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By G. T. Lineberry, W. J. Wiehagen

A Paradigm Shift As market economists, mine managers are interested in "staying in business" and even "prospering." Bottom-line results are the "order of the day." Concern for bottom-line results invokes questions such as: How much was produced? At what cost? And, was anyone injured? While these questions will always carry everyday emphasis at the mine, they are fundamentally lacking in that they often appear, especially to lower levels of management and to the production worker, as preeminent concerns. Driven by market economics, many organizations have decentralized, outsourced, downsized, restructured, and formed new coalitions. Investments in new technology and concentration on productivity have been part and parcel with these changes, contributing to improvements in both safety and efficiency. A reason for (and, perhaps a result of) these improvements has been the development of a highly experienced and flexible work force. These changes in mining present an interesting opportunity to modify a few paradigms about work life in general, and perhaps a few paradigms about how we invest in the miner, in particular. Studying these issues now might offer some interesting opportunities for the future, as the foundations for the next generation of mine workers are laid. With the average "experienced" U.S. miner five to fifteen years from retirement, perhaps a key determinant of future success in the world market might be how well we make the transition from today's work force to the work force of tomorrow. We can ill afford to wait a few more years to tap into the special knowledge residing within a veteran mining work force. The WCPM work Crew Performance Model, see pp. ) is one approach to defining, capturing, and transferring this expertise.

By R. Pakalnis, C. A. Dreesbach, L. A. Martin

Instrumented cable bolts developed at the Spokane Research Laboratory of the National Institute for Occupational Safety and Health were used in conjunction with existing ground control systems to monitor rock mass loads at Tg Soda Ash’s trona mine, Granger, WY. Axial and shear loads were determined to levels of strain gauge accuracy of ±5 N or ±5 microstrain. These gauges were embedded in a remanufactured king wire that replaced the conventional king wire. Cable bolt performance, quality of grout, and installation techniques were also assessed. By using instrumented cables, a mine operator can determine axial load along the cable at predefined gauge locations. These data provide necessary input for an operator to design a safer working environment for miners.

By Frederick C. Trutt, Jeffery L. Kohler, Joseph Sottile

Twenty-five years ago, the former U.S. Bureau of Mines funded a research project aimed at developing the enabling technology for incipient failure prediction in electric power system components as a means of reducing the injuries and fatalities that sometimes occur when equipment malfunctions. Over the ensuing years, interest in this has waxed and waned, but recently interest has been growing for both civilian and military applications. This paper addresses the level of turn-to-turn insulation deterioration that can be resolved using an on-line monitoring technique. The detection of turn-to-turn defects is especially important because they are believed to represent the beginning stage of most motor winding failures.

By C. Sunderman, J. Johnson, S. Signer

Researchers at the National Institute for Occupational Safety and Health have developed a miniature data acquisition system (MIDAS) that can measure resistance changes and temperature, store data for later retrieval, and illuminate LED lights. This instrument can be used with strain-gaged bolts, cable bolts, CSIRO stress-measuring gages, string pots, and any other instrument that uses single-ended, resistance-type gages. MIDAS has the capability to measure up to 16 gages at preset time intervals and store more than 2000 scans, yet is small enough to fit in a 35-mm hole. Because the MIDAS consumes little power, a 9-V alkaline battery will operate the system for 6 months. Data from the MIDAS can be sent to a PC via an RS232/RS485/IRdA port. A software program was written to set operation parameters, graph data, and store all information directly to a spreadsheet. Three LED lights change from green to yellow then red based on reading levels and/or rates of change. This feature can be used with different types of gages to warn miners of possible rock instabilities. The MIDAS has received MSHA experimental permissibility approval and is currently being tested at several mines.

