of excavators may be required to

prevent vehicles reaching into the danger area.

Emergency procedures should outline what to do in the event of contact with an overhead power

line.

2 Electricity Safety Regulations


Figure 24: Working under overhead power lines

3.2.5.1 Mobile and transportable conveyors

3.2.5.1.1 Warning sign ‘Overhead Power’ A permanent sign warning of the hazards of overhead power lines should be installed in a

conspicuous place at each towing point on a transportable conveyor and adjacent to the driving

controls of a mobile conveyor. This applies to mobile or transportable conveyors which have any

parts that can be raised in excess of 2 metres. Signs must state “Warning: Keep clear of power

lines”.

3.2.5.1.2 Safety distances from overhead power lines The conveyor must not approach any closer than at least 4 metres to any live overhead power

line.

3.2.6 Other overhead structures You should measure and record the vertical clearance under overhead obstructions on routes. The

measurement should take account any underhanging lighting, ventilation or other service features,

which are often added after the initial design.

If possible, routes used by vehicles should allow for a 6 metre clearance (the desirable clearance

for over dimension routes on NZ roads).

Protect any potentially dangerous obstructions (such as overhead electric cables or pipes

containing flammable or hazardous chemicals) using goalposts, height gauge posts or barriers.

Vehicle routes should also avoid anything that might catch on or dislodge a load.

Give clear warnings of any limited width or headroom, in advance and at the obstruction itself e.g.

signs or audio warnings. See section 3.1.1.7 for more information about signs.

If there is a steep ramp running down to an overhead obstruction, the effective height could be

reduced for longer vehicles as shown in figure 24.


Figure 25: Slopes can make a difference to the amount of clearance a vehicle needs

3.2.7 Dust suppression Dust generated by moving vehicles can reduce visibility to dangerous levels and harm engines.

Dust is typically reduced by application of water to the road surface. In summer, watering helps

maintain compaction and strength of the surface layer. It also maintains the surface shape and

reduces the loss of gravel. Watering also helps reduce wash boarding or corrugation of the road

surface.

The quantity of water needed to control dust depends on the nature of the road surface, traffic

intensity, humidity and precipitation. During drier months, a typical road may require 1 to 2 litres

per square meter per hour. Liquid stabilisers and polymers can also be used. In addition to dust

suppression, these can help strengthen the surface layer as well as provide a degree of water

proofing.

3.2.7.1 Safety when watering roads The watering of roads to suppress dust has the potential for vehicle accidents; either by the water

tanker turning over or by the roads becoming very slippery because of wet bends and declines and

any other sections of road where brakes may be applied (e.g. intersections).

Drivers of water tankers should take extra care, especially when full, to avoid driving across

gradients due to the potential increase in instability of trucks carrying fluids.

‘Patch’ or ‘spot’ spray roads and avoid blanket spray or excessive amounts of water being

deposited on the roads (especially in braking areas, gradients and junctions of haul roads). It is

recommended water tankers are fitted with pulsed infusion or similar systems that can be

effectively controlled by the operator to manage the water output.

Procedures for watering roads should detail what actions to take where roads have inadvertently

been excessively watered potentially reducing traction. This is particularly important on haul roads.

3.2.8 Fuelling vehicles Fuel vehicles in areas designated for this purpose and in accordance with the site fuelling

procedure. Fuel vehicles on level ground, in a safe position away from normal site traffic. Fuelling

should not take place adjacent to faces or high walls.

Lower excavator or loader buckets, dozer blades and rippers to the ground before fuelling

commences.

Establish suitable storage facilities for fuel taking into account such things as:

Storage containers (including bunds as appropriate); Labels; Transportation; Segregation; and Ventilation.


3.2.9 Railway sidings Placeholder for information on railway sidings or lines

3.3 Safe Driver Drivers must3 be competent to operate a vehicle safely and receive appropriate information,

instruction and training for the make and model of vehicles they use. It is particularly important

that younger or less experienced drivers are closely monitored following their training to ensure

they work safely.

Drivers should wear their seatbelts. Accident experience has shown that staying in the cab with

the seatbelt fastened offers the best opportunity to avoid a serious injury or death when a vehicle

goes out of control.

3.3.1 Training and competency of drivers Training requirements will depend on an individual’s experience and the training they have

previously received. Your risk assessment should help decide the level and amount of training a

person receives.

In general, newly recruited drivers have the greatest training needs but there should also be a

programme of reassessment for more experienced drivers (e.g. every two years).

It is important to assess the information provided by newly appointed drivers, particularly in

relation to their training and experience. Monitor them on-site, to establish both their actual level

of competence and any further training needs.

Keep a training record for each driver to help ensure the most appropriate person is allocated a

particular task and identify those requiring refresher training.

For more information on training and supervision refer section 0.

3.3.2 Fitness to operate A person’s fitness to drive a vehicle should be judged on an individual basis but the aim is to

match the requirements of the task with the fitness and abilities of the driver.

Detailed advice on medical standards of fitness to drive is published by the New Zealand Transport

Agency (NZTA): http://nzta.govt.nz/resources.

3.4 Safe Vehicle

3.4.1 Suitability Vehicles must4 be suitable for the type of work they do and for the place where they are used.

The selecting of suitable vehicles can reduce or eliminate many risks at the site. It is generally

much easier and cheaper to start with the right vehicle than to modify it later. The following are

important factors to consider when choosing a vehicle:

The effectiveness of the braking system, bearing in mind the slopes it is expected to work on;

Adequate all-round visibility for the driver;

Stability under all foreseeable operating conditions; Protection for the driver and any passengers from falling objects (falling object protective

structure (FOPS)), overturning (roll-over protective structure (ROPS)) and seat belts; Safe access and egress to and from the cab and other areas of the vehicle where access

may be required; Lights, windscreen wipers, horn and other warning devices;

3 HSEA Section 13

4 HSEA Section 6 (c)

http://nzta.govt.nz/resources


Guarding for dangerous parts during use or maintenance work;

Protection for the driver and any passengers from rain, high and low temperatures, noise,

dust and vibration; Suitable seating for the driver and any passengers Maximum loads that may be carried or towed

3.4.2 Visibility To manoeuvre safely the driver needs to be able to see all around the vehicle or to be

automatically warned if there is a person or object in the hazard area. Vehicles should be designed

to provide adequate visibility and be fitted with windows (including side windows), mirrors, closed

circuit television (CCTV) and sensing equipment as appropriate.

Many vehicles have substantial blind spots, not only immediately behind the vehicle, but also

alongside and immediately in front of it. Accidents occur when vehicles move off or turn while a

pedestrian or vehicle is passing or parked in a blind spot.

As a guide the driver should be able to see a 1 metre high object 1 metre away from any danger

point of a vehicle and be able to detect the presence of other vehicles and pedestrians in their

intended line of travel when moving off or when reversing.

3.4.2.1 A clear view Drivers should not place items in the windscreen areas or in the way of mirrors or monitors, where

they might impede visibility from the driving position. The area of the windscreen that is kept clear

by the wipers should not be obscured, and nor should the side windows. Windows and mirrors

should be kept clean and in good repair. Dirt or cracks can make windows or mirrors less effective.

3.4.2.2 Closed-circuit television (CCTV) CCTV may help drivers to see clearly behind or around the vehicle. CCTV can cover most blind

spots.

Colour systems can provide a clearer image where there is little contrast (for example, outside on

an overcast day). However, black-and-white systems normally provide a better image in lower

light or darkness, and usually come with infra-red, which can be more effective than standard

cameras at night.

Monitors may have adjustable contrast, brightness and resolution controls to make them useful in

the different light conditions in which they will be used. You may need to use a hood to shield any

monitor from glare.

If possible, on heavy vehicles fit the camera for a CCTV system high up in the middle of the

vehicle’s rear (one camera), or in the upper corners (two cameras). This will provide a greater field

of vision and a better angle for the driver to judge distance. It also keeps the camera clear of dust

and spray, and out of the reach of thieves or vandals.

Drivers should not be complacent about safety even with CCTV systems installed. They must be

trained in proper use of the equipment.

3.4.2.3 Radar and reversing alarms Radar is useful as a reversing aid on open sites where the number of unwanted alarms is likely to

be low.

Reversing alarms may be drowned out by other noise, or may be so common on a busy site that

people do not take any notice of them. Using reversing alarms may be appropriate (based on your

risk assessment) but might be most effectively used with other measures, such as warning lights.

Directional reversing alarms may be best on busy sites (i.e. sound is directed to the rear of the

vehicle).


3.4.2.4 Pedestrians Even when the driver’s visibility if considered adequate, pedestrians should, so far as is reasonably

practicable, be prohibited from vehicles operating areas.

3.4.2.5 Light vehicles Significantly smaller vehicles may be at risk of being crushed by heavy vehicles. Like pedestrians,

they should ideally be kept away from areas where heavy vehicles operate. If this cannot be

achieved, paint them distinctive colours, fit them with rotating beacons or otherwise make them

readily visible to drivers of other vehicles.

For light vehicles expected to enter heavy vehicle areas the following examples should be used:

Fit a warning flag (buggy whip) which can be seen by the operator of the tallest vehicle Establish exclusion zones around heavy vehicles Fit vehicles with rotating or flashing orange warning lights visible 360 degrees from the vehicle

unless multiple lights are fitted to cover blind spots

Fit two-way radios so drivers can communicate with site supervisors or directly to heavy

vehicle drivers Fit with reflective strips when operating in the hours of darkness Placeholder for diagram(s) similar to below (examples of different diagrams we could consider)

Example of blind zones around a typical haul truck. Grey areas indicate where operator cannot see

a 6-ft-tall person.

Picture from http://www.cdc.gov/niosh/mining/content/pwsselection.html

Specific to a type of vehicle (TR100) but potentially work something up like this in terms of

improved visibility based on types of mirrors and cameras - Information from CoalPro

http://www.cdc.gov/niosh/mining/content/pwsselection.html


HSE Document: Quarries – Vehicles and visibility

HSE Brief Guide document – Visibility around earthmoving machines

Photo montage of large dumper truck fitted with CCTV and mirrors to improve visibility from the

driving position from HSE HSG144 - The safe use of vehicles at construction sites


Plan view of visibility alongside and at rear of large articulated vehicle From HSE 144 The safe use of vehicles on construction sites

Figure 36 Side-mounted mirrors Figure 37 Mirrors fitted to Figure 38 CCTV monitor in vehicle cab off-highway construction plant

3.4.3 Brake testing A suitable inspection scheme must be in place to ensure that brakes are in good condition at all

times. This is often combined with other maintenance work.

Electronic brake testing equipment is available which can be used regularly to accurately measure

brake performance (e.g. an electronic system may be permanently fitted in a haul truck). This has

the advantage of showing up deficiencies in the brake system before they become a problem.

3.4.3.1 Brake system maintenance strategies Correct brake system functioning depends on the condition of system components, which in turn

depends on the quality of the maintenance, so any brake system maintenance strategy should

focus on detecting and rectifying a defect before it results in a loss of brake function. The ultimate

loss of brake function (e.g. failing a brake performance test) should not be the trigger for

inspection and rectification.

Brake system maintenance strategies should initially be based on the original vehicle manufacturer

(OVM) recommended maintenance programs, and on condition monitoring, inspection and testing

schedules. OVM stipulated operating procedures and repair techniques help ensure brake system

integrity is not compromised.

The OVM information should be stored, maintained, updated and be readily accessible by relevant

workers, whether it be hard copy, electronic copy, or on-line based systems.

To ensure that risks arising from site conditions, operating parameters and work cycles are within

acceptable limits, and as low as reasonably practicable, additional testing and monitoring might be

warranted. In fact, the risk assessments aimed at improving brake system reliability should


consider anything that could affect the safe operation of vehicles, including maximum loads,

operating speeds, operating grades, effects of heat fade, component failure, and loss of pressure.

Controls needed may include more frequent component inspections for wear or damage, and

regular brake performance verification techniques, such as Dynamic Brake Testing (DBT) and

thermographic temperature profiling, to detect poor performance.

Note that a positive DBT result doesn’t necessarily verify brake system integrity or confirm the

system has been maintained to OVM recommendations. It only indicates the brakes were effective

at that time of testing.

In introducing a DBT program, the risk assessment to determine appropriate controls should

consider, but not be limited to:

OVM consultation on any deviations from the stated recommendations

Applying relevant brake performance testing standards or appropriate industry practice

Site facilities and limitations relating to surface, space, and controlling vehicles in case of

brake failure during testing

Variations in test methodology and acceptance criteria for different vehicle types and

categories (for further information refer to AS 2958.1:1995 Earth-moving machinery – Safety,

Part 1: Wheeled machines – Brakes)

Reliability of the DBT test instruments

Applicability and integrity of the standards, procedures and methods used to interpret the

results

Training and competency of workers conducting the tests.

3.4.3.2 Industrial trucks and load shifting equipment

(forklifts, mobile cranes etc.) Inherent instability and lack of traction of forklifts and cranes on mine and quarry sites,

particularly on ramps and slopes, present a challenging risk management task. You should ensure

operators understand the brake system design limitations and that brake system monitoring,

inspection, testing and maintenance are appropriate for the risks in particular applications.

The Australian Standard AS 2359.13-2005 Powered industrial trucks Part 13: Brake performance

and component strength provides guidance on methods for assessing and testing the performance

and components of brakes fitted to industrial trucks with rated capacities up to, and including, 50

tonnes.

Safe forklift operation on gradients largely depends on the type, size and design of the forklift. Ask

the OVM if you’re unsure of the braking system’s performance capabilities.

For further guidance on requirements for the operation, maintenance, repair and modification of

industrial trucks refer WorkSafe New Zealand Approved Code of Practice for training operators and

instructors of powered industrial lift trucks (forklifts) and supporting document Safety Code for

Forklift Truck Operators: Front Loading Forklift Trucks.

3.4.3.3 Recommendations for brake testing You should ensure:

the site Health and Safety Management System requires operating, monitoring and

maintaining brake systems according to OVM recommendations, as a minimum

brake testing by the relevant driver is conducted at the start of every shift (pre-start

inspection)

the condition of brake system components is monitored according to OVM’s recommendations,

reducing the likelihood of catastrophic failure and ensuring they continue to function as


intended

brake system performance is tested according to OVM’s recommendations

drivers and maintenance workers can access OVM operating and maintenance manuals at site

as appropriate

braking system repair, monitoring, inspection and testing records are readily available at site

drivers and maintenance workers are trained in the relevant aspects of braking systems

safety critical aspects of vehicle operation, including emergency braking systems, retarders

and other controls available in the event of engine failure (e.g. accumulators), are

incorporated into driver training and assessment processes with appropriate input from

competent maintenance workers

operating and brake maintenance practices for contractors’ vehicles are not inferior to the

vehicle maintenance practices adopted by site

contractors’ vehicles are not allowed to operate on site unless maintenance and testing records

are checked to verify the integrity of brake systems

brake maintenance, including processes used for contractors’ vehicles, is regularly audited for

effectiveness

if OVM manuals are unobtainable (e.g. due to the age of vehicle), manuals are prepared so

effective brake system operation and maintenance strategies can be established, using people

with appropriate skills and technical expertise to facilitate the process

3.4.4 Inspecting and servicing vehicles Vehicles at mines and quarries work in harsh environments and require effective maintenance

regimes to avoid developing defects. Establish a programme of daily visual checks (or pre-start

checks), regular inspections and servicing schedules according to the original vehicle

manufacturers instructions and the risks associated with the use of each vehicle.

Inspections and maintenance should include, where appropriate:

Braking systems Seats and seat belts Tyres, including condition and pressures Steering

Convex mirrors, CCTV and other visibility aids Lights and indicators Safety devices such as interlocks Warning signals Windscreen washers and wipers Firefighting equipment

Condition of cab protection devices e.g. ROPS and FOPS Condition of tailgates Condition of hydraulic hoses (rigid and flexi) Fluid levels Functional checks on the vehicle

Other accessories such as quick hitches and (if applicable) their locating pins, are correctly fitted and in place

Where vehicles are hired, determine who is responsible for maintenance and inspection during the

hire period and make this arrangement clear to all parties.

Put in place a safe system of work that addresses issues such as safely blocking the vehicle and its

attachments, isolating stored energy (e.g. gravity) and preventing the vehicle from inadvertently

being started. When using jacks they should be rested upon suitable load bearing substrata and

the vehicle should be fully de-energised. Raised objects should be lowered wherever possible (e.g.

excavator or loader buckets etc.).

Determine a procedure to address defects where they are found in vehicles or attachments. Such

procedures could include:


Recording of defects when completing:

o Daily visual checklists (pre-start inspections)

o Scheduled inspections o Maintenance logs

Establishing protocols for safety critical defects (when a vehicle should be removed from operation, time frames to fix specific defects etc.). For example how deep does a cut in the tyre need to be before they should be replaced?

Lock-out tags for safety critical defects Keys or other starting devices removed and secured until safety critical repairs are

completed.

3.4.4.1 Tipping bodies Fit vehicles with devices to prevent tipping bodies accidentally collapsing from the raised position

during maintenance. It is useful to put a notice on the vehicle to reinforce the use of the devices.

Consider:

Fitting safeguards to the tray-raising system Ensuring the tray includes built-in props to secure it

Ensuring controls for the tray-raising mechanism are clearly marked and shrouded or protected from accidental operation

Fitting hydraulic cylinders with restrictors to slow the rate of descent Providing audible warning in the event of unintentional pressure release.

3.4.5 Protection of drivers, operators or passengers

3.4.5.1 Operator protective structures Operators of heavy mobile plant such as bulldozers, excavators, loaders and graders, are at high

risk of serious injury or deaths by crushing if their machines roll over, tip on to their sides or

objects enter the cab.

