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By Sean Gallagher, William S. Marras, Alan S. Litsky, Deborah Burr

This paper describes a comparison of the fatigue failure responses of older versus younger lumbar spine cadaver motion segment specimens. These specimens were repeatedly subjected to loads simulating those experienced by the spine in lifting a 9 kg load in different torso flexion postures (0, 22.5, and 45 degrees of flexion). An older sample of 36 motion segments (average age 81 years + 8 SD) is compared with a younger sample of 18 motion segments (average age: 47 years + 9 SD) with respect to the number of cycles to failure and results of survival analyses evaluating the effects of flexion and bone mineral content with and without the younger data set. Compared to the older sample of spines, the younger sample exhibited many more cycles to fatigue failure in all the torso flexion conditions (10020 versus 8267 average cycles to failure in 0 degrees flexion, 7124 versus 3262 in 22.5 degrees flexion, and 3229 versus 263 cycles to failure in 45 degrees flexion). The increased cycles to failure in young specimens is likely due to the increased bone mineral content (BMC) in younger motion segments (30.7 g + 11.1 g per motion segment versus 27.8 + 9.4 g). Cox regression analyses modeling both flexion effects and BMC indicate that betas are similar when just older spines are modeled and when younger specimens are included in the analysis. Betas for survival analysis models with and without younger specimens generally show little change for flexion (2.716 versus 2.756 for 22.5 degrees [0 degrees referent], 3.926 versus 3.380 for 45 degrees [0 degrees referent]). Bone mineral content shows a similar protective effect in both models (Betas: -0.127 versus -0.087). Overall, comparison of the models indicate that risk ratios are similar for 22.5 degrees flexion, slightly increased for 45 degrees flexion and slightly more protective influence predicted for BMC in the combined sample versus the older sample alone.

Roof screening for ground control originated with metal miners in the western United States. At first chain-link fence was used, but because it was so difficult to handle, the miners started installing a more rigid welded wire screen used in the concrete industry. Eventually coal mines in the west began to use screen, and now more and more coal operations, especially longwall mines, are installing roof screen on a regular basis. Screen use has recently increased in the Illinois basin and is now making its way to underground coal mines in the eastern U.S.

USBM Contract H0133045 consists of the design, build and test of 50 waveform generators. The waveform generator is a small ULF transmitter operating in the 1 to 3 KHz frequency range for the purpose of locating trapped miners during a mine disaster. This contract provided for the design, test, and building of 50 waveform generators using a discrete component construction with an option of using hybrid construction techniques within 105 days after the effective date of the contract. Because of large quantity economic considerations, this option was not initiated. Two engineering models were designed, constructed and tested and 50 final production units were fabricated using discrete construction. Complete documentation is supplied under a separate package which includes final schematics, parts list, layout information, equipment specification, production test procedures and qualification test procedures. Ten units have been delivered to the USBM. The remaining 40 units are being retained for packaging under contract H0242010 Transmitter Package and Receivers. A great deal of experience has been gained as a result of this contract. A final discrete potted printed circuit configuration has been arrived at that is now ready for field testing. After field testing, any desired changes should be incorporated into a final design. However, as a result of the current experience gained building and testing the production units, this printed circuit package together with potting procedure could be improved to reduce future costs. For example, the printed circuit board could be increased in size by 0.125 to 0.2 inches and all components could be mounted directly to the board eliminating costly hand stacking of components. The new printed

By David C. Byrne

From an engineering perspective an ideal industrial noise control solution focuses directly on the actual source of the poise. Eliminating the noise-generating mechanism altogether obviates the need for other noise contra l treatments or hearing protection devices. However, in cases where attenuating the source is not feasible engineering controls must be oriented toward blocking the path that the sound waves travel toward employees. Acoustical enclosures are commonly used as sound path treatments to contain the noise from a machine: alternatively a control room/booth or equipment operator's cab may be used to isolate the worker from the noise. Anyone who has successfully used acoustical enclosures knows that the design procurement, and installation process is deceptively simple. Alt too often First-time efforts fait to account for many of the constraints that can render the enclosure essentially useless. Things that cannot be overlooked include: providing convenient worker access (physical and visual): allowing for proper machine operation/product flow; and supplying fresh air or preventing undue heat or contaminate build-up inside the enclosure. All of these factors must be given careful consideration, otherwise the enclosure will not perform adequately.