By Dennis R. Dolinar

Screen material in the form of welded wire mesh and geogrids are used in underground coal mines to prevent the fall of small pieces of rock from the roof between roof bolts. Further, if the screen is installed during the production cycle, roof fall injuries can be reduced significantly. Therefore, the National Institute for Occupational Safety and Health (NIOSH), because of the safety implications, conducted an evaluation of screen materials commonly used in U.S. coal mines to determine their support characteristics and identify the parameters that could affect their performance with respect to controlling the fall of rock from the roof surface. To evaluate the load and stiffness characteristics of the screen, a test frame was designed and installed in the Mine Roof Simulator (MRS) at the NIOSH Pittsburgh Research Laboratory (PRL). With this test set up, the screen is bolted at four corners of the frame and a center load is applied. The test set up allows for up to 20 in of screen deflection while the load and screen defection are continuously recorded. A series of tests were conducted to evaluate the effects of various parameters such as bolt tension, the type of load bearing surface and the size of bearing plates on welded screen performance. The most common screen material used in U. S. coal mines is an 8-gauge wire welded in a 4-by-4-in spacing or aperture. The peak screen load was normally limited by wire breakage. The conditions at the bearing plate influence the nature of the wire breakage. However, the screen stiffness was controlled by slippage at the bearing plates, and by weld and wire failure. The size of the bearing plate had a significant effect on the performance of the welded screen. Therefore, the design capacity of the 8-gauge screen is evaluated based on plate size. For a 6-by-6-in bearing plate the average peak load is 2,900 lb with a stiffness of 250 lb/in. For an 8-by-8-in bearing plate, the average peak load is 4,500 lb with a stiffness of 430 lb/in. These test results are based on a 4-by-4-ft bolt spacing. A geogrid mesh was also tested.

By R. A. Franks, G. F. Friel, J. C. Edwards, A. C. Smith

An evaluation of a nuisance-emissions-discriminating smart mine fire sensor system was made in an operating coal mine. These field evaluations were conducted to determine the sensor system's ability to discern nuisance emissions, such as diesel exhaust, emissions from flame cutting and welding operations or hydrogen gas from a charging station, from real fires and to compare the number of falsely reported fire alarms generated between the sensor system and a standard carbon monoxide (CO) monitor. The sensor system's ability to operate successfully in the working environment of an operating coal mine was also evaluated. The smart mine fire sensor system consisted of four sensors whose data outputs were fused with the use of a neural-network-type computer program. Long-term trials were conducted in a haulage way, a belt entry, and a track entry. The system functioned successfully in the belt entry, in accordance with its developmental goals, where the sensor system even discriminated events not anticipated during development. It was not totally effective in the haulage way and track entry, though, due to a combination of significant diurnal air temperature variations, dust, and mechanically induced vibrations. Also, deteriorating rib conditions contributed to operational problems in the haulage way evaluation. In general, the smart mine fire sensor provided nuisance emissions discrimination and was shown to be a viable new approach for mine atmospheric monitoring, enhancing miner safety. This paper describes the in-mine evaluation of the smart mine fire sensor system and discusses recommendations for improving the system.

By R. Larry Grayson, Douglas F. Scott

Data on health-related illnesses and disease in the mining industry are scarce, and information on rates and costs is not readily available. Substantial amounts of research are being directed to addressing these issues, including work at the National Institute for Occupational Safety and Health’s (NIOSH) mining health and safety laboratories in Spokane and Pitts-burgh. This paper briefly discusses the current status of some miner health-related issues, including those involving coal dust, silica dust, diesel particulate matter, asbestos, noise, lead, welding fumes, and skin disorders, as well as research and other activities aimed at protecting miners from occupational illnesses and disease.

By Launa G. Mallett, Kathleen M. Kowalski, Michael J. Brnich

The characteristics of leaders under the duress of an emergency are important in the development of emergency planning, training, and in the management of an actual emergency. Knowledge of human behavior is an important component in the formation of emergency strategies. The U.S. Bureau of Mines analyzed the leadership behavior in three underground mine fire escapes. The subjects described their escapes during open-ended interviews. Data were coded according to: (1) evidence of leadership behavior, (2) evidence of lack of leadership behavior, and (3) characteristics of the individual in each group who led the subjects out of the mines. This paper discusses the profile of six individual leadership characteristics which emerged from the data.