Generally the risk depends on the terrain. There’s a low risk on flat, stable ground and a high risk

on steep or unstable ground, or on work adjacent to embankments, excavations or working over

top of old mine workings.

Operator competency has a bearing on the risk. An inexperienced operator may fail to recognise

hazardous situations and take evasion action.

Fitting an operator protective structure, together with wearing a seat belt, can reduce the risk of

serious injury or death in the event of a roll-over or tip-over.

Where there’s a risk of objects falling on to the operators or entering the driving position, such as

rock falls, the operator also needs the security of a protective structure. Refer 3.4.5.3.5 for

information on Falling Object Protective Structures (FOPS).

Mining operations are required to address the fitting of devices to protect the operator of mobile

plant including rollover protection and falling object protection (refer Regulation 98 Mechanical

Engineering Control Plan).

For more information on design and types of operator protective structures refer to Approved Code

of Practice for Operator Protective Structures on Self-Propelled Mobile Mechanical Plant

3.4.5.2 Seat belts Many injuries are the result of vehicles overturning. All drivers and passengers should therefore

wear appropriate seat belts, preferably with a full harness.

Refer to Approved Code of Practice for Operator Protective Structures on Self-Propelled Mobile

Mechanical Plant for more information on seat belt requirements for vehicles fitted with operator

protective structures.


3.4.5.3 Transportation of people Control risks to the driver and other workers due to the vehicle travelling. Protect drivers or

passengers from falling out of the equipment and from unexpected movement, including

inadvertent movement of the load. You should also control risks associated with the environment

and the place in which the vehicle is used (for example falling objects, low structures and the

surfaces on which it operates).

3.4.5.3.1 Suitable for carrying people Operator stations with seats or work platforms normally provide a secure place on which the

drivers and other people can travel in vehicles.

3.4.5.3.2 Seating Provide seats wherever necessary. They can provide security for:

(a) Drivers who need to be seated when operating vehicles e.g. the seat in a truck

(b) People who need to be seated while being transported by the vehicle e.g. bench seats

(c) People who are involved in on-board work activities which are best carried out in a seated position

3.4.5.3.3 Cabs, operator stations and work platforms Cabs, operator stations and work platforms, with suitable side, front and rear barriers or guard

rails can prevent people from falling from vehicles when they are travelling. Where provided, they

should be properly designed and constructed. They can be fully enclosed or may be open to the

environment where safe to do so.

Vehicles not specifically designed for carrying people should not be used.

3.4.5.3.4 Speed adjustment When carrying people, drive vehicles within safe speed limits to ensure the vehicle is stable when

cornering and on all the surfaces and gradients on which it is allowed to travel. In addition, limit

the speeds at which the vehicle travels to avoid sudden movements which could put people being

carried at risk.

3.4.5.3.5 Falling object protective structures (FOPS) If people carried on vehicles are at significant risk of injury from objects falling on them while it is

in use, FOPS must be provided. This may be achieved by a suitably strong safety cab or protective

cage which provides adequate protection in the working environment in which the vehicle is used.

3.4.5.3.6 Segregation from the load Wherever possible, carry loads separately from passengers. If the cab is not separate from the

load area (for example, a van), fit a bulkhead between the load compartment and the cab which is

strong enough to withstand a load shifting forwards in an emergency.

Use the most suitable securing method for different types of load.

It is important to also consider small equipment which may become a missile in the event of a

collision (e.g. fire extinguishers could be stored in a bracket).

3.4.5.4 Preventing falls from vehicles Access to heavy vehicles should be by a well-constructed ladder or steps. Ladders or steps should

be well built, properly maintained and securely fixed. Avoid using suspended steps wherever

possible. If they cannot be avoided, use rubber or cable suspension ladders, not ladders made of

chains. Ladders and steps should slope inward towards the top if this is reasonably practicable.

They should not lean outwards towards the top.

Rungs or steps on vehicles should have the same features as those on site-based ladders or stairs.

This means they should:


Be level and comfortable to use;

Have a slip-resistant surface; and

Should not allow, for example, mud, grease, or oil to build by dangerously (e.g. grating could be used to allow things to pass through a step).

The first rung or step should be close enough to the ground to be easily reached – ideally about 40

cm, and never more than 70 cm.

If fixed to a vehicle, place ladders or steps on the front or back of the part of the vehicle that

needs to be accessed, as close to the relevant part of the vehicle as possible.

Opening (and holding open) a cab door on a vehicle should not force a driver to break the ‘three

point hold’ rule or to move to an unsafe position.

Wherever possible, use walkways. Walkways should be made of slip-resistant grating (with enough

space for mud or oil to pass through the grate and away from the walkway surface) or another

slip-resistant material.

Position walkways, steps, ladders, handrails and so on away from wheels if possible, to prevent

thrown mud from making them slippery. Mudguards can also help to keep them clean.

Top and middle guard rails may be needed, to protect people when they are standing or crouching.

You can consider collapsible rails that can be locked onto the access ladder.

Vehicle owners should consider fitting further safety features (such as those we have described

above) if they are not already present.

If features are retrofitted to existing vehicles, the alterations should not affect the structural

integrity of the vehicle and the actual fitting should be safe (for example, welding onto petrol tanks

might be very unsafe).

Placeholder for photos or diagrams similar to below (1st and 5th photo courtesy of MacMahon via

Newmont Waihi, 2nd and 3rd from HSE, 4th courtesy of BlueScope Steel via Taharoa)

Figure 26: This excavator has a good access system, with platforms, guardrails, kick plates and ladder. The ladder is interlocked so the vehicle cannot be started without the ladder being raised.


Figure 27: This vehicle is fitted with a set of foldaway steps to make accessing the load easier Figure 28: This drop side vehicle has been fitted with two footholds (one of which folds flat) and a handrail (not shown) to help works access the load bed

Figure 29: Guardrails were retrofitted to this excavator to protect workers accessing the top of the machine for maintenance purposes

Figure 30: A stairway and platform were retrofitted to this haul truck to increase driver access and egress safety

3.4.5.4.1 Sheeting Sheeting or removing sheets can be dangerous, especially when it is carried out by hand.


You should consider the risks associated with sheeting and take effective measures to ensure

sheeting is as safe as possible. Take into account the types of load and vehicle, how often sheeting

or unsheeting happens and other specific characteristics of the workplace.

There are a number of solutions but some options are better than others. A method of sheeting

and unsheeting that does not involve getting onto the vehicle or even touching the sheet should be

the first choice.

A hierarchy of solutions may look something like this:

1. Leave the load unsheeted (if road traffic and environmental law allows it); 2. Use automated or mechanical sheeting systems, which don’t require people to go up on the

vehicle; 3. Use manual sheeting systems which don’t require people to go up on the vehicle; 4. Use work platforms to provide safe access to carry out sheeting from the platform without

having to access the load; 5. Use gantry or harness systems to prevent or arrest a fall.

Consider the following points, whatever method of sheeting is used:

Do not overload the vehicle and try to load evenly to avoid the need for trimming. Load evenly along the length of the vehicle (not in peaks), or use a loader to pat down the load to flatten peaks.

Train and instruct staff on safe systems of work (and provide refresher training where necessary) for using automated sheeting, manual sheeting, platforms and personal protective equipment. Supervise and monitor sheeting and unsheeting activities.

Regularly check sheets are in good condition, and replace when necessary. Visually check straps and ropes used for pulling and securing the sheet.

Regularly inspect, repair and maintain sheeting mechanisms, platforms, gantries and fall-arrest equipment (like harnesses and lanyards)

During loading, unloading and sheeting, consider vehicles used by workers of more than one company ‘shared workplaces’, and arrange for suitable controls to be followed by everyone concerned.

Ropes, straps and sheets can snap or rip. The driver should avoid leaning backwards when pulling the sheet tight.

Park vehicles on level ground, with their parking brakes on and the ignition key removed. Sheet vehicles before leaving the site. However it is done, carry out sheeting and unsheeting in designated places, away from passing

vehicles and pedestrians and, where possible, sheltered from strong winds and bad weather. Extra

care will need to be taken in wet and icy conditions.

Placeholder for photos or diagram similar to below

Figure 31: Rolling sheets from front to back of the vehicle body

Figure 32: Unrolling sheets from side to side


Figure 33: Most sheeting platforms are simple drive through systems providing a guard railed platform on each side of the vehicle

Figure 34: Overhead gantry harness


4 TIPS (Including Stockpiles)

Tipping material from trucks is a common practice in the mining and quarrying industry. No matter what type of tip point is involved, a waste pile, an overburden tip, a stockpile, or a hopper, accidents can occur if certain precautions are not taken.

Accidents can occur for various reasons at tip points. Mainly these reasons are unsafe tip point

conditions, unsafe tipping practices, or from some combination of the two.

Potential hazard areas are:

The properties of the material being tipped Potential congestion around the tip head The construction and maintenance of the tip head The type of equipment in use The tip or stockpile foundation The toe of the tip

Water below the tip

When developing a tip decide on the safest practicable tipping method. (e.g. paddock tip, tip short

and push, end tip, or a combination of these) and implement safe work practices.

If there is any question or uncertainty about the safety of the tip point, the material should be tipped one-truck length back from the edge and then pushed over. Tipping short of the edge or moving to another location when potentially unsafe conditions exist would prevent the vast majority of serious tip point accidents.

Never tip over benches. Instead, tip and push or side cast over benches.

4.1.1 Stability of tips Anytime heavy vehicles are operated near the edge of a slope, there is a risk of the edge material

not being able to support the vehicles. This is especially a concern on tips and stockpiles where the

material is normally in a relatively loose condition and the side slope is steep.

In a pile created by end-tipping with trucks, the pile material is typically at its “angle of repose”.

The angle of repose is the angle at which the material rests when simply tipped in a pile. This

angle will vary somewhat depending on the size and shape of the particles, how the material is

tipped (e.g. how far it is dropped) and the amount of moisture in the material.

For a pile of material at its angle of repose, the edge of the pile is marginally stable. In other

words, when tipped or pushed over the edge, the material tends to slide until it comes to rest at

an angle where it can just barely support its own weight. This is why it is hazardous to bring the

heavy weight of a truck too close to the edge of an angle-of-repose slope. When this occurs, the

slope material should support not only its own weight, but also the additional weight of the loaded

truck. If the additional weight of the truck causes the material’s shear strength to be exceeded,

the edge of the pile will give way under the weight of the truck.

The edge of a pile can also become unstable if the foundation material cannot support the weight

of the pile and begins to give way. Or, especially in a pile of overburden, the edge may become

unstable because of a zone of weaker material in the pile. Finer-grained material, for example, will


tend to have lower strength than coarser material. Sliding may occur on a layer of the weaker

material.

For further information on ground control refer section 7.

4.1.2 Base preparation of tips and stockpiles Compaction under the tip or stockpile is important as this creates the base which the tip or

stockpile will be placed. Ideally the base will be slightly crowned towards the centre to avoid

creating a dip as the weight increases. This will also help drain runoff from the tip or stockpile.

4.1.3 Access to tips and stockpiles Access to tips or stockpiles will vary dependent on the quantity of material, the type of material,

the size of the vehicles that need access to the tip or stockpile, the available space and visibility. It

is essential there is enough space to keep the tip or stockpile load out face from becoming vertical.

For further information on road and vehicle operating areas refer section 3.

4.1.4 Working a tip or stockpile At stockpiles, the removal of material from the toe of the pile can have a significant effect on the

stability of the edge of the pile. In the case of loose, free-flowing material, loading out at the toe

may have little impact because the material tends to slide back to its angle of repose. But more

typically, once material in a pile has become more tightly packed, such as from traffic on the pile,

or even just from sitting for a period of time and settling in, then the area where material is loaded

out will stand at a steeper angle. Material standing at about 35 degrees when tipped over the edge

can typically stand at 45 degrees once loaded out. In some cases, such as when material has sat

for a long time, the material may stand even steeper or may even stand in an overhanging

condition. With these steepened conditions, there is less slope material to support loadings on the

pile, and a sudden failure of the pile could occur.

Type of product has several influences on the siting and size of tips and stockpiles. For example,

chip product can only be stockpiled in a single lift (generally 3 to 4 metres high depending on the

reach of the stockpiling loader) where base courses are often stockpiled much higher.

Mobile plant operators should be trained to continuously collapse the peak so it does not overhang

and collapse. Faces should be worked in a straight line so that wings do not develop and create a

crescent face which can be self-supporting in the short term.

Placeholder for diagram similar to below - also need diagram of overhang

Figure 35: Cross section of stockpile

Underground reclaims for bulk loading have trap hazards and engulfment hazards for vehicles that

may be needed to push the material to the reclaim. In these situations clearly marked draw points

should be established so the vehicle can avoid becoming trapped. Pedestrians should be prohibited

from the hazardous area around the draw hole at all times.


Engulfment can also occur from stockpiles. Benching may be needed to assist in lowering any risk

of engulfing the loader and driver. Emergency procedures in the case of an engulfment should be

established.

4.1.4.1 Accessing the tip point Clear rules should be established for accessing the tip point, including approach direction, tip

areas, communication systems and in some cases a tip point spotter to ensure trucks are tipping

where there is no conflict with the mobile plant pushing the material out. This may include trucks

being routed to arrive in a specific direction (e.g. a clockwise or anti-clockwise approach) so the

drivers can see clearly where they are to tip prior to backing into a tipping position.

Signals from spotters or mobile plant operators should be clear and can include flags, lights or

radio telephones (RT’s) (also refer section 3.2.2). In situations where mobile plant is used to

continuously maintain the tipping area and push material over, the mobile plant operator is often

used to position the trucks. This is especially useful at night.

You should consider the types of vehicles entering the tip point when determining a direction of

travel (e.g. driver cabs may be on the left or the right hand side). Approaching with the tip point

to the drivers cab side gives the driver the best opportunity to check the condition of the tip area

just prior to tipping.

Drivers should stay back from the edge of the tip on their approach and in making their turn at the

tip point. Staying back a truck length from the edge is a good rule of thumb.

Drivers should understand that edge protection that appears to be in good condition from their

viewpoint on the top of the pile may actually have been undercut and may not be a full berm at

all. Backing-up to such a berm would be hazardous. This situation can be avoided if:

truck drivers can examine the tip area from the bottom side as their vehicle approaches

the stockpile, or

if the mobile plant operator notifies drivers of this condition and takes action to block

access to the hazardous area, or

the drivers routinely tip back from the edge

There should be communication between the mobile plant operators and the truck drivers since

the mobile plant operators are in a good position to know when unsafe tipping conditions exist.

Placeholder for diagram showing vehicle paths at a tip head

4.1.4.2 Segregation of vehicles at the tip point Vehicles in the tipping area should remain in the view of the driver of a reversing vehicle at all

times i.e. on the cab side. Vehicles should remain at least one truck width apart from other

vehicles while on tip edges. This leaves room in case a truck tips over to the side while attempting

to tip. It also better distributes the truck loadings along the edge of the pile. Truck drivers should

never drive within the reversing path of another vehicle.

On no account should a vehicle be reversed blindly in a tipping area. Drivers should make full use

of visibility aids and should not reverse until they are certain the path is clear and only if a

protection is in place adjacent to any edge of a hazard. Your safe system of work procedures

should outline the protocols and rules when working at a tip point.



4.1.4.3 Approaching berms Drivers should back slowly and come to a gradual stop at the tip point. As a truck backs up and

the brakes are applied, dynamic forces are produced which push down and out on the pile. The

more abruptly a vehicle stops, the higher these forces are. These forces are applied at a contact

between the tyres and the top of the tip and can make a stable edge give way.

Drivers should back-up perpendicular to the edge, or with the driver's side tyres leading just

slightly. In many tip point accidents, the tyre tracks have revealed the truck was backing at an

angle, with the rear tyres opposite the driver leading. In these cases the driver’s side mirror would

have indicated the driver still had a distance to back up, while the opposite side rear tyres were

already contacting the berm or going over the edge.

The berm should be used as a visual guide only. The berm should not be used to help stop the

truck but only as a visual guide to judge where to stop.

Loads should be tipped progressively along a tip point to help prevent damage to berms.

Rearward looking cameras or other sensing devices, mounted on trucks can help drivers by

providing better information on their position and alignment relative to the berm.

Only discharge loads at a tip when suitable berms are in position.

On no account should a vehicle be allowed to mount berms.


Figure 36: Approaching tip head edge protection Figure 37: Tipping along an edge

Tip edge berm profile

1st tip 2nd tip 3rd tip


4.1.4.4 Safe tip site Carry out tipping operations on ground that is level and stable, and clear of overhead hazards such

as power lines, pipework and so on. A general rule is to make sure there is a least 9 metres

clearance overhead, although ideally there will be nothing at all overhead. Continuously check for

overhead hazards. If a pile increases in size, vehicles may gradually begin working closer and

closer to overhead hazards that were too far away to be a concern when the tip was started.

Adequate illumination must be provided for night-time operations. This is especially critical where

trucks back right up to the edge protection. The area should be illuminated well enough to allow

signs of tip point instability, such as cracks, to be detected. If the tip area is not adequately lit or if

visibility is poor due to bad weather conditions, trucks should tip back from the edge.

It will not usually be possible to completely avoid reversing where tipping has to happen. However,

you should reduce the amount of reversing to as little as possible. See Section 3.2.1 for more

information on reversing.

The top of the tip should be kept level from side to side so trucks do not tend to tip on their sides

whenever the bed is raised (refer figure 38).

The top of the tip should be kept sloped a small amount so in backing up to the tip, the trucks will

be going up a slight grade. This gives the driver better control. It also provides a better

opportunity to get the truck out if any shifting of the ground occurs and keeps the tip point better

drained (refer figure 39).