By D. E. Pollock, J. A. Organiscak

Water sprays and water powered scrubbers have both been utilized in the mining and milling industry to suppress airborne dust. Unconfined water sprays operated at lower water pressures of ?689 kPa (?100 psig) can be very effective at wetting the mine product at the dust source and significantly reducing the amount of respirable dust that becomes airborne. However, unconfined waters sprays can be somewhat ineffective in actually removing airborne dust from the air. On the other hand, water powered scrubbers operating at higher water pressures of ?1,724 kPa (?250 psig) in physical enclosures or ducts have previously been demonstrated to be very effective in removing airborne dust from the air. These higher operating water pressures are uncommon in many mines and mills, so their use is limited. The National Institute for Occupational Safety and Health (NIOSH) recently investigated the performance of a lower-pressure, water powered inline series spray scrubber for removing localized airborne dust emitted at the source. Results showed noticeable improvements in airborne dust capture efficiency through the operation o f multiple inline series hollow cone spray nozzles within a round duct or pipe at the same water pressure as a single spray. Operating hollow cone spray(s) at higher water pressures noticeably improved airflow through the scrubber and yielded some additional scrubber efficiency improvements. Thus, in-line spray scrubber efficiency trade-offs were observed to be made by altering spray power components of water pressure and/or quantity (number of sprays). Results show that, on average, up to 0.23 and 0.32 m3/s (484 and 679 cu ft per min) of airflow at 0.81 and 0.69 dust capture efficiencies can be achieved with three 81° and 33°hollow cone inline series sprays, respectively, operating at 1,655 kPa (240 psig).

By J. A. Organiscak

This paper examines methods for limiting occupational silica exposures for roof bolting personnel in underground coal mining. A canopy air curtain and an air tube were evaluated as means to provide filtered air over the breathing zone of these personnel. Laboratory testing showed that dust reductions beneath the air curtain and air tube approached 60 percent and 40 percent, respectively, with low interference air velocities. The data also showed that dust reductions were highest for positions closest to the device and that these levels decreased with distance. This paper also evaluates a metal rake, a flexible insert, and a rigid insert for cleaning the roof bolter dust collector box. Less dust was produced when using the rigid insert. Surprisingly, the flexible insert was sometimes no better than scraping or raking the dust onto the mine floor. However, little dust got on the coveralls when using either of the inserts.

By Michael S. Wieland

The work-principle from thermodynamics was used to formulate a model for predicting toxic fumes from mining explosives in underground chamber tests, where rapid turbulent combustion within the surrounding air noticeably changes the resulting concentrations. Two model constants were required to help characterize the reaction zone undergoing rapid chemical transformations in conjunction with heat transfer and work output: a stoichiometry mixing fraction and a reaction-quenching temperature. Rudimentary theory with an unsteady uniform concentration gradient was taken to characterize the combustion zone, yielding 75% for the mixing fraction. Four quenching temperature trends were resolved and compared to test results of ammonium nitrate compositions with different fuel-oil percentages (ANFO). The quenching temperature 2345 K was the optimum choice for fitting the two major components of fume toxicity: carbon monoxide (CO) and total nitrogen oxides (NOx). The resulting two-constant model was used to generate comparisons for test results of ANFO compositions with additives. Though respectable fits were usually found, charge formulations which reacted weakly could not be resolved numerically. The work-principle model yields toxic concentrations for a range of charge formulations, making it a useful tool for investigating the potential hazard of released fumes and reducing the risk of unwanted incidents. Keywords: Toxicity; Fumes; Explosives