By A. T. Iannacchione

Underground limestone mines typically use the room-and-pillar method of mining in the generally flat-lying limestone formations. In some cases the dip may exceed 5° which can result in unique roof instability problems. Stability may be further exacerbated by the presence of horizontal tectonic stresses. Field studies and numerical model analyses are combined to assess the affect of the dip in various stress conditions. The results showed that where the horizontal tectonic stresses are sufficient to cause intact rock failure, increasing dip results in increased failure potential. The effect of the dip is greater when the maximum horizontal stress is parallel to the dip. Two case studies are presented and evaluated against the findings of stress analysis results. The study showed that the empirical rules of orienting headings parallel to the maximum stress are generally applicable to dipping excavations, except when mining in the up-dip direction. The importance of accurately determining the orientation of the maximum horizontal stress is emphasized because the window of favorable orientations relative to the stress is small.

By John N. Murphy

In fiscal 1996, the US Congress directed that the US Bureau of Mines (USBM) be closed. Certain functions were reassigned to other agencies. The remaining employees were separated and the unoccupied sites were decommissioned. As a result, 12 locations were closed and about 1,200 employees were terminated in March 1996. About 600 employees at five locations were reassigned to other federal agencies. This article provides a summary of the continuing functions, the agencies involved and the points of contact for each continuing function. The functions that were discontinued are also identified.

By Richard J. Mainiero, Michael J. Sapko, Marcia L. Harris

Since 1988, there have been 17 documented incidents in the United States and Canada in which carbon monoxide (CO) is suspected to have migrated through ground strata into occupied enclosed spaces as a result of proximate trench blasting or surface mine blasting. These incidents resulted in 39 suspected or medically verified carbon monoxide poisonings and one fatality. To better understand the factors contributing to this hazard, the National Institute for Occupational Safety and Health (NIOSH) carried out studies in a 12-foot diameter sphere to identify key factors that may enhance the levels of CO associated with the detonation of several commercial trenching explosives. The gaseous detonation products from emulsions, a watergel, and ANFO blasting agents as well as gelatin dynamite, TNT, and Pentolite boosters were measured in an argon atmosphere and compared with those for the same explosives detonated in air. Test variables included explosive formulation, wrapper, aluminum addition, oxygen balance, and density. Major contributing factors to CO production, under these laboratory test conditions, are presented. The main finding is the high CO production associated with the lack of afterburning in an oxygen poor atmosphere. Fumes measurements are compared with the manufacturer’s reported IME fume class and with the Federal Relative Toxicity Standard 30 CFR Part 15 in order to gain an understanding of the relative toxicity of some explosives used in trench blasting.

By Theresa Y. Schulz

It is interesting to study the noise standards that have been promulgated in the US over the last decade or so. These regulations are likely to have long-lasting impact. The Occupational Safety and Health Administration (OSHA) Hearing Conservation Amendment (March 1983) continues to have influence not only in the workplace but in the debate over new regulations. Both the Mine Safety and Health Administration (MSHA) and Federal Railroad Administration (FRA) regulatory preamble documents state the desire to be consistent with OSHA. An examination of Table 1, which compares the major components of the three regulations and the 1998 NIOSH “best practices” criteria, depicts the extent to which that intent is met. There has been some regulatory activity in the last decade which may give some hope for evolution and updating based on the wealth of science that has occurred during the last quarter of a century since the OSHA regulation was enacted. However there has also been some “back-sliding” toward more lenient standards. The MSHA noise standard made regulatory progress in September 2000 by emphasizing engineering and administrative controls, followed by personal protective equipment, in the hierarchy of noise intervention. MSHA’s requirement for technician certification (today only available from CAOHC) strengthened the training requirements for audiometric testing in hearing conservation programs and MSHA also added the requirement of dual hearing protection at 105 dB TWA. There were many subtle differences between OSHA and MSHA based on comments and a desire to clarify some of the vague aspects of the OSHA noise standard, and meet the needs of the regulated mining industry. One example pertains to the ceiling for exposures. OSHA says, “no exposures >115 dBA,” which is interpreted to mean no unprotected exposures above that level, giving credit for the assumed effectiveness of hearing conservation programs, hearing protection devices and administrative and engineering controls. MSHA specified that a “P” code1 violation be issued for any protected or unprotected exposures >115 dBA. The Federal Railroad Administration (FRA) noise standard for railroad operating employees, which went The Modern Evolution of Hearing Conservation Regulationsinto effect February 26, 2007, was expressly based on the OSHA standard but also uses MSHA for comparison. The preamble states that the FRA defers to OSHA as the “primary regulator of noise in the workplace,” but also acknowledges the need for some departure from the OSHA regulation (FRA Preamble II.B). As an example, FRA requires testing at 8000 Hz “because it will allow employers to identify hearing loss sooner.” The FRA rejected MSHA’s hierarchy of noise controls in favor of requiring specific engineering interventions and focusing on appropriate hearing protection which would still allow communication and audibility, and identification of excessive noise through employee-filed “excessive noise reports.”2 Where OSHA has no specific mandate requiring employees to take advantage of the employer-paid audiogram, it has been traditionally a condition of employment and is generally accepted that OSHA-covered workers require an annual audiogram. MSHA addressed this issue in its preamble; however, they made no significant change. MSHA employers are required to offer annual audiograms but MSHA stopped short of requiring employees to comply with annual audiometric testing. The MSHA preamble does allow that mine operators can also make audiometric monitoring a condition of employment. FRA requires employees to