It is worth repeating that to avoid the hazards associated with tipping near the edge of a pile, the

best safety practice is to routinely tip back from the edge, and push the material over, preferably

with a track-dozer. This practice should be encouraged. A good rule of thumb is to tip one truck-

length back from the edge. Benefits of using this method are the truck drivers are not exposed to

the potential hazards at the edge of the pile, and they can complete the haul quicker since they

don't need to be as precise in backing and positioning the truck when they are tipping.

The bed-height and bed-overhang on some of the larger trucks now in use allows these trucks to

tip material over the top of an axle-height berm even when the truck is not backed up all the way

to the edge protection. The heavy weight of these larger trucks makes it prudent to keep the rear

tyres back from the edge as much as is practicable.


Figure 38: Vehicles should be parked on level ground Figure 39: Tip on level ground with a slight uphill gradient

4.1.4.5 Raised trays and alignment of articulated vehicles The vehicle should stay level if it is moved forward during tipping. Running with the tray raised

should be restricted to short distances, and only where it is required to fully discharge a load.

Raised tray alarms can reduce the risk of vehicles being driven ‘tipped’.


Gears should be locked while the tray is lowering.

Always tip articulated vehicles with the tractive unit and trailer in line (refer figure 36). Provide

enough space for a vehicle to manoeuvre the trailer and cab so they are lined up.

Drivers should be trained on how to safely handle sticking material (hang-ups). Sticking material

can make the truck tip over as the bed is raised or cause a more critical loading condition on the

edge of the pile. A rule of thumb is if the bed gets to about two-thirds of the way up and material

is still sticking, the driver should lower the bed and find another means of getting the material out

(e.g. using a backhoe). When material sticks in the bed, drivers should never try to jar it loose by

jamming on the brakes as they back up. The truck could tip over or if this is done near the edge of

a tip, the added force could cause the edge to collapse.


Figure 40: Articulated vehicles should be parked straight

4.1.5 Edge protection (berms) at tip points Refer Section 3.1.2.6 for information on berms including stop blocks where trucks tip off ramps or

into hoppers.

4.1.6 Drainage of a tip Water can affect the stability of the edge of a pile. As material at the angle of repose absorbs rain,

it may become heavier than it was when it was tipped. In the heavier condition it will have more of

a tendency to slide. This would mainly affect the material near the surface on the slope. A second

effect of water occurs if there is sufficient water, either from heavy rainfall, or from other sources,

to saturate a portion of the pile. If this occurs then the water in the saturated portion f the pile has

a buoyant effect and reduces the strength of the material, making the pile more prone to sliding.

For this reason, measures should be taken so that water drains away from tipped piles.

4.1.7 Evidence tip points may fail The tip point should be capable of supporting the weight of the vehicles, normally a truck, and

withstand the other forces imposed in stopping and tipping near the edge. To avoid accidents, the

conditions at the tip point should provide the driver with a reasonable margin for error in carrying

out the tipping operation. The weight imposed by the rear tyres of a loaded haul truck can be

substantial.

Look for indications that a tip point may fail to support vehicles on a regular and ongoing basis.

4.1.7.1 Tension cracks or settlement in the area where

vehicles operate near the edge of the pile A tension crack or settled area near the edge of a pile is a warning sign of an unstable, or

marginally stable, slope. Cracking is an indicator that some movement has already taken place. If

movement has occurred, then the slope material is having trouble holding up its own weight, and

it should not be relied on to hold additional weight, such as a truck.

If there is a tension crack in the tip area, the haulage vehicles should not travel over or near the

crack. The additional weight of the vehicles may trigger the slope to fail. Loads should be tipped


back from the crack (back one truck-length from the crack is a good safety rule) or in another safe

area.

Cracked areas at a tip point should either be clearly marked so the area is not used, or the

condition should be corrected by flattening that area of the pile. This can be done by some

combination of tipping material at the base of the pile, and carefully pushing material down from

the top of the pile, preferably using a track dozer.

Tension cracks will tend to run parallel to the edge of the slope. In some materials, other types of

surface cracking may occur as a result of the material drying out. Drying cracks tend to be

randomly oriented.

4.1.7.2 A berm that is inadequate It may seem odd to indicate an inadequate berm should be considered evidence that a tip point

may not support vehicles. Berms are normally thought of mainly in terms of providing restraint.

However, a critical function of a berm at a tip point is to keep the heavy load on the rear tyres of

the truck from getting too close to the edge of the pile. In this respect the height of the berm is

important because the higher the berm, the wider the base of the berm. It is this wide base that is

critical in keeping the load back from the edge.

This is another reason why it is important vehicles not back forcibly into the berm. As the tyres

sink into the berm, the heavy loading on the rear tyres gets closer to the edge of the pile. If you

notice tyre marks penetrating well into the berm material, the potential hazard of this practice

should be discussed with the driver and appropriate action taken.

Refer 3.1.2.6 for more information on edge protection.

4.1.7.3 Tipping at the edge in an area where the pile has been

loaded-out and made steeper than the material’s angle

of repose This condition has been a common factor in many of the accidents where a truck has gone over a

stockpile. When material is loaded out from the toe of a slope, it makes the slope less stable and

more prone to sliding. In this weakened condition, the material at the edge of the slope may not

be able to support both its own weight and the additional weight of a truck. An over-steepened

slope is especially hazardous at a tip point because the additional weight of the truck, if positioned

too close to the edge, can cause the edge to suddenly give way.

Because of this hazard, even without cracks or other signs of instability, you should consider

tipping above a point where the pile has been loaded-out, and made steeper than the material’s

normal angle of repose, to be evidence the ground may fail to support the vehicle. Tipping at or

near the edge of a pile, where the pile has been loaded-out and over-steepened or under-cut,

should be strictly prohibited.

Possible remedies for this situation are to tip back from the edge, (a good rule-of-thumb is to stay

one truck length back from the edge); to tip at the base of the pile; or to tip in another area where

the pile has not been loaded-out.

The best safety practice on stockpiles is to routinely tip back from the edge and push the material

over with a track-dozer. Alternatively, an excellent safety procedure used at some operations is for

the loader operator to block the access ramp to the top of the pile whenever material is going to

be loaded out from the toe of the pile (e.g. the loader operator uses the first bucket or two of

material to block the ramp). With the ramp blocked, no truck can access the top of the pile and be

exposed to a potentially hazardous area while material is being loaded out. Once the loading-out is

completed, the loader operator ensures that the tip area is safe by carefully pushing material down

from the top and constructing an adequate berm before trucks again have access to the top of the

pile. Whatever method is used the procedure should ensure that a truck never attempts to tip

above an area where the pile has been loaded-out and over-steepened or under-cut.


Stockpiling procedures should routinely incorporate methods such as the practices indicated above

to prevent this hazardous practice from occurring.

4.1.7.4 Movement of the slope material below the tip point If the material on the slope below the tip point is unstable, this would be evidence that the tip

point may not support a truck. A crack or a scarp (a steepened area where the material has slid)

on the slope is an indication of instability. Bulging of the slope material is not always as apparent

as cracks, but it is another sign that the slope material is moving. Bulging can be detected by

looking along the slope of the pile, especially the area near the toe, and paying particular attention

to any material that is not at the normal angle of repose. Bulging of the ground next to the pile

would be an indication that the foundation material underneath the pile is too weak to support the

weight of the pile. A failure through the foundation material could cause a portion of the pile to

slide.

Another condition to be aware of is the presence of soft areas at the dump site. This may be

indicated by ruts and accumulations of water. The hazard in this situation is as a truck starts to

tip, the tyres may sink into the soft area. In the worst case, this could result in the truck tipping

over, especially if combined with material hanging up in the bed.

You should instruct your truck drivers to avoid soft areas. Drivers should stop tipping and move to

a firmer area if they feel the tyres sinking into the tip. Eliminate soft areas by regrading and by

sloping the area to promote better drainage.

On overburden tips problems can occur because of the variability of the material being tipped. In

general, finer-grained soils will have less strength and be less free draining than gravel-size or

rock fill type materials. As a result, portions of the tip where finer material has been tipped may be

less stable, or less capable of supporting vehicle weight. You should make use of your experience

and knowledge of the way your tip materials behave. In dealing with weaker materials near the

edge the recommended practice is to tip back from the edge and push material over with a track

dozer.

4.1.8 Other considerations Walls or other supports provided to contain stockpiles are likely to need designing by a competent

engineer to ensure their stability.

If the market for a product declines significantly, a stockpile may grow dramatically, to an extent

that was not anticipated. If this happens, the safety of the stockpile should be subject to a

fundamental review. In the past it was often difficult to assess the extent of the associated risk

because the original site investigation was limited and tipping was not closely controlled. This

ought not to be the case in future, as all tips should be properly designed.

Adjacent stockpiles can have an effect on each other, for example, stability may be altered where

they overlap. The adequacy of traffic routes for vehicles should also be considered when planning

the position and size or stockpiles. In particular the risk of collision can be minimised by ensuring a

clear field of view for drivers (refer section 3.4.2).

If necessary water should be sprayed on the stockpiles in windy conditions to stop fines being

blown around.

4.1.9 Training in tip safety Mobile plant operators and drivers should be trained to recognise unsafe tip conditions and either

take prompt action to correct the situation or barricade the unsafe area.

4.1.10 Reworking tips Tips which are subject to routine geotechnical assessment may be worked or used for landscaping.

It is normally appropriate to consult a geotechnical specialist when planning such operations, since

dangerous movement is more likely to take place when a tip is disturbed.


5 PLANT, EQUIPMENT AND

INSTALLATIONS

All mines and quarries will use plant and equipment in their day to day workplace activities. If the hazards associated with plant and equipment are not safely managed, then serious injury and death can occur.

5.1 Scope The scope of ‘machinery’ and ‘plant’ as defined in the HSEA is extremely wide. It covers almost

any equipment used at work including:

a) ‘Tool box tools’ such as hammers, handsaws etc. b) Single machines such as circular saws, photocopiers, trucks etc. c) Apparatus such as laboratory apparatus (Bunsen burners etc.) d) Lifting equipment such as hoists, forklifts, elevating work platforms, lifting slings etc. e) Other equipment such as ladders, pressure water cleaners etc. f) An installation (a series of machines connected together), for example a crushing plant

and associated conveyor systems etc.

The WorkSafe New Zealand Best Practice Guidelines for the Safe Use of Machinery has information

for managing hazards associated with plant and equipment and should be referred to in addition to

this document. In particular the Guidelines cover:

Choosing and buying plant and equipment Installing plant and equipment Use, inspection and maintenance of plant and equipment Modifying plant and equipment Decommissioning plant and equipment Specific plant and equipment hazards Undertaking risk assessments

Eliminating hazards in the design process Guarding types Safe systems of work

Likewise, the WorkSafe New Zealand Approved Code of Practice for Managing Hazards to Prevent

Major Industrial Accidents outlines information for processes employed after crushing and

screening (e.g. bitumen production, ore processing) and should be referred to in addition to this

document. Appendix 2 of the code lists activities the code may apply to.

This section covers specific large plant and equipment commonly used at mines and quarries

where the information in the above documents, or other WorkSafe New Zealand Guidelines, may

not be sufficient to provide industry specific guidance.

5.2 Siting of Plant As a general rule, activities such as crushing and screening are noisy and dusty so are sited away

from boundaries to lessen the nuisance value of the activities. Placement or stockpiles and

buildings close to boundaries assist in controlling dust and noise. Some noisy and dusty processes

should be housed to control these effects. The safety of workers in the processing area is

paramount and traffic should be routed around the plant areas wherever possible.


Services, including electricity, air and water should be included in a site layout plan as appropriate,

particularly when placed underground. Plant and processing is usually positioned away from faces

and benches to ensure it is unlikely to be damaged from explosives and a safe area is left for

stockpiling and sorting of feed material for the plant.

Siting of stockpiles, buildings, ponds and dams are generally governed by the position of faces,

benches, overburden and topography of the site, as well as the resource consent considerations.

5.3 Dredges and Pontoons Placeholder for information on dredges and pontoons (will cover specific water hazards, gaining

access to the plant and ropes, pulleys, winches and rigging)

5.4 Processing Plant and Equipment (Crushers,

Conveyors and Screens) Introduction to be written here

5.4.1 Platforms, walkways, stairways and ladders Crushers, screens and conveyors often have areas where access at height is required. Provide

fixed platforms, walkways, stairways and ladders wherever access to the crusher, screen or

conveyor is required for operation. This also applies to mobile crushers.

Climbing up or walking on plant that was not designed for that purpose should be prohibited.

Suitable barriers should be in place to prevent falls into crushers and other hazardous plant and

equipment.

For further information on platforms, walkways, stairways and ladders refer to AS/NZS 1657:1992

Fixed platforms, walkways, stairways and ladder design, construction and installation.

5.4.1.1 Fixed vertical access ladders to platforms, landings

and walkways Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for

example purposes only, permission to use not sought)

Figure 41: Example of high-rise ladder with cage

High-rise ladders, where a person could fall more than 6 metres, should be fitted with a ladder

cage commencing at 2 to 2.2m from ground level. The hoops should be spaced at no more than

2m intervals. The internal clearance of cages should be approximately 0.75m.

High rise fixed ladders should be provided with interim landings at distances not exceeding 6m.


A physical device should be provided to ensure there is no risk of workers falling into the ladder-

way from the top of the ladder.

Wherever possible, consideration should be given to replacing vertical-rung ladders with inclined

stairways. New designs should incorporate inclined stairways in preference to vertical-rung

ladders.

5.4.1.2 Fixed ladder gate systems Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 42: Example of lockable gate system on high-rise ladder

Where access to ladders needs to be controlled, a hinged lockable gate should be provided to

prevent unauthorised access. If required, gates can be fitted with a suitable electrically interlocked

system. Irrespective of need, where a ladder is fitted with a cage (refer 5.4.1.1) a lockable gate

system should be in place.

5.4.2 Guarding A risk assessment should be carried out to identify the hazards relating to the plant and

equipment, the potential for an injury, its severity and the likelihood of occurrence for each hazard

identified. Risk reduction measures can then be applied. Guarding and risk assessment should be

done in accordance with the AS 4024 series.

The measures to be taken ranked in the order they should be implemented where practicable are:

1. Close-fitting guard 2. Other guards or protection devices such as interlocked distance guards, pressure mats and

induction loops 3. Light beams and light curtains 4. Protection appliances such as jigs, holders and push sticks 5. Provision of information instruction training and supervision

Guarding may also be required from extreme temperatures, the potential for ejected particles and

the potential to fall into storage hoppers and silos.

Wherever possible equipment should be close guarded i.e. no-one can enter the guarded area and

then the guard closed behind the individual. Where it is not possible to close guard equipment a

suitable electrically interlocked perimeter guard should be fitted. This should be applied with a safe

system of work involving isolation and lock off.

Perimeter fencing is often used in surface mines and quarries. However, maintenance workers may

require access behind the perimeter fence to watch, listen to or test the equipment while the plant

is running. In these situations fixed guards rather than perimeter fencing should be used to guard


individual nip points and entanglement hazards. This will ensure maintenance workers will not

inadvertently come into contact with the exposed moving parts.

All designers, managers, supervisors and operators who have responsibility in the life cycle of a

guard should be trained in the safe guarding of plant and equipment.

For further information on guards, including the selection of suitable guards, refer to the WorkSafe

New Zealand Best Practice Guidelines for Safe Use of Machinery.

The following diagrams are suggested guarding around specific plant or equipment often found at

quarries or mines. It is not intended to be a comprehensive list.

5.4.2.1 Mixers driven by direct drive electric motors Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 43: Example of enclosure guarding on direct drive electric motors

Enclose the drive shafts and flexible couplings connecting the electric motors to the mixer shafts

with a fitted guard.

5.4.2.2 Fixed dryers Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 44: Example of perimeter guarding of fixed dryer

Panel type guards secured to fixed uprights are a suitable guard for fixed dryers. The minimum

height of the guard above ground level should be [as per 4024]. All access gates should be


secured with a suitable electrically interlocked system. Remote greasing lines should be provided

to enable lubrication of bearings without entering the guarded area (refer 5.4.2.17).

5.4.2.3 Mobile dryers Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 45: Example of panel type guards on mobile dryer

Panel type guards should be securely fastened to the main dryer chassis on both sides running the

full length of the dryer cylinder. The guards should be attached such that a tool is required for

removal. Guards should extend upwards as a minimum to the centre line of the cylinder. Measures

should be taken to prevent access to moving parts of the plant from underneath the chassis.

5.4.2.4 Elevated feed hoppers man protective grids Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 46: Example of steep man-grid on elevated feed hopper

Steel grids, to prevent unauthorised or inadvertent entry, should be provided in the top of all

process plant feed hoppers (with the exception of primary dump hoppers or where products of a

large dimension are being processed which may obstruct the grid). The grids should be secured so

they require a tool for removal. The aperture size of the grid should be designed to enable process

material to pass through and be of sufficient strength to withstand any anticipated loads.

Points for consideration:

If access hatches are built in the grid they should be secured in such a way that access

requires a tool to open them.


Fitment of grids on elevated hoppers may encourage people to walk on them next to an

unprotected edge. Appropriate access prevention measures should be incorporated in the

design.

5.4.2.5 Ground feed hoppers man protective grids Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 47: Example of steel man-grid on ground feed hopper

Steel grids, to prevent unauthorised or inadvertent entry, with sufficient strength to withstand any

anticipated loads, should be provided in the top of all ground feed hoppers (with the exception of

primary dump hoppers or where products of a large dimension are being processed which may

obstruct the grid).The grids should be secured so a tool is required for their removal. The aperture

size of the grid should be designed to enable process material to pass through. Provision should be

made to enable drivers to release tail gate latches from a position of safety.