By Launa Mallett, Charles Vaught, Michael J. Bmick

Since 1991 the Pittsburgh Research Center (PRC formerly part of the U. S. Bureau of Mines) has been tapping u valuable resource-researchers have recorded extensive interviews will, 30 individuals who are recognized as experts in the area of mine emergency response. These veterans related stories and observations from events experienced during as many as 47 years of response activities. Overall, the response veterans averaged 29 years of mine emergency response experience and 35 years mining experience. Individuals [ ] interviewed included representatives from mining companies, the UMWA and state and federal government agencies. This information was gathered so dial it could he provided to today's miners and to tomorrow's emergency response personnel. It is hoped the collective wisdom that has been obtained can be used to help train new responders and guide those decisions which mill have to be made on the scenes of future events. During interviews file emergency response experts were asked to discuss lessons they had learned through experience. The interviewers asked them to tell what they had learned that would cause them to handle similar situations differently and to tell about things they saw at past events shat the would warn others not to do in the future. In response the experts discussed a variety of things. Most of their responses, however, touched on some of the same topics including: preparedness, experience people on-site mine rescue teams, and decision making. A summary of their responses provides alt overview of [lie lessons learned on-site at tile largest mine disasters in the country.

By Fred N. Kissell, Jerry C. J. Tien, Edward D. Thimons

At coal mine working faces, simultaneous application of three basic elements reduces the methane explosion hazard: (1) adequate ventilation, (2) regular monitoring of gas concentrations, and (3) the elimination of ignition sources. This paper reviews the application of these elements in a manner relevant to Chinese coal mines. Adequate ventilation is provided by using the mine entries to convey air for the long distances between the mine portal and the working sections (main ventilation systems) and then using line brattice or ventilation duct (face ventilation systems) to convey air the last hundred meters to the working face where coal is broken and removed. The air quantity provided is enough to safely dilute methane and the air velocity is enough to prevent layering. Gas concentrations are regularly monitored in accordance with regulations using knowledge of the circumstances under which the highest concentrations are likely to be found. Ignition sources are eliminated by ensuring that electrical equipment does not ignite methane, that sparking from cutter picks is minimized, and that smoking by workers is strictly forbidden. Risk-reduction studies using fault-tree analysis have shown that large reductions in explosion risk only result from multiple preventive actions. For example, a ventilation upgrade or a methane monitor upgrade by itself offers risk reductions under 50 pct. A risk reduction of 90 pct. or more would typically require much more. Other studies have shown that the everyday vigilance of those working underground is as important as engineering design.