By Mark Larson, Steve Iverson, Brian G. White

The authors hypothesize that excavation-induced extension fractures are caused by elastic shearing displacement that in turn causes tension oblique to a propagating shear zone. Such extension is manifested as tension on scales larger than that of microcracks. En echelon fracture patterns are a common result. FLAC modeling confirmed that localized tension is created near the corners of mine openings. In the model, tension was concentrated at the leading edge of a simulated fracture in a pattern that could promote the formation of an en echelon fracture. Particle Flow Code models confirm progressive formation of en echelon tensile failures with distance from an opening. The elastic displacements and the resulting fractures facilitate reduction in applied load at the expense of shear deformation and lateral dilation. Understanding the mechanics of fracture and deformation is vital for designing more effective ground support practices, a major objective of ground control research being conducted at the Spokane Research Laboratory of the National Institute for Occupational Safety and Health.

By R. Karl Zipf, David Newman

The objective of this is paper is to review the current state of knowledge and practice in highwall mining (HWM). HWM has become a widely-applied method in surface mining, commonly used alone or in conjunction with contour or slot mining. It provides 800-feet to 1,200-feet of additional recovery when the economic stripping ratio is reached in contour mining or in slot mining when surface access to a reserve is limited. A significant attribute of the highwall miner is its versatility. HWM has been used successfully to mine abandoned pre-reclamation law highwalls, points or ridges uneconomic to mine by underground or other surface methods, outcrop barriers left adjacent to underground mines, separate benches of the same seam where the parting thickness or quality differences between benches render complete extraction uneconomic, previously augered areas containing otherwise inaccessible additional reserves and close or widely spaced multiple seams. The theory and design methods to assess roof, pillar, and floor stability are presented followed by three case histories. Simple design charts for sizing HWM web and barrier pillars are also presented. A recommended web pillar width may be obtained from the design charts given the overburden depth, the HWM cut width, and the mining height. Given the depth and panel width for a set of HWM cuts, another set of charts gives a suggested barrier pillar width. The case histories, from Northern and Southern Appalachia are used to illustrate the application of rock mechanics to quantify the stability of the highwall, roof, web pillars, and floor. The case histories involve 1) mining through a previously augered highwall, 2) mining under back-stacked spoil and 3) selective mining of closely spaced benches of the same seam. Because each site is unique, the appropriate pre-mining geotechnical analyses range from the calculation of roof, web pillar, and floor bearing capacity stability factors to detailed numerical modeling of the auger and underground mine workings. When operating in the vicinity of existing underground mine or auger workings, the determination of ground deformation and strains resulting from highwall mining is a necessary facet of a ground control investigation.