5.4.2.6 Screw conveyors Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 48: Example of cover guarding on screw conveyor

Where screw conveyors are provided with inspection covers all covers should be secured with

fastenings that require a tool for their removal. Exposed rotating shafts on the ends of screw

conveyors should be fitted with adequate secure covers.

5.4.2.7 Gravity take-up units Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for



Figure 49: Example of perimater guarding on gravity take-up unit

Conveyor gravity take-up units should be enclosed with mesh panels which prevent access to

moving parts within the tower including the risk of the gravity take-up weight falling to ground

level in the event of the belt breaking. All panels should be secured so they require a tool for

removal.

5.4.2.8 Motor and reduction box drive couplings Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 50: Example of panel and enclosure guards on motor and reduction box drive couplings

Where using electric motor and worm reduction gearboxes for driving equipment, the drive

assembly utilises directly coupled shafts with flexible couplings. Guards are required to enclose the

couplings.

It is necessary to guard the flexible couplings on both the input and output shafts of the gearbox.

The guards can be constructed in sheet metal or by welding expanded mesh to a steel framework.

Where guards obscure lubrication points extension pipes should be fitted to avoid removal of the

guard when lubricating the equipment.

5.4.2.9 Batch feeder belts Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for



Figure 51: Example of close fitted guards on batch feeder belts

Batch feeder belts, while generally slower, possess the same hazards as a normal conveyor. The

feeder and all associated nip points should be enclosed within suitable mesh guards fitted along

the full length of the feeder. Guards should be provided on the underside to prevent access to tail

and head drums. Guards should be designed so routine maintenance and adjustment can be

carried out without removal of the guards.

5.4.2.10 Vee-belt drives Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 52: Example of close fitted guards on vee-belt drive

Vee-belt drives are commonly used on various items of process plants. The type illustrated (with

open mesh) enables more efficient cooling of the vee-belts and pulleys and allows vee-belt tension

to be visually checked without removal of the guard.

Where joints are necessary for easy removal of the guard, sections should be joined by flat metal

or angle iron welded to each section and drilled to secure the bolts. Caps at the point where shafts

enter the guard (which may be necessary for adjustment) should be kept to a minimum.

5.4.2.11 Primary jaw crusher drives Placeholder for diagram similar to below photos (first photo from Quarry Products Association (UK)

for example purposes only, permission to use not sought. Second photo courtesy of Newmont

Waihi.)


Figure 53: Example of enclosure guard on primary jaw crusher drive

Figure 54: Example of enclosure guard on primary jaw crusher drive

As with vee belt drives, a mesh guard totally enclosing the drive with the outer section

manufactured from steel sheet is suitable to guard primary jaw crusher drives. Alternatively mesh

guarding fitted around existing structures may be suitable.

Where joints are necessary for easy removal of the guard, sections should be joined by flat metal

or angle iron welded to each section and drilled to secure the bolts. Gaps at the point where shafts

enter the guard (which may be necessary for adjustment) should be kept to a minimum.

Consideration should be given to manual handling requirements when maintenance is being

carried out. The provision of lifting attachments should be considered where mechanical means of

lifting may be required. Similar guards will generally be provided to enclose the flywheel on the

opposite side to the crusher drive.

5.4.2.12 Primary jaws or toggle plates Placeholder for diagram and information for primary jaws or toggle plates

5.4.2.13 Resonance type screens or vibrators Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for



Figure 55: Example of enclosure guard on vibration unit

Totally enclosing sheet metal guards should be provided over each of the vibrating units with

additional sheet metal guards over the associated shafts and couplings.

5.4.2.14 Vibrating screen vee-belt drives and flywheels Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 56: Example of enclosure guard on vee-belt drive and flywheel

Drive guards with mesh sides and sheet metal around the guard should be provided. In addition, a

sheet metal guard should be provided to enclose the flywheel.

5.4.2.15 Fines dewaterers Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for



Figure 57: Example of panel mesh guards on fines dewaterer

Fines dewaterers use slowly rotating scraper blades to extract the finer particles. In addition to a

sheet metal guard on the main dewatering section, a mesh guard should be provided around the

trough of the scraper blade section. This should be fitted high enough to avoid workers falling into

the trough or being able to reach the scraper blades and be at least 2 metres above ground level.

5.4.2.16 Small pan mixers Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 58: Example of enclosure guard on pan mixer

Small pan mixers are normally used in laboratories. A cover should be provided over the mixer

drum which is electrically interlocked to prevent the mixer operating unless the guard or cover is in

position.

5.4.2.17 Remote greasing Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for



Figure 59: Example of remote greasing points

All guards should be designed so lubrication and adjustment can be carried out without removing

the guard.

5.4.2.18 Stone guillotines Stone guillotines (or stone cutters) with unguarded cutting blades can cause amputations and

other serious injuries.

Using machine-guarding methods that eliminates worker access to the cutting blades (called the

“point of operation”) is the preferred method of hazard control. Examples of machine guarding

methods include barrier guards, two-handed starting devices, remote-operator controls and

electronic safety devices (e.g. light curtains).

Two-handed starting devices (refer figure 60) are a cycle-initiation method that requires constant,

simultaneous pressure from each hand on two separate controls to move the cutting blade. It the

operator removes either hand from either of the controls, the blades will stop immediately. Two-

handed starting devices are essential where fixed guards are not practicable (e.g. where the

operator needs to feed blocks of stone into the cutting area) and operating controls are close to

the blade or saw. A suitable guard should be fitted to the side of the guillotine opposite to the

controls where workers may reach into the hazardous area. Guillotines which rely on someone

picking or pushing the stone after being cut should be fitted with a drop side or conveyor so the

stone is feed away from the hazardous area (refer Figure 61) or alternatively a suitable tool should

be provided.

Remote-operator controls force the operator to remain at a safe distance from the hazard point

(refer Figure 62). Hold-to run controls should be used for remote-operator controls (i.e. the

machine will run down in the time it would take someone to reach the hazardous area when the

operator removes their finger or hand from the control). Suitable controls should be in place to

stop anyone else entering the hazardous area.

Placeholder for diagrams similar to below photos (first photo courtesy of Hinuera Stone Quarry.

Second photo from OSHA for example purposes only, permission to use not sought. Diagrams

examples for a placeholder only.)


Figure 60: Stone circular saw with fixed guards Figure 61: Example of two-handed starting device on guillotine

Figure 62: Example of drop side extraction Figure 63: Remote operation controls on circular saw

5.4.2.19 Bridge saws Bridge saws range from sophisticated equipment capable of cutting large slabs of stone and

intricate designs to smaller machines capable of simple cuts. Regardless of the size of the bridge

saw it is foreseeable that an operator may be in close proximity to the hazardous area when

operating and suitable guarding or controls should be in place to avoid injury to workers.

For larger bridge saws the use of perimeter fences and interlocked gates would prevent

inadvertent access and the operator from working in close proximity to the equipment.

Fixed guards alone might not be feasible as access is required for loading and unloading the stone.

The following would all offer a high standard of protection:

A perimeter fence and interlocked guards, such as manually-actuated sliding access gates. The

interlocked guards should be fitted with a locking device so the guard remains closed and

locked until any risk of injury from the hazardous machine has passed, to allow for the

rundown time of the saw blade.

Electro-sensitive protective equipment e.g. light curtains at the front of the enclosure in

conjunction with a braking system to stop the movement before access to dangerous parts can

be reached or the saw head should immediately return to a home position with a local

guarding enclosure.


Local retracting guards around the circular saw blade and pressure sensitive edges on the saw

head and traversing table but this would have to be in conjunction with fast stopping times of

the head and saw blade.

Guards may be extended to serve as noise enclosures. Local exhaust ventilation systems may be

integral with the guard where appropriate.

Placeholder for diagram similar to below photo (photo courtesy of Hinuera Stone)

Figure 64: Bridge saw with gate at access points Figure 65: Bridge saw with light curtains at access points

Fixed guards, two-handed operator controls or remote-operation such as those outlined for stone

guillotines may be suitable for smaller bridge saws.

5.4.2.20 Vehicles Measures should be taken to guard the following areas of vehicles:

Engine cooling fans and their associated drive belts and pulleys Any ancillary drive belts and pulleys which are accessible when engine covers are open Injector pump drive couplings in certain equipment

Power take off shafts on agricultural type tractors Ancillary prop shafts

5.4.3 Conveyor guarding Most serious accidents and fatalities with conveyors result from the plant not being adequately

guarded. They usually include nips between the conveyor belt and:

(a) The discharge plate or discharge roller

(b) Head pulleys, tail pulleys, drive pulleys, bend pulleys, and tension pulleys (c) Idler pulleys, where the upward movement of the belt away from the pulley is restricted

where skirt plates are fitted, or where the slope of the belt changes (d) The conveyor frame, or between pulleys and the conveyor frame (e) Projecting shafting; and (f) Belt cleats and belt fasteners.

Fixed guards that enclose in-running nip-points and the drive mechanism are usually the best way

to guard conveyors. Large conveyors, such as stockpilers, generally need both carry idlers and

return idlers guarded where they are under high tension and accessible. Guarding should be done

to an appropriate standard, such as AS 1755 Conveyors – Safety Requirements and AS 4024.3610

Conveyors – General Safety Requirements or equivalent.



Figure 66: Dangerous parts of conveyors

The following diagrams are suggested guarding around conveyor parts.

5.4.3.1 Conveyor return rollers Placeholder for diagrams similar to below photos (first photo from internet, second photo from

Quarry Products Association (UK) for example purposes only, permission to use not sought)

Figure 67: Plate type guard

Figure 68: Open mesh guard

Conveyor return rollers do not generally present a trap hazard. However, in the following

situations a trap hazard exists:

Where the belt cannot freely lift sufficiently it presents a trap point because a structure is positioned above the belt.

Where a tensioning roller has been positioned on the upper side of the return belt the belt is under tension and several nip points are created.

There are varying types of guard available to guard nip points relating to return rollers:

Plate type guards can be fitted along the full length of the roller in front of the in-running nip point. Measures should also be taken to prevent access to the nip from each side of the

roller. A suitable open mesh guard can be provided to totally enclose the roller. The guard should

be of robust construction with a mesh of sufficient size to prevent the accumulation of


spillage within the guard and yet prevent finger or hand contact with the trap points

within.

5.4.3.2 Head drum guarding Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 69: Example of head drum guards

Guards should be provided to prevent access to head drums and all associated nip points. The

distance from the guard end to the centre shaft of the head drum should be a minimum of

1000mm. Where troughing idlers are positioned close to the head drum and place the belt under

tension, the guards should be extended a further 1000mm beyond such idlers.

Note the wide walkway extending around both sides of the head drum giving adequate clearance

for pedestrians.

5.4.3.3 Tail drum guards Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 70: Example of tail drum guard

Guards should be provided to prevent access to tail drums and all associated nip points. The

distance from the guard end to the centre shaft of the tail drum should be provided on the

underside of the conveyor to prevent access to the return nip of the tail drum.

All guards should be designed so lubrication and adjustment can be carried out without removing

the guard. Pull cords where possible should be linked through all sections of the guard as a further


safeguard, so the pull cord system is activated or dismantled when maintenance is taking place.

This should not be regarded as a method of isolation. The guard should be of robust construction

with a mesh of sufficient size to prevent the accumulation of spillage within the guard and yet

prevent finger or hand contact with the trap points within.

5.4.3.4 Skirting guards Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 71: Example of skirting guards

In situations where fixed skirts are fitted above conveyor idlers, a trap point exists between the

idler and the belt. Panels of guards should be fitted to prevent access to the trap points associated

with the skirts of the conveyor.

5.4.3.5 Conveyor snub drums Placeholder for diagram similar to below photo (photo from Quarry Products Association (UK) for


Figure 72: Example of conveyor snub drum guarding

Conveyor Snub drums/pulleys are generally situated on the underside of a conveyor directly

behind the head drum and serve the purpose of providing a maximum contact area between the

drum and belt. Trap points exist between the underside of the belt and the in-running nip of the

drum.

A suitable open mesh guard should be provided to prevent access to the in-running nip of the belt

and drum from the underside of the conveyor and each side. The guard should be of robust


construction with a mesh of sufficient size to prevent the accumulation of spillage within the guard

and yet prevent finger or hand contact with the trap points within.

5.4.4 Conveyor skirt boards The use of skirt boards can limit the amount of material that falls from conveyors and exposes

workers to injuries. The cost can be optimised by placing the skirt boards at “high-risk” areas

along the belt line, where these types of accidents are more likely to occur or where frequent

pedestrian access is required.

Placeholder for diagrams of skirting boards

To reduce such accidents, you should:

Install skirt boards on conveyors at locations that have a higher likelihood of material falling off the belt, or a higher chance for workers to be exposed to this hazard, such as:

o At loading and transfer areas. It is recommended that the skirt boards be at least 2

and a half times longer than the belt is wide, to allow the material to ‘settle down’.

o At areas that have unusual features, such as magnets, crushers, and grizzlies o At places where persons regularly travel along or cross under the belt o At areas where maintenance, clean-up, or inspection activities are frequently

performed At your safety meetings, emphasize the following:

o In the ‘high-risk’ areas mentioned above, workers need to be aware of the potential for falling material while doing clean-up, maintenance, or inspection work

o Under certain operating conditions, such as when a belt is not fully loaded, material may be more likely to bounce or fall off a belt

o When travelling along conveyors (even in a vehicle), workers should keep as far away from the conveyor as possible without exposing themselves to other hazards

o Even small material can cause injury if it falls from a height or from a fast moving belt

5.4.5 Feeding crushers If the crusher is to be fed directly by a loader or excavator, then:

Standing pads should be suitable (stable) and high enough for the operator to be able to monitor the feed hopper from the cab.

Where wheeled loaders or trucks are used, the ramp should be wide enough to allow for adequate edge protection (min 1.5m high) on either side of the ramp as well as for the travel of the machine

The maximum gradient of the ramp should be within the capacity of the loading vehicle The last few metres of the ramp should be level so the vehicle is not discharging uphill. This

helps operators to monitor the feed. The vehicle will also be more stable. Ensure pedestrians and obstructions are prohibited from the bucket operating arc or loading

area If the crusher is to be fed directly by a conveyor all hazardous parts of equipment should be

suitably guarded.

5.4.6 Blocked crushers Clearing blocked crushers can be very hazardous and many plant operators have been killed

carrying out this task. Blockage incidents can be greatly reduced by supplying material that is

properly sized to match the primary opening.

Prevention of oversize feed material starts at the face with good fragmentation. Removal of

oversize material before delivery to the plant and vigilant control of the crusher feeder will make

blockages less likely.

Causes of crusher blockages can be grouped under two main headings:

Stalling due to:

Electrical or mechanical failure


Material jammed in the chamber causing an overload

Overfeeding material

Entry of tramp metal or wood Accumulation of material in the crash box Accumulation of fine material in the crusher discharge chute Bridging due to:

Oversize feed material Excessive clay or other fines in the crushing cavity preventing small material passing through

the crusher A foreign body in the crusher feed or discharge chamber obstructing the feed material

5.4.6.1 Prevention Working on the premise that prevention is better than cure, every effort should be made to

prevent oversize material or tramp metal entering into the crusher feed hopper by:

Designing any site blast to achieve optimum rock fragmentation Training and instructing the loader driver not to load oversize material

Sizing bars on crusher feeds Following the original equipment manufacturers recommendations on the rate, presentation of

feed and crusher settings Instituting a programme of good housekeeping to prevent scrap steel entering into shovel

buckets Ensuring the size of buckets are appropriate to the capacity of the crusher Regular inspection of metal parts (e.g. bucket teeth, dumper wear plates and drilling

components etc.) to ensure they are unlikely to break off and enter the crusher feed The strategic placing of electrical magnets or the installation of metal detectors to prevent

tramp metal from entering the crusher The use of level indicators for feed control Maintenance of drive systems Removal and adequate cleaning of the discharge chute

A properly designed crushing operation should not need any person to be present on the crusher

access platform during normal crushing operations.

It may be necessary for a worker equipped with the appropriate PPE (e.g. ear protection, dust

mask, eye protection, hard hat, protective footwear, high visibility outer garment) to spend a few

minutes setting the feed speed initially if there is no remote facility. The feed should then be

controlled from the machine feeding the crusher by varying the loading rate into the feed hopper.

5.4.6.2 Clearing blockages Intro here

5.4.6.2.1 Bridged crushers The preferred method of clearing a bridged crusher is by using a hydraulic arm (typically an

excavator fitted with a quick hitch bucket attachment and either a static pick or a hydraulic

hammer).

Depending on the result of your risk assessment, clearing out a bridging blockage with a hydraulic

arm (with pick attachment) may be carried out with or without the crusher still operating.

When hydraulic arms are not available and it becomes necessary for a worker to enter the crusher

to position hooks or slings, the crusher and feeder should be stopped, isolated and locked off (in

accordance with original equipment manufacturers or suppliers instructions) and safety harness

worn.

Where other options are considered they should be subject to a detailed and thorough risk

assessment. The crusher should be shut off and isolated before considering the use of bars and

hand hammers. Bars should never be used on or near a crusher while it is running.


Careful consideration should be given to the risk of large pieces of feed material moving and

causing trap or crush injuries. Wedges should not be used due to the risk of them becoming a

projectile (this has caused fatalities in the past).

Other options, which require more specialist expertise and competence, include: gas or chemical

expansion, hydraulic ramp plates, permanently mounted hydraulic breaker (may include the use of

closed circuit television to assist the operator) and use of explosives.