By F. C. Turin, K. M. Cornelius

1. INTRODUCTION Underground mining in the USA has undergone significant change in the past 20 years. Two key elements have been increased mechanization and a more educated work force in spite of these changes, many jobs continue to be labor-intensive and repetitive in nature. They entail tasks that, performed over time, can take a toll on the soft tissues and joints. The problem may be compounded by an aging mining workforce. In 1996 the mean age of the coal mining work force was 45 years and the median total years of experience was 20 (NMA 1998). As a person ages, the body resilience to chronic wear and. tear is reduced, which may cause a worker to pay an increasingly higher health price for performing the same task. Mining companies, like many others, are becoming more aware of cumulative effects to the worker as reports of these types of injuries rise. . Conducting a job analysis is an important step when considering a job redesign or modification to reduce worker cumulative trauma exposure. A basic approach to job analysis is to examine the types of aches and pains reported, the tasks performed, and work site conditions. The US Bureau of Mines (USBM) conducted an evaluation of roof-bolting tasks performed at an underground coal mine concerned about early warning signs of cumulative trauma. This evaluation will comprise the primary focus of this chapter. The approach used for the roof-bolting race study may be applicable to other work environments. 2. FUNDAMENTALS OF CUMULATIVE TRAUMA EXPOSURE Musculoskeletal injury is a term used to describe a wide range of soft tissue disorders that affect the nerves, tendons and muscles. Common examples include lower back pain, tendinitis and carpal tunnel syndrome. The majority of these injuries are not the result of sudden mishaps, but usually develop gradually from repeated wear and tear. Symptoms may not appear immediately, but can take weeks, months or even years. Symptoms may result from many types of activities, performed at work or at home, and it is often difficult to attribute there to a single event. In fact, it is more common to identify factors that may have contributed to the development of the condition. The terms repetitive strain injuries or cumulative trauma disorders (CTD) have been commonly used to refer to disorders that have occurred due to work-related activities. Three main risk factors contribute to CTD: force, repetition and awkward postures. Any one or combination of these may contribute to the development of CTD. Therefore, the design of equipment in conjunction with the required tasks should be evaluated when attempting to reduce these risk factors. Examining the layout of the work area to help identify tasks which may contribute to cumulative trauma is necessary. The following list (Putz-Anderson 1988), describes ergonomics concerns that, overall, should be minimized at the work area: • Crowding or cramping the worker: a work area layout may unnecessarily constrain movements of the worker. • Twisting or turning: placement of tools and materials may require the worker to twist the spine to fulfill the requirements of the job. • Repeated reaching motions: the layout of the work area may require the worker to lean to reach and grasp the necessary tools and controls. • Misalignment of body parts: the arrangement of the work area may require the worker to frequently have one shoulder higher than the other or have the neck or spine bent to one side. While many of these concerns are a function of equipment design and environmental conditions, making workers aware of these issues may help them to adapt their work habits to reduce risk of injury. Additionally, this information is useful when conducting an ergonomic evaluation of a work area and associated tasks. 3. UNDERGROUND MINING ENVIRONMENT The underground mining environment is a unique challenge. It is more difficult to develop controls for an underground mine site as compared with a factory setting where equipment and facilities can be more easily designed to reduce worker force, posture and repetitive exposures. In an underground mine, workers are required to perform labor-intensive tasks that often cannot be avoided due to environment constraints. The dynamic nature of the environment does not allow easy implementation of mechanical assists to reduce force exposure. Many of the tasks performed by workers are repetitive. Restrictive work areas due to low ceiling height, low lighting levels and large pieces of equipment cause workers to perform these tasks in postures that are not desirable. Designers of underground mining equipment can control how a machine will function, but not the environment in which it will be used, Hazards in an underground mine cannot be completely removed by redesigning the system. There are many hazards and information sources that must be continually monitored by workers including their position in relation to large pieces of mobile equipment and unpredictable geological anomalies. Thus, immediate dangers may take priority over awareness of ergonomic considerations while performing a job. 4. CASE STUDY OF UNDERGROUND ROOF BOLTING 4.1. Roof Bolting and Cumulative Trauma Exposure In an underground coalmine, after an area is mined it is necessary to support the roof to keep it from collapsing. Since 1950, the primary method for supporting the mine roof has been installation of roof bolts. Long bolts installed into the roof compress the layers of strata achieving a uniformly distributed support anchorage. Roof bolts, typically 6-8 feet long, are installed by workers using large roof-bolting machines. There are different types of machines

By William D. Monaghan, Michael A. Trevits

Over the period 2000 to 2003, roof falls have accounted for 4 to 14% of the fatalities in underground mining operations. The National Institute for Occupational Safety and Health (NIOSH) is conducting research to reduce the frequency, exposure, and risk of these events through an ongoing program of field and laboratory studies. One area of research involves the evaluation of polyurethane grouting technology that is commonly used to stabilize fractured mine roof strata. Concurrently, NIOSH is conducting work to evaluate the application of ground penetrating radar for advanced delineation of problematic mining areas. In this study, NIOSH partnered with Sub-Technical, Inc. who injected a polyurethane grout (also known as glue) into a roof area of NIOSH’s Safety Research Coal Mine. The mine roof area was scanned using ground penetrating radar technology before and after grout injection in an attempt to determine the extent of grout infiltration. A comparison of the pre-and post-grouting radar records showed a significant change at a mine roof depth of about four to five feet. The interpreted radar records were then compared with drill core information, borescope evaluation of roof-bolt holes in the study area, and underground observations. At this site, the interpretations of the radar records correlated with data obtained from the core holes, borescope evaluations and underground observations. This study showed that ground penetrating radar technology can be a useful tool for detecting changes in mine roof due to the injection of the grout.