By M. K. Larson, J. K. Whyatt, R. B. Langston, J. C. Johnson, H. Kirsten, T. M. Brady

An experiment is described in which hollow inclusion cells (HICells) were used to measure stress in a jointed rock mass during drift development at the Stillwater Mine, Nye, MT, USA. Two HICells were installed in the footwall approximately two drift widths ahead of the face. One HICell was over cored and then immediately tested in a biaxial chamber. The other HICell was left in place and monitored as the drift was excavated in three advances, each one-half the width of the drift. Strains were recorded hourly by a datalogger. Results show that there was little stress change during the first and second drift advances, but that a large stress change occurred after the third advance. The measurements also showed that the in situ principal stress directions lined up with regional geologic structures. Stress changes during face advance were likely caused by deformation along localized joint sets and inelastic deformation near the face.

By D. K. Ingram, G. L. Mowrey, T. R. Rehak

Problem: Blasting is a hazardous component of surface mining. Serious injuries and fatalities result from improper judgement or practice during rock blasting. This paper describes several fatal injury case studies, analyzes causative factors, and emphasizes preventive measures. Method: This study examines publications by MSHA, USGS, and other authors. The primary source of information was MSHA’s injury-related publications. Results: During the 21-yearperiod from 1978 to 1998, the mean yearly explosive-related injuries (fatal and nonfatal) for surface coal mines was 8.86 (95% CI: 6.38 -11.33), and for surface metal/nonmetal mines 10.76(95% CI: 8.39 - 13.14). Flyrock and lack of blast area security accounted for 68.2% of these injuries. This paper reviews several case studies of fatal injuries. Case studies indicate that the causative factors for fatal injuries are primarily personal and task-related and to some extent environmental. A reduction in the annual injuries in surface coal mines was observed during the ten-year period of 1989 - 1998 [5.80 (95% CI: 2.71 - 8.89) compared to the previous ten-year period of 1979 - 1988 [10.90 (95% CI: 7.77 - 14.14)]. However, such reduction was not noticed in the metal/nonmetal sector, i.e., 9.30 (95% CI: 6.84 - 11.76) for the period 1989-1998compared with 11.00 (95% CI: 7.11 - 14.89) for the period 1979-1988. Discussion: A multifaceted injury prevention approach consisting of behavioral/educational, administrative/regulatory, and engineering interventions merits consideration. Impact on industry: The mining community, especially the blasters, will find useful information on causative factors and preventive measures to mitigate injuries due to flyrock and lack of blast area security in surface blasting. Discussion of case studies during safety meetings will help to mitigate fatal injuries and derive important payoffs in terms of lower risks and costs of injuries.

By Steven J. Knoll, Theodore J. Williams, Douglas F. Scott

Highly stressed rock in stopes continues to be a primary safety risk for miners in underground mines because it can result in failures of ground that lead to both injuries and death. Spokane Research Laboratory personnel investigated electromagnetic (EM) emissions in a deep underground mine in an effort to determine if these emissions could be used as indicators of impending catastrophic ground failure. Results suggest that (1) there is no increase in the number of EM emissions prior to recorded seismic activity, (2) some EM signals are generated during blasting, (3) interference from mine electrical sources mask seismic-generated EM signals, (4) EM emissions do not give enough warning (compared to seismic monitoring) to permit miners to leave a stope, (5) the distance an EM signal can travel in the rock is between 18 and 40 m, and (6) current data acquisition systems do not differentiate between EM signals generated from seismic activity and random mine electrical noise. These results preclude monitoring EM emissions as precursors of impending catastrophic ground failure.

By Elaine T. Cullen

Miners, like many skilled blue-collar workers, are not traditional learners. They have not generally been successful in classroom-type settings, preferring to learn on the job in a hands-on environment. U.S. miners are required to have annual safety training, but they rarely view this positively. In fact, it has been called “safety jail” by many of them, who regard it as a time to get a little extra sleep. The challenge then, was to find a way to develop effective safety training for these people, particularly in view of the fact that their work is among the most dangerous of all occupations. Miners are born story tellers. They share “near-miss” stories, stories about master miners they have known, and stories about how things used to be. These stories not only pass along information about what will happen if a miner fails to respect the mining environ-ment, they also instruct listeners in the culture of mining and the values it embraces. Stories, it seems, are a way to get safety messages to miners, especially inexperienced ones, and using older, wiser miners in these stories is an obvious choice. This paper will discuss how the training videos created to get safety messages to miners were developed, how “master miners” and story lines were chosen, and how the resulting videos have been received in the mining industry.