5.4.6.2.2 Stalled crushers A stalled crusher should be treated as possibly being jammed with tramp metal, which could be

ejected with fatal consequences. Written instructions should be issued to plant operators detailing

what to do in the event of a crusher stalling. These instructions should include the following:

Isolation of motive power to the crusher and associated plant; and Clearing the area of all workers; and Notifying the site manager of the stalled crusher. If, after careful examination, there appears to be no electrical or mechanical reason why the

crusher has stalled, it may indicate that the crusher is jammed by tramp metal.

A safe work procedure should be implemented. This work should only be carried out by people who

are suitably trained and competent.

Wherever possible any inspection of the crushing cavity of a crusher should be carried out from

below the crusher, not from above. Fatal accidents (due to material being ejected) have occurred

to people who have examined the crushing cavity of a stalled crusher from above.

5.4.7 Slips and trips (spills) Keeping working areas clear of spills improves operational efficiency and also reduces the risk of

slips and trips – a major cause of lost time accidents.

Minimise spillages by:

Maintaining conveyor skirts Maintaining the correct adjustment and condition of belt scrapers. Ensure that any feed

conveyor discharges centrally into the feed hopper. Designing loading shovel ramps to minimise the amount of material that will spill from the

ramp itself

Never remove guards to clean up while the machine is in operation. If guards need to be

removed, shut off and lock out.

5.5 Working Near Water Safe means of access should be provided to plant, draw off points or submersible pumps where

people have to access them for work purposes. In addition, workers required to access any

equipment where there is a risk of falling into deep water should be adequately protected by the

use of suitable guardrails and working platforms.

Placeholder for diagram similar to below photos (photos from BlueScope and internet for example

purposes only, permission to use not sought)


Figure 73: Example of guardrails around a water pick up station Figure 74: Example of gangway

Where using gangways, platforms, bridges or walkways they should be fitted with suitable

handrails or other means to stop people falling in the water. Cables and pipes should be separated

or stored away from access ways to avoid tripping (e.g. in cable trays etc.). Surfaces of access

ways should be slip resistant.

Where traversing of gangways, platforms, bridges, walkways, stairs or ladders is required in the

hours of darkness sufficient lighting should be provided.

Where life jackets are required to be worn there should be sufficient numbers and sizes available

for workers and visitors.

For further information on dredges and pontoons refer 5.3.

5.6 Prevention, Detection and Suppression of Fire and

Explosion Insert introduction (HSE (Mining and Quarrying) Regulations 98 (d), (e) and (h))

5.6.1 Typical causes of fire Typical causes of fire include component failure or inadequate maintenance. When completing a

risk assessment for prevention of fires consider:

The design:

Ensure hydraulic components are ‘like for like’ and considered suitable for use. Always consult the original equipment manufacturers (OEM) before making changes.

Ensure any contractor installations or design modifications that are undertaken off-site are verified on-site by you before use and are equivalent to OEM’s standards and design

Implement quality checks by OEM authorised service providers periodically as a cross check for internal maintenance

Evaluate potential alternative higher flash point OEM approved hydraulic oils, which

contain Polyol Ester based fluids, phosphate esters or water glycol and emulsions. Such fluids should be compatible to the existing in situ components such as seals or fittings.

The installation:

Properly fit any attached or in situ hoses with approved OEM components Maintain hydraulic equipment with the appropriate fit-for-purpose tools

Routinely check hose clamp type Use fire resistant anti-static hoses whenever possible and consider high temperature

tolerant hoses designed for oil operating temperatures >150°C. Install and evaluate insulation around hot components or insulate hoses near hot

components and upgrade to braided armour type hoses. Ensure wiring is protected against fire, and connections are appropriate to OEM’s

requirements and suitably located.


Consider the location and rating of protective devices such as fuses, solenoids and non-

return valves.

Inspection and maintenance:

Complete pre-start checks for locating and acting on oil leaks, sprays and stains Ensure the maintenance work order system includes the correct selection integrity and

testing of control measures

Use thermal imaging equipment to detect hot spots and high temperature areas of plant during maintenance programs

Routinely wash, clean and check hoses for any sources of rubbing, oily mist or leaks Carry out periodic checks on hydraulic braking systems to ensure sound operation,

including bearings brake drums, rotor and callipers Routinely check electrical wiring including insulation Routinely check solenoid connections for corrosion and replace or check at set engine

hours or as per OEM recommendations. Consider protective devices for solenoids such as fuses.

Emergency response:

Install fire detection and automatic fire suppression on plant that is used in high risk zones and install engine auto-shutdown systems that operate when the fire suppression system

is discharged Ensure communication of fire-related events, maintenance incidents and subsequent

attendance and associated follow-up is clear to employees

5.6.2 Hot work Ensure no-one uses a naked flame or carries out any work which could lead to an unintended

explosion or fire unless sufficient measures to prevent such an explosion or fire are taken.

Do not allow smoking in any part of the site where there is a risk of fire or explosion.

Hot work should not be permitted near closed vessels which contain, or have contained, flammable

or explosive substances, except under a safe work system (such as a permit-to-work). Even a

trace may create enough flammable vapour to cause a substantial explosion. Flammable in this

context, includes substances which have flashpoints of over 55°C, but will burn or decompose at

the temperatures involved in work such as welding and flame-cutting.

Hot work also needs to be prohibited on closed pressurised systems which could explode or fail as

a result of heat. This includes tyres and wheels, which are often contaminated with grease or oil

and create hazards from both pressure and flammable substances.

5.6.3 Control of explosive atmospheres Work in most quarries or surface mines are not likely to create a significant risk of an accumulation

of explosive or flammable substances. If the risk is negligible then no action will need to be taken.

There are circumstances, however, in which such a risk could arise, for example as a result of

methane from a neighbouring waste disposal site, or in a confined space.

Explosive atmospheres may also arise in processing facilities. For example a potentially explosive

coal dust cloud in enclosed spaces, electroplating baths can generate highly flammable hydrogen

bubbles which may be released into the air etc.

Any possibility of significant concentrations of flammable substances on a site should be carefully

assessed, and measurements taken to determine typical concentrations.

Where applicable provide automatic devices to:

a) Monitor continuously the concentration of explosive or flammable substances in the atmosphere;

b) Trigger an alarm if concentrations reach a hazardous level; and


c) Cut off power to any plant which puts health and safety of any person at risk because of

the concentration of substances in the atmosphere.

At any place at the site where there is a risk of the occurrence or accumulation of an explosive

atmosphere, or, of a substance harmful to health, take all necessary measures to:

a) Prevent such an occurrence or accumulation, or, where this is not practicable, b) Prevent the ignition of such as atmosphere; and c) Extract or disperse harmful substances.

Electrical and any other equipment within the area of a potentially explosive atmosphere should be

suitable for use in such conditions.

Power cut-off devices are not an alternative to using equipment designed for use in a flammable

atmosphere. They are only appropriate where the risk of exposure is low, and the act of cutting

the power would not itself create a risk of ignition, for example from an electrical spark.

For further information on controlling explosive atmospheres in processing plants refer to the

WorkSafe New Zealand Approved Code of Practice for Managing Hazards to Prevent Major

Industrial Accidents.

For information on controlling occupational health hazards refer section 9.

5.7 Electricity You must comply with the Electricity (Safety) Regulations. As a general rule:

a) Use Residual Current Devices (RCD’s)

b) Electrical substations should be kept clean and should not be used as stores. They should be kept locked with access to authorised workers only.

c) All equipment should be part of the electrical maintenance and inspection scheme. d) Batteries should be treated with respect. Follow manufacturer’s instructions for

maintenance and precautions (e.g. PPE).

e) Dust accumulations can have a serious effect on the safe functioning of electrical

equipment. Ensure housekeeping procedures are in place. f) All electrically powered equipment should be capable of being isolated. The isolation points

should be clearly labelled and means of isolation provided (e.g. electrical hasps and padlocks).

g) Where the operators have been properly trained it may be appropriate to access some electrical equipment for the purposes of resetting trips. In these cases it may be permissible to open cabinet doors provided the equipment inside is properly shrouded to

prevent inadvertent access or arc flash. h) Switch gear cabinets should be securely locked at all times. Where wiring is damaged it

should be reported immediately. Water should not be allowed to accumulate in switch rooms.

i) Underground cables and pipes should be accurately located on a site plan and identified before digging

For further information on safety around underground cables and pipes refer the WorkSafe New

Zealand Approved Code of Practice for Excavations for Shafts and Foundations. Placeholder for information on Electrical engineering control plan

5.8 Maintenance and Inspection People performing tasks such as maintenance, repairs, servicing, clearing blockages and cleaning

are highly vulnerable to injury, and have a higher risk of being killed or injured through the

unplanned operation of the plant they are working in, on, or around.

Plant should be adequately maintained as this limits the need for operator interaction with the

equipment.


Establish a maintenance and inspection programme to ensure regular inspection, testing and

maintenance of plant is carried out by competent people. Maintenance and inspection programmes

should take into account:

a) The operational environment the plant is being used in, particularly where subject to corrosion or rot;

b) The original equipment manufacturers recommendations.

Maintenance and inspection programmes should take into account the whole of the plant or

equipment including, as appropriate:

a) The structure of the plant (bracing, supports etc.); b) Safety features (emergency stops, guarding, emergency equipment, props etc.); c) Integrity of walkways, stairs, ladders, railings or guardrails; d) Integrity of holding vessels (tanks, hoppers etc.); e) Integrity of lifting equipment (chains, strops, hooks, gantry cranes, lifting eyes, quick

hitches etc.); and f) Signage and other warning devices (lights, alarms etc.).

For further information on inspection and maintenance, including safe systems of work, refer to

the WorkSafe New Zealand Best Practice Guidelines for the Safe Use of Machinery.

5.8.1 Common hazards when undertaking maintenance Undertaking maintenance activities can potentially expose the workers involved (and others) to all

sorts of hazards, but there are five hazards that merit particular attention because of the severity

of the harm that could be involved, and because they are commonly encountered during plant

maintenance activities at mines or quarries.

5.8.1.1 Falls from height Maintenance work often involves using access equipment to reach raised sections of plant.

Eliminating the need to access plant at height by careful design is the most effective control.

Where this is not practicable, and frequent access is required, fixed platforms, walkways, stairways

and ladders should be provided wherever possible. Where fixed platforms, walkways, stairways

and ladders are not provided other suitable temporary access equipment with adequate barriers or

fall restraint systems should be used.

For further information on platforms, walkways, stairways and ladders refer to AS/NZS 1657:1992

Fixed platforms, walkways, stairways and ladder design, construction and installation.

For information on preventing falls from height when using temporary access equipment refer to

the WorkSafe New Zealand Best Practice Guidelines for Working at Height.

5.8.1.2 Energised parts Isolation and lock out arrangements, and in some cases permits to work, are essential to enable

maintenance work to be conducted safely.

You should ensure there are clear rules on what isolation procedures are required, and in what

circumstances (for example, some cleaning of mixing equipment may require isolation, even

though it might not be considered a maintenance task).

The basic rules are:

a) There should be isolation from the power or energy source (usually, but not exclusively, electrical energy);

b) The isolator should be locked in position (for example by a padlock), and a sign should be used

to indicate that maintenance work is in progress; c) Isolation devices shall be specifically designed for this purpose; not devices such as key-

lockable emergency stops or other types of switches that may be fitted to the machine; d) Any stored energy (hydraulic or pneumatic power, for instance) should be dissipated before

the work starts; and


e) There should be isolation from engulfment or the sudden release of pressure, chemicals and

hot liquids or materials.

Types of energy sources include: electricity (mains), battery or capacitor banks, fuels, heat,

steam, fluid or gases under pressure (water, air, steam or hydraulic oil), energy stored in an

object that is being stretched, squashed, twisted etc., energy an object contains due to its position

(gravitational energy) or radiation.

For further information on isolation systems refer to the WorkSafe New Zealand Best Practice

Guidelines for Safe Use of Machinery.

5.8.1.3 Falls of heavy items Heavy items sometimes have to be moved, or get disturbed, during maintenance work. If one of

these falls, the results can be fatal.

Typical incidents have included:

the failure of lifting equipment;

inappropriate lifting and slinging practices; inadequate supports or supports not resting on level or firm ground; incorrectly estimating the weight or centre of gravity of the load; and over estimation of an individual's capability to support a load or restrain its movement.

If a heavy item has to be moved or temporarily supported during maintenance work, it is crucial

the risks involved are assessed and a plan of action is properly thought through. The people

responsible for the maintenance work shouldn't presume that things will be OK, that others will

know what to do, or the right equipment will necessarily be available. These lifts, or the use of

temporary supports may be 'one offs', and will inevitably require more knowledge and skill than

routine production tasks.

Ensure:

a) Everyone involved in maintenance understands the risks from heavy items, and communicate your companies intentions clearly;

b) An assessment of the risks (including the risk of disturbing something inadvertently) is completed and a plan of action decided on, before a heavy item is moved or temporarily supported;

c) There is someone competent to provide advice on safe slinging and on safe working practices for work involving heavy loads;

d) Any equipment used to lift or support a heavy load is suitable and (where necessary) has had its inspection and test (e.g. three monthly) by a competent person;

e) Heavy items are not left unsecured where they may tip over, fall or slip, and no-one works under suspended loads that haven't been properly propped in position;

f) The ability of a person to prevent a heavy item from moving is not overestimated.

5.8.1.4 Selection of Contractors Mines or quarries may do some or most of their plant and equipment maintenance in-house, but

there will always be tasks that are too big or specialised and require contractors. To enable both

in-house and contracted workers to work in safety you should properly brief contractors on your

company’s processes and ensure the contractors follow safe working practices.

You can find information on the selection and management of contractors in the WorkSafe New

Zealand Principal’s Guide to Contracting to Meet the Health and Safety in Employment Act 1992

and its summary Health and Safety in Contracting Situations.

5.8.1.5 Confined Space Entry Placeholder for information on Confined Space Entry


5.9 Training and Supervision of Plant Operators Regulation 17 of the HSE Regulations states that operators must be adequately trained on how to

carry out procedures for cleaning, maintenance and repair of equipment.

All operators should be trained on the hazards associated with specific equipment and the safe use

of guards, isolation, lockout procedures and in safe work practices. The training shall be given to

operators in a way they are likely to understand. This is particularly important for operators with

English as a second language, or those with low literacy skills.

For more information on training and supervision refer to section 10.


6 HANDLING AND STORAGE OF

LARGE SHEET STONE SLABS

Handling and storing large sheet stone slabs carries a high risk of serious personal injury unless undertaken in a safe manner. Due to their size and weight, such slabs are potentially unstable when stored on edge.

To ensure the safety of workers within the vicinity of large stone slabs you must determine a safe

system of work. The safe system of work can include:

Prohibition zones: not allowing people into the area into which a slab might fall while it

is being handled

Written work instructions (or standard operating instructions): Workers must be given

appropriate information, instruction and training on the dangers of handling large stone

slabs and the need to follow safe working practices including the use of appropriate lifting

equipment and personal protective equipment (PPE).

Adequate supervision by a competent person

Always restraining slabs during loading or unloading operations (whether from

vehicles of from storage) when any person could be in the hazardous area into which a

slab might fall from its racked position or during lifting. This should include attaching and

detaching straps, lifting slings etc. This is especially important when loading or unloading

vehicles due to the variable and sometimes unpredictable effects of road camber or vehicle

suspension.

Suitable design of rack type storage systems to prevent slabs either toppling over or

slipping out from the base. Traditional “A” frame storage is not suitable in this context

unless modifications have been undertaken that achieve the above goal. Storage systems

on vehicles should be similarly suitable.

Providing, maintaining, using and inspecting appropriate lifting equipment and PPE


7 GROUND CONTROL

Excavations and tips should be designed, constructed, operated and maintained throughout their lifecycle so they are safe, and instability or movement likely to cause harm is avoided. Failure to do so can lead to ground movements that can have impact on the health and safety of those within and outside the mine or quarry.

This section gives guidance on how to ensure safety during and after excavation. Nothing in this

guidance should take precedence over specific advice from geotechnical specialists.

All excavations and tips, however small, should be designed, constructed and maintained to ensure

their safety. The effort expended should be proportionate to the danger the excavation or tip

poses. In the case of very small faces or tips, this will usually be minimal. While a full geotechnical

assessment is only required on certain excavations and tips, you should ensure they are all

properly designed. This involves considering issues such as drainage and the method of

construction.

Design and safe work systems for excavations and tips must eliminate, isolate or minimise the risk

to people at the site and those who may be affected by its activities. This includes workers who

need access to potentially hazardous areas for purposes such as carrying out inspections and

assessments.

It is important to ensure surveying, design, normal operation and inspection work is not carried

out in isolation from each other. Information gained from one of these activities needs to be

communicated and taken into account in others. For example, if a geotechnical specialist has been

involved in design their advice should help to draw up the inspection scheme.

For further information on tips and stockpiles refer section 4.

7.1 Geotechnical Assessment To fully understand how to safely develop an operational mine or quarry requires assessment of

the type of rock, minerals or coal, the factors which will affect the direction of development, the

dip and strike of the rock, minerals or coal, bedding planes, faulting, folding and the geological

stability of the area. For example, recent studies have shown that New Zealand rock is relatively

young and often has clays locked into the rock itself. This can affect stability of faces and benches.

For information on geotechnical assessments refer the WorkSafe New Zealand Approved Code of

Practice for Surveying in Mines, Tunnels and Quarries.

7.2 Design of Excavations and Tips Generally, the lower the face, the easier it is to manage and maintain. The maximum safe height

of excavated faces should be the result of an assessment of the properties of the material, the

extraction method and the size, reach and type of mobile plant to be used. At sites where blasting

takes place the face height will be additionally influenced by blast design and the effect of previous

blasting operations.