By Gabriel S. Esterhuizen, Anthony T. Iannacchione

The roof rock in underground limestone mines in Northern Appalachia can be subject to high horizontal stresses in spite of the shallow depth of the workings. The high stresses can cause roof stability problems. The National Institute for Occupational Safety and Health staff have observed a distinctive asymmetrical mode of failure at the pillar-roof contact in two underground stone mines, which is different from the typical failure mode observed in response to excessive levels of horizontal stress. A dip of greater than 5° was identified as a possible cause of this mode of failure. Numerical model experiments showed that an increase in the dip of the workings can cause an increase in the stress at the up-dip corner of the roof beam. A case study is presented in which failure at the pillar-roof contact was observed where the dip of the workings was 7° in a high horizontal stress field. Numerical modeling showed that the relatively small dip of the workings could have induced stresses changes in the immediate roof that would explain the failures. The model results also showed that this mode of failure is less likely to occur if the limestone pillars contain weak bedding planes that provide stress relief. In addition, the results showed that for the conditions at the case study site, the stress in the roof beam was not sensitive to the thickness of the roof beam or to the excavation span. The high horizontal stresses at this site are an important contributing factor to the observed failures.

By Stephen C. Tadolini, Steve Bessinger, James Pile, Christopher Mark

The San Juan Coal Mine, located near Farmington, New Mexico, supplies the San Juan Generating Station with more than 6 million tons of coal annually. To replace dwindling surface mine production, San Juan installed a longwall in 2002. The roof rock in much of the underground reserve consists of interbedded coals, carbonaceous shales, and mudstones. Roof support consists of fully-grouted roof bolts, both tensioned and non-tensioned, supplemented by modified cable trusses. Short-encapsulation pull tests conducted by San Juan’s geotechnical engineering department showed that some of the immediate roof layers provided variable bolt anchorage. To ensure that the roof bolts were obtaining the necessary anchorage, additional tests were conducted in a variety of locations. The results have been used to determine the optimum support design for different areas of the mine. Another series of tests evaluated the performance of several bolt and hole diameter combinations. The experience at San Juan Mine shows that short-encapsulation pull tests can provide the information necessary to improve ground control in variable roof conditions. It also illustrates how a pro-active geotechnical engineering program can be an essential component of a state of the art underground coal mine.

By J. Durkin

The Bureau of Mines has conducted field studies in coal mines throughout the United States to determine the effectiveness of electromagnetic techniques in locating miners trapped underground following a mine accident. Data from these tests have been used to generate models of expected signal and noise distributions as found above these mines. These distributions have aided in placing the expected performance of a through-the-earth electromagnetic communications technique into a probabilistic framework. Results show that at a 10% false-alarm rate, the expected probability o detecting a miner's signal" from a depth of 1000 ft is 54% at 500 ft it is 95%. These depths exceed the actual depths of 90 and 50%, respectively, of United States coal mines. Sensitivity studies have shown that at depth of 1000 ft, the probability of detection will improve approximately 2% for each dB of increase in signal-to-noise (SNR) ratio.