By Edward A. Barrett, Roberta A. Calhoun

MORE THAN 30 MILLION EMPLOYEES each year are exposed to hazardous occupational noise, and approximately one-third of them develop permanent hearing loss (NSC, 2000). Possible explanations for the latter statistic include worker regard for noise as a mere nuisance rather than as an occupational safety and health hazard, and consequent neglect of established protective measures (e.g., hearing protection); lack of knowledge concerning noise; improper use of hearing protection; worker indifference; and inadequate training (Bauer & Babich, 2004). Many drill rigs generate high sound levels, which vary according to the type of machine, its location with respect to the physical surroundings, and the location of the sound measured around the rig. A NIOSH study measured noise output from several types of drill rigs during field investigations (Ingram & Matetic, 2003). Two types of data were recorded the actual noise generated by the drill rig at various positions around the rig and the noise to which the drill operator was exposed during the drilling cycle. For the latter, sound level measurements up to 120 dBA were recorded while hammering casing (metal on metal) in drilling a water well (Photo 1). Several types of administrative controls exist to address worker exposure to loud drill rig noise. Rotating duties to decrease exposure time and posting warning signs in high-noise work areas are two such controls. Another is the use of hearing protection. Worker use of hearing protection has been disappointing, however. One study by the University of Michigan found that construction workers used earplugs and earmuffs only between 36% and 61% of the time that they were necessary (Lusk & Kerr, 1998). In a 2001 study, OSHA reported a relatively low rate of 30.4% for use of earplugs among construction workers (Walker, 2001). Why are rates for hearing protection use so low? One explanation may be workers' lack of concern for noise in the workplace. They expect workplace noise to be a loud and in¬ evitable nuisance and, therefore, accept it as part of the job. As a result, they disregard proven measures that can protect their hearing. Other workers may use hearing protection, but do so improperly. They may misguidedly remain in high-noise areas for extended periods thinking they are protected when in fact they are not. Other reasons for low use and/or misuse of hearing protection include poor education, lack of awareness and inadequate training (Nash, 2003). To address the training issue, NIOSH developed two exercises from which drillers can learn about noise, hearing loss and hearing protection. The first is an invisible ink exercise, titled "Drill Rig Incident" (DRI) (Photo 2); the second is a 3-D slide reel training aid, "Wearing Hearing Protection Properly" (WHPP) (Photo 3). DRI is an instructor-

By Kermit G. Davis, Sean Gallagher, William S. Marras, Kimberly Kovacs

This study evaluated spinal loads associated with lifting and hanging heavy mining cable in a variety of postures. This electrical cable can weigh up to 10 kg per metre and is often lifted in restricted spaces in underground coal mines. Seven male subjects performed eight cable lifting and hanging tasks, while trunk kinematic data and trunk muscle electromyograms (EMGs) were obtained. The eight tasks were combinations of four postures (standing, stooping kneeling on one knee, or kneeling on both knees) and two levels of cable load (0 N or 100 N load added to the existing cable weight). An EMG-assisted model was used to calculate forces and moments acting on the lumbar spine. A two-way split-plot ANOVA showed that increased load (p<0.05) and changes in lifting posture (p<0.05) independently affected trunk muscle recruitment and spinal loading. The increase in cable load resulted in higher EMG activity of all trunk muscles and increased axial and lateral bending moments on the spine (p < 0.05). Changes in posture caused more selective adjustments in muscle recruitment and affected the sagittal plane moment (p < 0.05). Despite the more selective nature of trunk EMG changes due to posture, the magnitude of changes in spinal loading was often quite dramatic. However, average compression values exceeded 3400 N for all cable lifting tasks.