Placeholder for principal hazard information


You should ensure any remedial work identified during a geotechnical assessment is carried out by

the date specified by the geotechnical specialist. When deciding how long to allow for remedial

measures, the geotechnical specialist should consider the risk involved. The greater the risk, the

sooner the work needs to be completed.

7.2.1 Drainage Water should not be discharged over a face except in a single controlled point to stop scouring on

the face. If possible the water should be directed along the bench to the roadway and travelled

along an open drain to a collection point, sump or settling pond. The bench should have a 1% fall

along its length and a 1% grade towards the toe to ensure the water does not travel over the face

in an uncontrolled manner.

Tips or stockpiles that are not free draining require adequate drainage.

7.2.2 Shoring Placeholder for information on shoring (will refer to ACOP for excavations and shafts for

foundations)

7.3 Working excavations, tips and stockpiles Excavations and tips should be developed in accordance with the design. Procedures to ensure

proper control of any design changes are essential. These can usually be explained in the health

and safety management system documents (e.g. excavation and tip rules) or the ground and

strata principal hazard management plan.

Working methods should not result in large vertical faces or overhangs, which constitute a

significant risk. Reprofiling or digging material from a tip also needs particular care since it may

lead to instability.

7.3.1 Extraction methods Determining a safe extraction method depends on the material, the transport system and the

quantities to be moved. Considerations can include:

a) Rate of extraction. Annual requirements broken down into tonnes or cubic metres per hour.

b) Types of extraction including explosives, large mobile plant, slurry and sluicing, dredging, rip

and push, push load, underground and surface. Each type comes with its own specialist

equipment, associated hazards and safety requirements.

c) Geology of the area to be extracted including slope stability, geological faults and folds,

bedding planes, depth and stability of overburden and access and security (not only for staff,

but also the general public).

d) Materials to be extracted e.g. weak or stronger rock, free running material such as sand

etc.

All methods used should be safe and all possible hazards controlled.

When working in deep quarries, care should be taken that temperature inversions do not cause

exhaust fumes to be trapped in the pit. Where required, monitoring equipment should be used to

ensure workers are protected.

7.3.2 Historic underground workings Placeholder for information on historic underground workings (Nigel Slonker)

7.3.3 Face heights Generally, a mine or quarry, when descending into the ground rather than advancing into a

hillside, should be developed like a very shallow cone structure.


In both hillside developments as well as “pit” developments into the floor, it is recommended the

final batter slope should approach 45° from the top crest to the bottom toe (Fig 43 shows overall

slope face as the dotted line through the cross section). If faces and benches are steeper than 45°

as an overall slope, the chances of face collapse is higher and very dependent on the strength of

the material. Any discontinuities or faults can overcome stable faces, so should be monitored by

suitable means to detect any movement before it becomes critical.


Figure 75: Bench width and sloping faces

The maximum safe height of excavated faces vary depending on the properties of the material, the

extraction method and the size, reach and type of mobile plant to be used (refer 7.2). Generally,

faces in consolidated ground should not exceed 15m vertical height, with a slope of up to 15° from

vertical. In unconsolidated ground (soft clays and sand) face heights should not exceed 3.5

metres.

Face heights should be within 1m of the reach of the machine used to extract. For example, if the

machine has a reach of 12m and the machine sits on a 2m high loading platform the face height

should be a maximum of 15m.

There should be special precautions to prevent loose rocks from travelling out from the face. This

can be achieved by placing the loading excavator on a loading bund of around 2m, with a trench or

bund between the loading excavator and the face.

Placeholder for diagram similar to below photo (photo from A Robertson for example purposes

only)

Figure 76: Loading excavator on loading bund


7.3.4 Bench widths Bench widths should be a minimum of half the vertical height of the face above, but should always

be suitable for the safe working of equipment on that bench e.g. excavator and trucks working.

Water controls should ensure there is no direct discharge over the face. This could be achieved by

sloping the bench around 1% towards the toe of the face above and having a drainage channel to

safely divert water.

Access to benches should be wide enough for the safe operation of vehicles on the benches and

the level of activity. Edges should be protected to stop vehicles falling over the edge (refer section

3.1.2.6).

There should be sufficient space on the working bench for trucks to safely turn.

7.3.5 Extracting beneath water The faces of excavations should be kept stable even though you cannot see them, for example

under water. In this case the slopes will be saturated and the rules should take into account the

stability assessment completed in the design.

Draglines and long reach hydraulic excavators may over steepen the slope on which they stand

and cause failure. These slopes should be treated as a significant hazard. Edge protection,

barriers, or other suitable controls should be placed around any water filled excavation to keep

people out. Edge protection, barriers or other control should be moved as excavation progresses

and the hazardous area changes. Rescue facilities must be provided (refer section 11).


Figure 77: Dragline working beneath water Figure 78: Long reach excavator working beneath water

7.3.6 Stability of High Walls and Faces Placeholder for information on Stability of High Walls and Faces

Placeholder for photos or diagrams similar to photos below (photos courtesy of Newmont Waihi)


Figure 79: Example of rock bolts and concrete spray Figure 80: Example of w-strap supporting face

7.3.7 Undetonated explosives Undetonated explosives should be treated as live, the area shut down, a prohibited zone set up

and control systems put in place, including advice to the authorities. Refer section 8.

7.3.8 Stripping (removal and placement of overburden) To ensure safety is considered when planning and undertaking stripping activities you should

consider:

a) The geology of the area to be stripped

b) The quantity and type of overburden

c) Access roads for vehicles and pedestrians

d) Any hazards which may affect safety (e.g. overhead power lines)

e) Security of the area

f) Preparation of the receiving area

g) Settling requirements

h) Drainage and runoff controls

i) Stabilising methods, including inspections

j) Rehabilitation of overburden

All tip sites should be prepared and able to safely receive the overburden. This includes removal of

vegetation and topsoil and keying into the substrata to ensure the stability of the overburden

placed above.

Subsoil drainage should be addressed to ensure there can be no liquefaction of the overburden

placed there. Subsoil drainage can be as simple as placing large rocks to allow moisture to “wick”

through or a more sophisticated system using drain coil and piping to capture and transport

moisture through the material to a controlled discharge below the work.

When placed, overburden should be stable, drained, covered, and planted as soon as possible to

prevent scouring and water damage through erosion.

Where tree felling is required in preparation for stripping, competent workers should be engaged

to undertake the work.

7.4 Inspections Placeholder for Inspections information


7.5 Falling from faces Any person who works on or near the edges of face tops has the potential to fall. Typically these

are the driller, shotfirer and person carrying out the daily inspection. Other people potentially

working on or near the edges are the surveyors, profilers, explosives engineers, explosives truck

workers, planners, geologists, geotechnical engineers, fencers, and even HSE Inspectors.

A risk assessment needs to be carried out to establish safe working procedures for any person

likely to be in a position where they may fall from an open face.

If possible, consider relocating tasks away from the edge of the face. If access is required,

physically restrict access to edges.

Bunds are preferable to other less substantial barriers but bunds may hide cracks or signs of

instability along the edge of quarry faces (refer figure 44). Bunds should be:

Constructed only after inspection of the face area below. Faces need to be inspected for faults,

change in appearance, loose surface, evidence of falling rocks, water seepage, joints and

cracks.

Constructed a metre or two from the edge where possible so any cracks or deterioration of the

edge can be seen.

Regularly inspected and maintained.

For pedestrians and shot-firing activities only, bunds should be a minimum height of one metre

and constructed from a suitable material to avoid trip hazards.

If it is not reasonably practicable to install bunds, other physical fall prevention barriers such as

guard railing should be used. If the guard railing is installed close to the face, the risk of falls

during erection and dismantling of the guard railing should be identified and controlled. Where

installing barriers that may not support the weight of a falling person (e.g. para-webbing etc.),

ensure they are installed at least two-metres away from the edge (refer figures 45 and 46).

If it is not reasonably practicable to install a physical fall prevention device (e.g. before blasting or

due to the set-up of a drill), limit working positions. This can include using a travel restraint such

as a harness connected at a fixed position (e.g. fixed equipment) to prevent workers approaching

the edge.

Workers should be trained in the appropriate selection and use of harnesses before starting work.

Ensure workers are closely supervised until assessed as competent.

Other factors to consider

When developing and implementing a safe system of work, you should consider:

Reviewing and documenting risk control measures if there are any changes to the work

process

Ensuring workers are adequately trained and experienced

Ensuring any worksite surface is clear of obstacles and rubble that may trip workers. Fine

material can be spread to level out rough surfaces or uneven ground.

Ensuring there is clear communication between workers

Placeholder for diagram similar to below photos (photos from QNJAC Blast Site Edge Protection

document (safequarry.com) for example purposes only, permission to use not sought)


Figure 81: Example of a pedestrian bund Figure 82: Cones indicating exclusion zone

Figure 83: Example of non-weight supportive barriers Figure 84: Example of fall restraint system

7.6 Rehabilitation When the site is temporarily or permanently closed it should be left in a safe condition.

Typically rehabilitation is carried out progressively, meaning parts of the site can be closed, while

other parts are still operational e.g. rehabilitation of overburden tips which have reached capacity.

The objectives of mine or quarry closure, or part thereof, are:

- To ensure the public is safe by preventing inadvertent access to site infrastructure

- To provide for the stable, long-term storage of waste rock and tailings

- To ensure the site is self-sustaining and prevent or minimise environmental impacts

- To rehabilitate disturbed areas for a specified land use (e.g. return of disturbed areas to a

natural state or other acceptable land use).

Rehabilitation plans should address management of water runoff, air quality, stability of material,

treatment and containment of any possible hazardous substances and erosion control.

Stability of material and control of water runoff are the most important as they will be the first

indicators of any problems in the total rehabilitation programme. Stability should be monitored by

study of the toe area of any overburden or waste material placement to ensure it is well

compacted and not bulging or moving out from its original placement. Another indicator of

movement would be cracks appearing around the crest or top of the reinstated material.

Rehabilitation is a requirement for all new consents and most current consents. Rehabilitation

plans should be considered and incorporated into all aspects of site planning, construction and

operation, so key aspects of the closure are planned for throughout the sites life cycle. Plans

should identify measures to be undertaken during the operations phase that are aimed at

progressive reclamation of disturbed or developed areas of the site.


Mine or quarry rehabilitation should be carried out in a way that prevents or minimises impacts

and risks not only to the environment but also to health and safety. Rehabilitation plans should

detail the processes that will be used to decommission and reclaim all aspects of the mining or

quarrying facility, including:

- mining, quarrying and ore processing facilities

- site infrastructure

- water and waste management facilities, including waste rock piles and tailings

management facilities

Rehabilitation plans should be reviewed and revised as necessary throughout the sites life cycle.

The plans may become more detailed, incorporating to a greater degree all activities related to the

site and taking into greater consideration site conditions and monitoring results. Rehabilitation

plans may also be revised in response to:

- the results of progressive reclamation activities

- the results of tests to assess specific aspects of the rehabilitation plan

- public response to a proposed rehabilitation plan

- changes in site operations, such as production rate or ore type

- changes in technology

- changes in economic conditions, such as input costs and other economics related to site

closure

- unexpected or adverse conditions encountered during the construction and operations

phases of the site life cycle

7.7 Changes to the Excavation or Tip A change to the excavation or tip itself, for example in design, method of working or material

tipped, may significantly increase the hazard. In such cases a further risk assessment should be

carried out. This may also be required if fundamental assumptions in the original risk assessment

or geotechnical assessment are found to be incorrect, for example regarding the geology of the

site.

Any new development on land adjacent to an excavation or tip, for example the construction of a

school, housing estate or road, could significantly increase the hazard. Such changes are likely to

be known well in advance and should be planned for.

7.8 Lagoons, Ponds and Dams Mines and quarries may have water storage, working ponds for extraction, settling ponds, finishing

ponds, associated channels and wetland areas. For example:

Ponds - Dependent on the water requirements for the site depths can vary from 1m to

over 5m. The size of the pond can also vary a great deal.

Lagoons are generally close to a large body of water such as a river that supplies the

lagoon through a gate system.

Dams are used to contain water and sometimes channel water back to process use or

capture water for process use.

Extraction ponds can be very deep dependent on the type of extraction. Iron sand

suction cutter dredges can work in approximately 5m of water, while gold dredges with

bucket chains can work as deep as 15 to 30m.

7.8.1 Wall stability Wall stability is most important in tailings or settling ponds where any breach of the walls could

cause inundation downstream. Walls should be compacted and either vegetated to stop erosion or

rock armoured. This prevents inadvertent breaches from occurring but should include controls for

overtopping to channel and divert overflow without eroding the pond wall.


Placeholder for more information on wall stability

Placeholder for photo or diagram similar to photo below (photo from Perry Aggregates,

Ngaruawahi via A. Robertson for example purposes only)

Figure 85: Example of rock armoured settling pond

7.8.2 Dewatering channels Dewatering channels should be checked for weed growth and side collapses. Safety issues include

edge collapse while inspecting, silt build up in the channel and vegetation disguising undermined

edges.

You should determine a safe method of inspecting dewatering channels. Care should be taken to

keep back from the edges when undertaking inspections. For more information on working near

water refer section 5.5.

Overflows can be decanting pipes, angled pipes, dip in the crest of the dam and armoured

channels. These should be inspected regularly, particularly when there are periods of high rainfall.

Inspections should include checking for partially blocked intakes of decant or angled pipes with

floating vegetation or other debris.

Partially blocked overflow channels should be cleared quickly and safely. Remedial measures to

limit the amount of floating vegetation in the ponds should be established. Ensure that armoured

channels are not scoured when there is a high water flow as this can erode the dam crest and

affect the integrity of the pond wall.

Placeholder for photo or diagram similar to photo below (photo from Perry Aggregates,

Ngaruawahi via A. Robertson for example purposes only)

Figure 86: Example of a decanting pipe in a finishing pond


Pipes are used through crest walls of settling ponds to drain settled water to discharge points, or

for further settling in a secondary settling pond. Pipes should be sealed where they pass through

the crest of the dam so no leaching can cause the crest to collapse. Inspect the discharge side of

the crest for signs of water wicking around the pipe.


Figure 87: Typical plan and cross section of a settling pond


8 EXPLOSIVES

Placeholder for introduction

Place marker for Explosive’s information


9 WORKER HEALTH

Placeholder for introduction

Placeholder for introduction to Approved Code of Practice for Worker Health at Mines and Tunnels

(requirement for a principal control plan for mining operations; covers noise, vibration, dust, diesel

particulates, fumes, temperature, atmospheric pressure, manual handling and lifting, hours of

work and fatigue, psychosocial hazards, ultraviolet radiation, ionising radiation, biological hazards

and consumption of drugs and alcohol)

9.1 Respirable Dust One of the health risks from working at a mine and quarry is exposure to fine dust containing

particles that may led to chronic and possibly severely disabling lung disease.

The following are suggested controls for specific situations often found at mines or quarries. It is

not intended to be a comprehensive list.

Further information is available in the Approved Code of Practice for Worker Health at Mines and

Tunnels and the Approved Code of Practice for Air Quality at Mines and Tunnels.

NOTE: Depending on context of ACOP some of this information may be removed

9.1.1 Drilling

9.1.1.1 Hand-operated drills Used mainly for the drilling of small diameter holes in monumental stone quarrying, these can be

used for explosives, plug and feathers or hydraulic splitters. Usually air flushing is used and dust

discharged from the hole causes the operator exposure and environmental nuisance.

Dust control can be achieved using water fed into the compressed air suppressing the dust, but

water supplies need to be maintained and precautions are required during cold weather to protect

against freezing. An alternative method involves a dry collection system.

9.1.1.2 Drilling rigs These usually have a hole size of more than 75 mm in diameter and are used mainly for the

drilling of holes for blasting at various types of mining and quarrying operations. Air flushing with

considerable quantities of dust discharged from the hole causes similar problems to those of hand

drills.

Dust control can be achieved as with the hand drills. Water can be used in the air stream but

additives need to be used (lubrication) and precautions taken for cold weather use. The use of a

foaming agent for dust control techniques is also available. Dry collectors in the form of cyclones

and bag filters are commonly employed. More modern and larger machines have integral control

cabins for the operator, from which all the machine functions can be controlled remotely. These

cabins additionally provide protection from noise and the elements, and further improvements can

be achieved with the fitting of air conditioning.

9.1.2 Crushing or milling There are basically two methods of crushing i.e. by compression and by impact. The main machine

types are:


compressive – jaw crushers, gyratory crushers, cone crushers, roll crushers, ball mills,

rod mills;

impact – rotary impactors, hammer mills (fixed or swing hammers)

All types of crushing reduce the rock in size. The compressive-type crushers produce dust but do

not themselves induce excessive air movement, although moving materials do, and dust either

from the materials or the actual crushing process becomes airborne. Impact-type crushing

machines involve a rotating member, which acts as a fan and generates considerable air

movement. With this type of high-reduction crushing, considerable quantities of airborne dust are

generated.

Water suppression can control dust on compressive crushers, provided the moisture content of the

product does not cause problems further along the process. Cold weather protection will be

needed. Extraction can be used with the placement of suitably designed capture hoods.

Water fed directly into impact crushers can have a marked effect on dust reduction as the action of

the crusher disperses the water. This method is particularly useful if an all-in-one product is being

produced.

Impact crushing machines can be installed over a hopper or stone box with a feeder underneath.

Providing the hopper is not emptied, the lower stone section provides a plug to prevent excessive

dust getting into the air. An extraction system attached to the top section of the encased hopper

removes the dust created by the rotor.