By Pete G. Kovalchik, Lynn A. Alcorn, Rudy J. Matetic, Adam K. Smith

Over-exposure to noise remains a widespread, serious health hazard in the U.S. mining industries despite 25 years of regulation. Most other categories of illnesses and injuries associated with mining have improved, with the exception of hearing loss. Mine Safety and Health Administration (MSHA) coal noise sample data collected from 2000 to 2002 show that 65% of the equipment whose operators exceeded 100% noise dosage is comprised of seven different types of machines. The continuous mining machine is first among all the equipment with 35% of the noise overexposures. The ational Institute for Occupational Safety and Health (NIOSH) is conducting research to reduce excessive exposure for operators of continuous mining machines and preventing additional cases of oise Induced Hearing Loss (NIHL) by developing low-cost retrofit noise controls for mining equipment. This paper describes a noise control for reducing the noise overexposures of continuous mining machine operators. Underground results show a 26.4% and 27.4% noise exposure reduction for the continuous mining machine operator. This research is providing the mining community with an additional noise control to be utilized on continuous mining machines, therefore reducing operator noise overexposure. Utilizing this newly developed noise control, along with previously proven controls for the continuous mining machine chain conveyor, will provide operators of these machines an opportunity to be within the MS HA-Permissible Exposure Limit (MSHA-PEL).

By W. R. Reed, J. A. Organiscak

Surface mining operations use large off-road haul trucks extensively to move material at mining properties. Past research, using the United States Environmental Protection Agency’s (EPA) emissions factors for unpaved haul roads, has shown that haul trucks generate the majority of dust emissions from surface mining sites, accounting for approximately 78%-97% of total dust emissions. Observations of dust emissions from haul trucks show that if the dust emissions are uncontrolled, they can be a safety hazard by impairing the operator’s visibility. This increases the probability for haul truck accidents (See photos above). However, the greatest long-term health hazard of dust generated from hauling operations is due to inhalation of the respirable dust [median diameter <4 micrometers (µm)] and tho­racic dust, which is equivalent to the EPA’s definition of PM10 [particulate matter with a median diameter <10 µm]. Exposure to respirable dust has long been considered a health hazard at surface mining operations, especially if silica dust is present. There are two legislative acts that regulate the air quality for mining operations: the Federal Coal Mine Health and Safety Act of 1969 and the Clean Air Act of 1970. The Federal Coal Mine Health and Safety Act of 1969 established the limits for dust in the work place for health and safety pur­poses. The Clean Air Act of 1970 regulates air emissions from facilities from an envi­ronmental perspective.

By J. Walden, S. Rhoades, R. E. Miller, R. Gibbs, P. Boman

Accelerometers and pressure transducers mounted in suspension components can be used to monitor the ride of haulage trucks. Presently, it is difficult to tell what caused a jolt to the truck using either pressure or acceleration data alone. When information horn a Global Positioning System is recorded at the same time as shock pressures or acceleration data, then the exact location of an event can be determined. Mine management can then determine what caused the jolt to the truck.

By Launa Mallett, Charles Vaught, Jr. Brnich

This paper introduces a technique for incorporating employee participation into the prevention component of a contingency plan. Companies sometimes focus so much energy on response that they forget to put resources into the basics of emergency prevention. The training program discussed here was designed to make employees part of the prevention system. Examples of training materials from the program are provided, a sample method for introducing risk assessment to employees is shown, and a strategy to address limited training time using short videos is explained. Methods for tailoring the training to any worksite and for specific risks are also included. The program is being designed and tested by the Pittsburgh Research Laboratory/NIOSH and employees of an underground coal mine. Examples are taken from the implementation of the program at the mine during the summer and fall of 1998. Results of the program evaluation and lessons learned during the implementation are discussed.

By James C. Ault, Walter W. Kaufman

This Bureau of Mines manual for design of surface mine haulage roads covers such aspects of haulage road design as road alignment (both vertical and horizontal), construction materials, cross slope, and drainage provisions. Traffic control and design of proper lane widths to promote safe vehicle movement are included, as are suggested criteria for road and vehicle maintenance and for runaway vehicle safety provisions. The aim of this publication is to provide those involved with surface mine haulage road design with a complete manual of recommended practices that, if implemented, will promote safer, more efficient haulage routes.

The Ringelmann Smoke Chart fulfills an important need in smoke abatement work and in certain problems in the combustion of fuels. A knowledge of its history and method of preparation is, therefore, of interest to many. Since instructions on its use are not shown on the recent edition of the chart, those included in this revision of the previous Bureau of Mines publication now are a necessary complement to the chart. More detail regarding the use of the chart is included than was given in the earlier version.