Every crusher type has some limitations when it comes to dust control. To reduce dust exposure

levels on crushing plants that are constantly staffed, the operators should be inside a remotely

positioned control cabin. For information on operator control cabin air quality controls refer to

Approved Code of Practice for Air Quality Control in Mines and Tunnels.

Placeholder for photo or diagram similar to photo below (photo from HSE for example purposes

only, permission to use not sought)

Figure 88: Control cabin on crushing plant

9.1.3 Screening There are numerous types of screening equipment, many of which are designed for specific uses.

Screens are used to extract or reject specific-sized material from the feed product. These may be

located singly or in various arrangements or groups in a screen house. Screening equipment

creates dust by degradation and the action also affects the release of dust in the material.


Screening may be carried out using water to wash or rinse the material and in such cases

airborne dust may not be a problem. However, excessive moisture can cause binding of screen

decks. Asphalt or coated stone plants frequently screen hot materials, which presents airborne

dust problems.

Wet suppression can successfully be used to control dust on primary and scalping screens (subject

to cold weather protection being provided). On other screens either complete or partial

encapsulation with some form of extraction system can be effective, but on screens for hot

materials, complete encapsulation with extraction is essential. If complete screen houses are

considered as an enclosure, workers should only be allowed to enter if RPE is used. Entry to such

enclosures should be avoided where possible and the use of CCTV to view the interior should be

considered.

9.1.4 Conveyors, feeders and loading Conveyors, feeders and loaders are used to transfer the product from one position to another.

Dust is liberated from the transfer points and this can be aggravated if they are not enclosed and

protected from wind.

Wet suppression (depending upon the product) can be used to control dust. It should be

automatically operated so that it is only used when material is being conveyed. Hoods with

extraction-to-collection equipment can effectively control dust emission from this source. You can

also use integrated collection units at transfer points, with the collected dust being deposited onto

the conveyor; no ducting is required for this system. Another option is an enclosed conveyor

system, which has advantages in preventing dust emission and spillage problems.

Airborne dust is a particular problem during the loading of vehicles with dry materials. At the face,

you can prevent operator exposure by fitting air conditioning to the cabs of vehicles, and keeping

windows and doors closed. At stockpiles or other loading positions, alternative means of dust

control such as water sprays can be considered. Loading from conveyors onto vehicles can also

create dust problems, and again for most materials the use of water sprays has advantages. When

loading tankers with powders and dry, fine materials, you can reduce dust emission by the use of

local exhaust ventilation attached to the loading spout.

9.1.5 Heating or drying The heating of rock fragments inevitably gives rise to large emissions of airborne dust, unless the

exhaust gases are fully treated. Pre-cleaning using cyclones followed by wet collection or bag

filtration is usually necessary to give adequate control, and such systems should have enough

capacity to handle high gas volumes. Combined dryer or coating units or ‘drum mixers’ present

slightly fewer problems but still require adequate dust and fume arrest.

Whenever hot, dry materials are conveyed, screened or loaded onto vehicles etc., serious airborne

dust problems can occur. Extraction systems or encapsulation are usually employed to control the

dust, but on bin overflow chutes the free falling materials, especially the ‘fines’, create

considerable airborne dust. Directing the overflow into a confined area or hopper can overcome

the dust problem.

On heating and drying plant, cabins may be needed for operatives to achieve adequate control.

9.1.6 Bagging Products bagged while damp do not present any dust problems. Dry materials, particularly

powders, and bag damage do present dust problems.

Automatic bagging units keep workers away from dusty environments (as well as reducing the risk

of musculoskeletal injury), although there needs to be systems of work for dealing with broken

bags and spillages. Older bagging units may not have integral dust control. Air venting from the

filling bags and spillages are sources of dust exposure to the operators. The use of purpose-

designed bags with filling vents, which create a semi-closed system, is a valid control method as


part of an overall risk management scheme. The use of exhaust ventilation and hoods or

enclosures can bring about improvements, but RPE may still be necessary if engineering controls

do not achieve adequate control.

9.1.7 Sawing

9.1.7.1 Portable hand-operated saws These are generally used in monumental stone and slate quarries for the cutting of stone and for

the creation of a slit to enable wedges to be used for splitting.

Placeholder for photo or diagram similar to photos below (photo from HSE for example purposes


Figure 89: Sawing wet Figure 90: Sawing dry

A water supply onto the cutting position can considerably reduce any dust escaping to the

atmosphere.

9.1.7.2 Static saws A wide range of saw types is used for cutting blocks of stone and slate into selected sizes. Most

saw blades are diamond tipped and use water for cooling. The water also acts as a dust

suppressant. Enclosures around the saw, as well as ventilation as close to the work piece as

possible, are essential for effective dust or aerosol control. With well-designed control equipment,

workplace exposure levels can be well below the WES and RPE is unnecessary.

9.1.7.3 Splitting or dressing This activity takes place at monumental stone and slate quarrying operations. Some splitting

involves drilling small diameter holes and using plug and feathers or hydraulic splitters. The

control of drilling dust is as described in 9.1.1. The use of chisels for the splitting and dressing of

slate creates dust in the breathing zone of the operator; the hand dressing of stone (masonry

work) also creates dust emissions.



Figure 91: Dust cloud as seen under normal lighting Figure 92: Dust cloud as seen by forward scattering of light using a dust lamp


Well-designed extraction systems following the principles of good local exhaust ventilation (LEV)

with reduce RCS exposure during stone splitting and dressing, but regular checks need to be made

to ensure that control remains adequate. A dust lamp is particularly useful for demonstrating the

effectiveness of any extraction system. RPE may be necessary in the short term until improved

engineering control has been achieved, particularly where the operator’s face is close to the work

piece. Improved housekeeping can also benefit dust emission and exposure.

Other activities including stacking are a source of dust and you need to properly and competently

assess personal dust exposure during these activities. You may need to adjust working patterns to

achieve control below the WES.

9.1.8 Miscellaneous situations

9.1.8.1 Roads, tips and stockpiles During dry weather, dust levels generated from roads and similar areas can be high, particularly if

they are not surfaced. Dust is liberated by the wind and by vehicles. The use of windscreens,

suitably positioned alongside roads or stockpiles, can create sheltering. Every effort should be

made to prevent product spillage onto the road surface or vehicle operating areas.

Roads surfaced with tarmac or concrete will generate less dust, and these should be kept clean

with a sweeper or damped down with water from a bowser or from permanent sprays. On

unsurfaced and other roads the use of water can prevent excessive dust problems. Chemicals

(calcium chloride in particular) also have an application for the treatment of road surfaces to

reduce dust generation, but these have limitations in that a fresh application needs to be made

after rainfall and you need to be careful to avoid contaminating water courses.

Vehicle speed is a factor and exhausts directed towards the ground increase the problem. Vehicle

radiator fans can also distribute dust on roadways. Speed control, and exhaust discharges and fan

enclosures directed away from the road surface, can reduce dust levels.

If necessary water should be sprayed on to tips or stockpiles in windy conditions to stop fines and

dust being blown around.

9.1.8.2 Spills and dust accumulations Many airborne dust problems results from spills that are not cleaned up.

You should prevent spills from conveyors, transfer points etc. by improving plant design and

maintenance (i.e. repair holes in chutes and replace worn-out conveyor skirt rubbers).

Housekeeping should include routine cleaning up. Use vacuum cleaning equipment fitted with high-

efficiency filters for cleaning up fines and dust, rather than shovelling and brushing, to reduce

settled dust becoming airborne again.

9.1.8.3 Transfer of material Do not overlook the need for properly enclosed systems to empty and transfer dust from collection

units. Disposal methods and locations need to prevent the collect dust, or the dried-out sludge

from wet arresters, becoming airborne.

9.1.9 Respiratory protective equipment (RPE) Sometimes the use of RPE is likely to be the final option to achieve acceptable long-term time

weighted average (TWA) exposures to respirable crystalline silica. Generally, respiratory protection

is most important when operators are exposed to high concentrations of dust for short periods of

time. Longer-term exposures to high dust concentrations should be dealt with by other control

measures.

The use of RPE is not a substitute for other reasonably practicable control measures, but it an

extremely important part of the overall strategy to minimise personal exposures to respirable

crystalline silica. Failing to recognise the need for a respirator programme or poor management of


the implementation of the programme will result in completely unnecessary operator exposures,

and greater incidence of unnecessary occupational ill health.



Figure 93: Use of vacuum cleaning equipment Figure 94: Brushing up

Assessments of workplace dust concentrations will give an indication of the standard of respiratory

protection required. It will always be necessary to provide equipment that is effective against

respirable-sized particles.

Disposable filtering face piece respirators and half-mask respirators give the lowest level of

protection. Full-face respirators and powered respirators with helmets or hoods may provide a

higher standard of protection.

The greatest dust levels will generally require the higher standard of RPE protection, and you

should choose equipment which will be operating well within its designed capability. Powered

respirators require careful maintenance and recharging facilities if they are to remain effective.

The key to successful use of RPE is in identifying those areas where it is needed. Quarry workers

may need to wear RPE for as little as five minutes an hour if it is during that period that the

highest exposures occur. Well-defined mandatory respirator zones should be established. Careful

use of RPE can result in dramatic reductions in personal exposures, and in areas where dust

emissions are otherwise uncontrollable it will be a reasonably practicable option.

There are five elements for a successful respirator programme. Failure in any one results in loss of

protection and exposes the operators to greatly increased risk of developing irreversible and

progressive lung conditions in later life. The five elements are:

selection – performance of the equipment and consideration of the conditions of use;

training – how to use the equipment, why it is necessary and when it should be used to

gain greatest benefit;

use – understanding when the equipment is required and clear instructions on parts of the

plant that are mandatory respirator zones;

fit – ensuring that the operator achieves the essential face seal with the equipment, which

is vital if the suggested level of performance is to be reached;

maintenance – care and a programme of inspection ensure that the initial performance

characteristics of the RPE continue throughout its life.

9.1.10 Maintenance, examination and testing of control

measures Control measures should be maintained in an effective state, in efficient working order and in good

repair. In addition, where engineering controls are implemented, employers should ensure that


thorough examinations and tests of those engineering controls are carried out, and in the case of

LEV tested at least once every 14 months.

The control measures may include:

Dust collectors on drills

Water addition to the air line

Water suppression sprays

Screen hoods

Encapsulation

Extraction systems

Dust collection equipment

Integral units

Water supply to saws

Road damping

Examples of the examinations and tests required are given in the table below. Precise details, such

as frequency, pressures etc. should be obtained from the designers, suppliers or original

equipment manufacturer.

The risk assessment may have determined that taking a particular measure would provide

adequate control of exposure to respirable dust. The assessment should also contain the

specifications for that control, for example:

Dimensions of ducting, transport velocity, volume flow

Static pressures at various points in the system

Fan specification, volume, flow, direction of rotation

Filter efficiency as indicated by a change in pressure drop

Velocity at catchment points

This information is important not just to prove an adequate assessment has been done, but also to

provide the data against which future performance and maintenance checks can be compared.

It should be possible for the checks to be carried out by operators and ideally they should form

part of a planned preventative maintenance scheme. This would have the advantage of reducing

down time while ensuring effective control is maintained. Such checks should be carried out at a

minimum of weekly intervals.

Using a dust lamp can be useful for these checks. The Tyndall beam effect from the lamp only

provides qualitative information but can enable any leaks, for example on seals and encapsulation

systems, to be easily identified.


Table 3: Maintenance, examination and testing of respirable dust control measures

Wet systems Dry systems

Drilling - Water supply adequate

- Pipes and connections in good order and not kinked

- Cold weather protection (where applicable) adequate

- Water control valves in good order

- Water flow as specified

- Gasket or skirt on pick-up hood in good order

- Suction hose not damaged, kinked or blocked with dust

- Hose clips in correct position

- Rubber dump valve or collection sack in order

- Air supply to filter adequate

- Anti-freeze protection (where applicable) in order

- No blockages or build-up of dust inside collector

- Filters in good order i.e. not blocked or broken

- No holes in collector or wear plate

- On hydraulically powered units, pressures, fan condition and speed satisfactory, suction pressure and airflow tested

Other processes: crushing, milling, screening, conveying, heating, drying, sawing, bagging etc.

- Water supply adequate

- Pipes and connections in good order with flow not restricted

- Frost protection (where applicable) adequate

- Water control equipment and valves in good order

- Water flows as specified

- Filters and sprays regularly checked and cleaned

- Sufficient additives (where used) available and in use

- Sprays correctly positioned

- Electronic control system functioning correctly

- Fans working with correct airflows

- Seals, ducting, covers, enclosures correctly positioned and not damaged or blocked

- Checks for signs of water, teat or damage to ducts, hoods etc.

- Static pressures within limits at various positions should read as specified

- Look out for worn or torn bags in bag filter units

9.1.11 Information, instruction and training Where workers are, or may be, exposed to respirable crystalline silica they must be informed

about the risks and the precautions to be taken. They also must5 be informed of any monitoring

that is carried out, and the collective anonymous results of health surveillance.

Instruction and training should include information on the correct use of control measures and, if

necessary, details of the maintenance requirements. You should select suitable RPE for particular

circumstances and to ensure it is correctly used. Training and instruction is required to ensure

workers understand how to fit and wear RPE provided, where to store it and what to do if damage

occurs or a replacement is needed.

5 HSEA Section 11 and 12A


9.2 Noise The following information gives practical examples of how to reduce and control noise from typical

mines or quarry plant and equipment. The information does not address the more technical

aspects of noise and should be read in conjunction with the WorkSafe New Zealand Approved Code

of Practice for the Management of Noise in the Workplace and the Approved Code of Practice for

Worker Health at Mines and Tunnels. For example, noise measurement and design methods to

control noise should only be undertaken by suitably competent persons. This is important, not only

because workers may be unnecessarily put at risk, but because money may be wasted.

You must ensure workers are not exposed to noise levels above 85 dB(A) LAeq,8h and a peak noise

level of 140 dB Lpeak regardless of whether they are wearing a personal hearing protection device6.

Personal protective equipment (PPE) (ear protectors) can only be used as an interim solution, but

may in practice be used long-term when all other reasonably practicable measures have been

taken, but have not, in themselves, achieved adequate noise reduction. The reduction of noise

exposure should be the main objective.

Much can be achieved by careful design and maintenance of equipment and possibly by changing

work practices.

Methods for reducing exposure include:

a) using low noise plant and equipment; many mines and quarries equipped with modern

plant and vehicles achieve employee noise exposures below work place exposure

standards

b) reducing sound radiating surfaces e.g. use mesh guards instead of plate metal

c) vibration isolation e.g. of operators’ cabins and vehicle cabs

d) using sound absorbing linings e.g. in vehicle cabs and engine cover linings

e) exhaust silencers e.g. on pneumatic drill rigs and vehicle engines

f) using enclosures around equipment e.g. to control noise in saw shops

g) using noise refuges for workers e.g. a cabin at the control console of crushing and

screening equipment

h) maintenance e.g. replace defective silencers and repair broken windows in vehicle cabs

etc.

Such measures may be used singly or in combination. The list is not exhaustive and other

techniques might be applicable. Many effective solutions are low cost.

9.2.1 Blasting

9.2.1.1 Primary The noise from blasting is of very short duration and, depending upon the distances involved, can

reach the peak exposure level. An added problem is the environmental nuisance.

The adequate covering of detonating cord, if it is used with at least 0.6 m of material, can reduce

noise levels. More common now is the use of in-hole initiation, or the use of non-electric (shock

tube) initiation techniques, and substantial noise reductions can be achieved by this method.

9.2.1.2 Secondary Secondary blasting is not common, but when used it often leads to complaints on environmental

grounds. Unconfined explosives (plasters) cause greater problems than POP shots (small diameter

holes). Careful attention to blast design to achieve good fragmentation can substantially reduce or

eliminate the need for secondary blasting. The use of drop balls or other types of breakers have

largely overcome the secondary blasting problem.

6 HSER 11 Noise


9.2.2 Drilling

9.2.2.1 Hand-operated drills Hand-operated drills are used mainly for the drilling of small diameter holes in monumental stone

quarrying, which can be used for explosives, plug and feathers or hydraulic splitters. They are

usually powered by compressed air and the noise arises from the action of the motor, hammer and

air vent, causing operator exposure and environmental nuisance. Vibration to the hands and arms

can also be a problem with this type of equipment.

Recent developments in the design of equipment with the fitting of mufflers to the body and

dampers to the moil point can achieve reductions in the order of 6-7 dB(A). Also noise levels

reduce as the moil penetrates the material being drilled.

Many of the older types of equipment can be retrospectively fitted with mufflers and dampers for

the moil point to reduce noise levels. Unfortunately, excessive muffling of the exhaust noise can

cause back pressure which reduces the equipment’s performance; this is most noticeable in old

worn units. In practice, mufflers usually reduce noise levels by 5-7 dB(A) while reducing

equipment performance by about 10%.

9.2.2.2 Drilling rigs Drilling rigs are used mainly for the drilling of holes for blasting at various types of mines and

quarrying operation. They can be powered by compressed air, hydraulics or electricity, however,

hole flushing is often achieved using compressed air. Water or other mediums are manually

employed for hole flushing when coring for exploration or other purposes. In mines or quarries

three main types are used:

a) drifter

b) down the hole hammer (dth)

c) rotary

On the air-operated drifter, the reciprocating hammer and rotation motor are located on the mast

and therefore they are particularly noisy. Noise levels in excess of 110 dB(A) have been measured.

With the dth machine, the hammer is positioned above the drill bit and for most of the drilling

cycle it is located inside the hole, but the initial penetration can result in excessively high noise

levels.

Hydraulically driven motors are available, are much quieter and should be considered when

purchasing new equipment.

The fitting of mufflers or suitable silencers can reduce noise levels. In addition, conducting the

exhaust from the rotation motor via a transfer hose to a remote position e.g. the mast, and using

a silencer can reduce noise still further (see Table 2).

Table 4: Examples of noise reduction benefits by fitting a silencer to the rotation motor on a dth drilling machine

Rotation motor on dth drill dB(A)

Without silencer 105

Fitted with silencer 94

Silencer positioned on mast 89

It is important to fit properly designed silencers to avoid blockage and freezing up problems.

Many of the larger and more modern plant has integral control cabins for the operator, from which

all of the plants functions can be controlled. These cabins also provide protection from dust and

the elements, and to avoid the door or window being left open during hot weather, air-conditioning

units can be fitted. With well-designed cabins, levels below 85 dB(A) are easily achievable.


9.2.3 Compressors Diesel powered compressors, either mounted on the drilling equipment or on wheeled trailer units

are often used for powering drills or for hole flushing. Although the trailer units can be located well

away from the drill, the noise levels can contribute to the drillers’ exposure. Silencers should be

kept in good order and covers and doors should be kept closed. Silenced equipment is available

and should be considered when purchasing new equipment.

9.2.4 Excavators or draglines These are usually diesel or electrically powered machines used for the excavation and loading of

material and are controlled by an operator located in the driver’s cabin. On new machines, the

noise levels in the cabins are usually not a problem. On older machines, soundproofing and

physically dividing the engine and draw-works from the driver’s cab may be necessary to reduce

the noise to acceptable levels. Successful noise level reductions can only be maintained if the

mobile plant is kept in good order and the doors and windows fit properly and are kept closed.

9.2.5 Wheel loaders, dump trucks and other vehicles Insulation and covers around engines and fans can greatly reduce noise levels and sound-proofing

of the driver’s cab can keep exposures well below 85 dB(A). The benefits of any sound-proofing

will, however, be lost if windows and doors are not kept closed. To avoid overheating during hot

weather, air-conditioning units should be fitted. Engines should be fitted with suitable intake

silencers.

Retrofitting can be worthwhile but is seldom easy. With all types of vehicles the driver can be

protected by a sound-proofed cab or by modifying the existing one. All cabs that are sound-

proofed are likely to have the following features:

a) anti-vibration mountings

b) complete enclosure with any openings (for ventilation) fitted with an acoustic attenuator

c) vibration damped panels

d) acoustic lining of the cab

All vehicles having an internal combustion engine can expose both the driver and others to high

levels of noise. Noise reduction can be obtained by providing an acoustic enclosure for the engine,

which is likely to have the following features:

a) an efficient exhaust silencer placed away from the driver’s position

b) a complete enclosure - dampened to prevent vibration

c) anti-vibration mountings between the engine and frame

d) a low noise cooling fan

e) silencers fitted to air inlets

9.2.6 Crushing or milling There are basically two methods of crushing i.e. by compression and by impact. The main plant

types are:

Compressive e.g. jaw crushers, gyratory crushers, cone crushers, roll crushers, ball mills

and rod mills

Impact e.g. rotary impactors, hammer mills (fixed or swing hammers)

All types of crushing plants are used to reduce mineral in size and the process involves heavy

metal parts or units and the utilisation of considerable amounts of energy. Depending upon the

location, installation and particular type of crusher, high levels of noise are involved.

Resilient mountings, chute linings, acoustic curtains, lagging, covers etc. can bring about useful

reductions in noise levels. However it is difficult to reduce noise below the 85 dB(a). In many cases


this can only be achieved by housing the operator in a control cabin. If the control cabin is

remotely situated, the use of closed-circuit television (CCTV) can ensure adequate operation.

9.2.7 Screening There are numerous types of screening equipment, many of which are designed for specific

purposes. Screens are used to extract or reject material of a specific size from the feed product.

They may be located singly or in various arrangements or groups in a screen house. Screening by

its very action creates noise and the larger the material the greater the noise problem.

The use of synthetic screen mats or cloths to replace the traditional metal plate or woven wire has

immense benefits and, coupled with chute linings, enclosures or complete encapsulation, further

reductions can be achieved.

If a complete screen house is considered to be an enclosure, workers should only be allowed to

enter if suitable PPE is used. Entry to such enclosures should be avoided when the plant is in use

and the use of control techniques including bin level indicators and CCTV should be considered.

9.2.8 Conveying and feeding Material being conveyed does not create noise in itself and it can be at the loading end or

discharge position that noise problems exist. The use of ‘stone’ baffles or chute linings can reduce

both noise and wear. Efficient maintenance can reduce ‘squeal’ from conveyor idlers. An example

of the beneficial effects of chute lining is given in Table 5.

Table 5: Examples of lining a chute to reduce the noise level

Meta/chute dB(A)

No ling 119

Loose conveyor belt lining 116

25mm thick rubber lining 102

By reducing the drop height and by preventing material impacting onto empty bins or hoppers (i.e.

by ensuring material drops onto material) noise levels can be restricted. In addition the use of

spiral chutes or lined cascade towers will lower noise levels.

9.2.9 Heating or drying The heating of materials inevitably causes noise problems. The larger the size of material being

heated often the greater the problem. Burners and fans are sources of high noise levels.

Much can be achieved by fitting enclosures or silencers to burners and fans. Silencers should be

placed on both the inlet and outlet sides to reduce noise effectively. Anti-vibration mountings can

help to avoid vibrations being transmitted through the structure. Remote operation, including

lighting up can help to keep workers exposures down.

9.2.10 Saws Both static and portable hand-operated saws are used to cut blocks of stone and slate into

selected sizes.

The use of dampened saw blades with enclosures where possible and keeping the blades straight

and sharp can restrict noise emission (see Table 6). A reduction in the speed of saws can also

reduce noise levels. Remote and automatic control of saws can also be used.

Table 6: Noise reduction using dampened saw blades

Saw blade type dB(A)

Standard 100

Dampened 87


9.2.11 Miscellaneous situations

9.2.11.1 Preventative maintenance Well-planned preventative maintenance programmes will have beneficial effects on noise control.

Examples of the causes of excessive noise are: worn bearings, air leaks, cover or enclosures not

properly fitted or in position, loose materials on platforms, loose bolts, rattles and worn chute

linings etc.

9.2.11.2 Roads Gradients should be as shallow as appropriate to avoid excessive vehicle revs. Road surfaces

should be kept clean and dirt free and tight corners should be avoided.

9.2.11.3 Examples of noise reduction The following table outlines examples of noise reduction by carrying out simple modifications.

Table 7: Examples of noise reduction by carrying out simple modifications

Plant Modification Reduction dB(A)

Before After

Primary crusher cabin Improve and insulate 108 89

Compressor Change to silent type 100 84

Drill Fit silencer to rotation motor and attach to mast 105 89

Secondary crusher Install cabin 107 91

Secondary crusher Fit rubber mounts under cabin 91 81

Metal transfer chute Fit conveyor belt lining 119 116

Metal transfer chute Fit 25mm thick rubber lining 119 102

Screen building Tighten handrails and remove debris 88 85

Screen Fit polyurethane module screen decks 100 91

Screen Line chute under screen and fit rubber screen cloth 107 94

Mobile crusher platform Fit efficient exhaust silencer 103 92

Mobile crusher cabin Fit efficient exhaust silencer 93 84

Hand drill Fit muffler and dampened moil point 110 106

Mobile crusher Install insulated cabin 92 75

Stone saws Remote operation inside control room 93 74


10 TRAINING REQUIREMENTS

Everyone working at the mine or quarry should be competent for the work they are required to do. They, and their managers, need to know the limits of their competence.

People working at the site should not undertake any work for which they are not competent –

except under the careful instruction and supervision of a competent instructor.

Competence can be described as the combination of training, skills, experience, knowledge and

other qualities a person has and their ability to apply them to perform a task safely. Other factors,

such as attitude and physical ability can also affect someone’s competence.

Everyone who works at the site should be properly trained and have appropriate experience and

knowledge to enable them to do their work safely. A few will need other qualities such as

management skills, of formal qualifications, for example geotechnical specialists, shotfirers and

explosive supervisors. Management training should, where appropriate, include training in safety

management, risk assessment and developing and using safe systems of work.

The risk assessments and national standards can help to determine the health and safety

competencies needed for particular jobs. By comparing the competencies needed with those which

people already have, managers can determine what additional skills are required and how these

can be achieved, for example through training and coaching.

It can be useful to involve experienced workers in training as they are often best placed to

understand the risks involved in their work. Take care, however, to ensure bad habits are not

passed on.

Providing health and safety training helps to develop competence and encourage safe working

practices. It contributes positively to the health and safety culture, and is required at all levels,

including top management. Everyone who is new to a site should be given suitable induction

training; this is particularly important for young recruits and those who are new to the industry.

Induction should cover all matters which are site-specific. This includes relevant aspects of health

and safety policy statement, the health and safety document, risk assessments, the arrangements

for first aid, fire, evacuation, standard operating procedures etc. Further training is likely to be

needed whenever:

a) Someone takes on substantial new responsibilities; or

b) There is a significant change in work equipment or systems of work

Skills decline if they are not used regularly and refresher training should be provided as necessary

to ensure continued competence in skills that are not often used (e.g. confined space training etc.)

Information from personal performance, health and safety monitoring, accident investigation and

near-miss incidents can help identify a need for additional training.


11 EMERGENCY MANAGEMENT

Emergency events can occur. Every site must plan for these events. They are generally incidents that may be unlikely to occur but with potential high consequences.

You must develop procedures for dealing with emergencies that may arise while people are at

work.7

Task assessment should indicate the emergencies which might arise and the action and equipment

required to deal with them.

For mining operations a detailed process for obtaining urgent medical treatment for workers who

suffer serious harm must be completed8. The process should take into account the nature of the

terrain where the site is located and the remoteness of the site from the nearest hospital or other

place where medical assistance may be provided.

For further information on emergency procedures refer WorkSafe New Zealand Guide to

developing Safety Management Systems for the extractives industry and the Approved Code of

Practice for Emergency Management in Mines and Tunnels.

An emergency procedure flipchart (a set of simple forms that can help you identify and manage

your emergency procedures) is available from the Environmental Protection Agency (EPA). Phone

0800 376 234 or email [email protected] to order a free copy or download a pdf version from

www.business.govt.nz/worksafe/information-guidance/all-guidance-items/emergency-procedures.

11.1 Communications Good communications are of paramount importance in an emergency, particularly in remote areas

and for lone workers. Suitable communication equipment might range from bells to more

sophisticated public address or closed-circuit television systems. Radios or telephones can enable

rapid communication if they are carefully positioned. They may, for example, be fitted to mobile

plant or backup service vehicles, or issued to appropriate individuals. Electrical systems, radios or

mobile telephones may be unsuitable where explosives are in use or where there is a risk of an

explosive atmosphere and the equipment may cause ignition or initiate the explosion.

In most mines and quarries, liaison with the emergency services is helpful. In particular, it is

advisable to inform them in advance of any dangers that might affect their operations, for example

the presence of explosives, LPG storage, unstable faces and burning tyres which may explode.

For mining operations you must consult fire, police and ambulance emergency services that have

responsibility for the area in which the mining operation is located, and, in the case of a coal

mining operation, the Mines Rescue Team9.

7 HSEA Section 6(e)

8 HSE (Mining and Quarrying) Regulations 108(2)(b)

9 HSE (Mining and Quarrying) Regulations 104(a) and (b)

http://www.business.govt.nz/worksafe/information-guidance/all-guidance-items/emergency-procedures


11.2 Suitable Access and Egress for Emergency Services Well-constructed and maintained roadways allow emergency vehicles easier access. These vehicles

are generally made for road use, and are not suited to difficult terrain. In an emergency, it can be

helpful to have a person waiting at the site entrance to direct the emergency services.

In remote areas it may be faster for emergency services to respond with a helicopter. In these

situations knowing the GPS co-ordinates and other landmarks near the site will ensure the location

is easier to find.

You must provide means of leaving the place of work in an emergency10.

11.3 Means of Escape Means of escape should be taken into account when designing both fixed and mobile workplaces.

Sometimes a second exit may be necessary, for example in some areas where highly flammable

liquids are used.

11.4 Rescue and Emergency Equipment Examples of the type of rescue and emergency equipment which may be required include:

a) Breathing apparatus (for confined space entry)

b) Ropes

c) Ladders (rigid or rope)

d) Tripods, winches

e) Tools (e.g. pickaxe, crowbar, shovel, cutters)

f) Stretchers

g) Buoyancy aids e.g. lifejackets, lifebuoys (rings)

h) Rescue boats

i) Chemical spill kit

j) Fire extinguishers

k) Fire hose reels

l) Bush fire kits

m) First aid supplies

Lifting and cutting equipment may also be needed in some mines and quarries. Rescue and

emergency equipment should be subject to appropriate inspection to ensure it is always ready for

use.

11.5 Training in Emergency Procedures Most people only need to be able to leave their workplace and go to a designated place of safety in

the event of an emergency. You must inform workers on what to do if an emergency arises.11

Where rescue equipment is provided, enough people should be trained to use it without

endangering themselves or others. Training in rescue equipment and procedures should be specific

to the type of emergency e.g. confined space rescue, heights rescue, use of an extinguisher etc.

There should also be enough trained workers to administer first aid. The WorkSafe New Zealand

First Aid for Workplace, A Good Practice publication outlines expectations regarding first aid

equipment and training of workers. For remote operations a higher level of first aid training may

be required.

10

HSE Regulation 4(c) 11

HSEA Section 12(a)


12 EMPLOYEE FACILITIES

You must provide suitable and sufficient numbers of facilities to ensure the health and safety of everyone at the site12. Facilities are those that are necessary for the well-being of your workers, such as washing, toilet, rest and changing facilities, and somewhere clean to eat and drink during breaks.

All facilities should be kept in a clean and sanitary condition.

Where the workplace is permanent, facilities must comply with the New Zealand Building Code and

local authority bylaws.

12.1 Washing Facilities As a minimum requirement, cold water, cleansing agents and suitable hand drying facilities must

be provided at all work sites.

Where chemicals are being handled, mixed or applied, facilities may need to include a shower

with, if the original equipment manufacturer instructions require, the washing of the whole body

after working with them or in the event of contamination from spills. Otherwise, cold water,

suitable cleaning agents and individual towels should be provided.

12.2 Toilets Due to the mobile nature of some mine and quarry operations, the type of toilets, will vary from

operation to operation.

As a guideline, toilets should be provided when:

There is no natural screen available

When requested by employees

In a water supply catchment area

At any mine or quarry operation occupying a site for over four weeks, a screened off

facility should be provided

At mine or quarry sites occupied for long periods, consideration should be given to the

installation of a chemical toilet. When sanitary conveniences are provided, cleaning to a

high standard is required.

Regardless of the above you must ensure workers have access to toilets in a way that is

convenient to them.

12.3 Drinking Water You must supply an adequate supply of wholesome drinking water. It should be readily available

and clearly labelled as drinking water. A common drinking container should not be used.

Containers for drinking water should be kept clean and protected from contamination.

12

HSE Regulation 4, 5 and 6


12.4 Facilities for Employees who become ill at work You must provide rest facilities, or if necessary, transport to home or medical assistance for

employees who become ill at the place of work.

12.5 Facilities for changing and storing clothes You must provide an area where workers can change, in privacy, clothes that become wet or

contaminated at work. Adequate clean space should be provided so workers can store clothes not

used at work where appropriate.

12.6 Facilities for meals You must provide facilities for workers to have meals and rest periods in reasonable comfort and

sheltered from the weather. Any facility used for shelter and meal purposes shall not be used for

the storage of tools, materials or petroleum products.

Suitable rubbish disposing facilities should also be available.


13 SITE SECURITY AND PUBLIC

SAFETY

The safety of the public is just as important as workers. Employers and people in control of a place of work have a duty to ensure, as far as is reasonably practicable, the safety of those not in your employment where they may be harmed due to a hazard that is, or arises, at the mine or quarry.

You must consider ways in which working the site may create a risk to the public. The use of

explosives and any public access to the site are obvious examples13.

Members of the public in a mine or quarry are likely to be exposed to significant risks. From a

health and safety point of view, it is normally better if public rights of way are diverted around

mines or quarries. Where diversion is not possible, precautions should be implemented based on a

detailed risk assessment of the route and the area around the site. The precautions should be

reviewed regularly in the light of experience.

13.1 Barriers The provision and maintenance of suitable barriers around the site to discourage trespass may be

appropriate. In this context, trespass means entry to the site without your express or implied

permission.

Barriers are appropriate where it is reasonably foreseeable that members of the public, including

children, are likely to trespass on the site and could suffer injury if they did so.

The type of barrier required depends on the risks. In a rural area where the risk of public access is

low, hedges, trenches and mounds may be enough. At the other extreme, where there is evidence

of persistent trespass by children which places them at significant risk, substantial fences may be

required.

Workers should be encouraged to report cases of trespass or evidence that children have been

playing on the site. They should also be told what action to take if they discover trespassers.

13.2 Signage Suitable signage warning people of the possible hazards at the site should be erected at entry

points and, where necessary, along boundaries. Any signs should be maintained in a legible

condition.

Placeholder for diagrams similar to the below diagrams and photo (signs off the internet and photo

from HSE for example purposes only, permission to use not sought)

13

HSEA Section 16


Figure 95: Examples of signage warning of hazards

Figure 96: Example of sign at gate


WorkSafe New Zealand

56 The Terrace

PO Box 165

Wellington 6140

Phone: +64 4 897 7699

Fax: +64 4 415 4015

0800 030 040

www.worksafe.govt.nz

ISBN: Request from [email protected] (print) ISBN: Request from [email protected] (online)

http://www.worksafe.govt.nz/



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