The South African mining industry has endeavoured through meandering pathways in its safety journey towards Zero Harm. Everyone in mining recognises the importance of constant focus, continuous learning and innovation with respect to inculcating a culture of safety in all activities on mining operations. Safety learning and sharing of lessons are imperative for the sector to grow and avoid repeat incidents, writes Dushendra Naidoo – head of Safety and Sustainable Development at the Minerals Council South Africa.
Figure 1: Fatality trends (2003-2023) Supplied by Minerals Council South Africa
The ever-evolving landscape of mining necessitates a proactive approach to ensuring the well-being of workers and the sustainability of operations. This piece aims to highlight the latest statistics, emerging trends, threats and opportunities within the sector, alongside the strategies and insights from the Minerals Council South Africa on how suppliers can contribute to enhancing safety. Safety is not just a requirement for the mining industry, it is our commitment to every miner’s future and ensuring that every person working at a mine returns home safely – this is the “heart” of our Khumbul´ekhaya strategy.
Current safety statistics
There has been an average downward trend in the number of lives that were lost in the mining industry since 2003. There were 270 fatalities in 2003 and by the end of 2023, 55 deaths were reported, an 80% reduction.
Platinum and gold sectors are the highest contributors to fatalities with 22 and 20 fatalities in 2023 respectively. In 2023, 7 people died in the coal sector compared to 90 in 1993 and 31 in the year 2000. The sharp contrasts in incidents between the hard-rock sector and the coal sector could be attributed to the fact that gold and platinum mining involve more complex mining methodologies, are deeper level mines and involve more intensive usage of explosives.
The overall downward trend in fatalities is indicative of the strides that mining companies have made over the years to improve safety performance, however much is still to be done on a granular level across the individual operations to prevent incidents. It is encouraging to witness and experience the collaboration and sharing between mining companies with respect to safety incidents through the Minerals Council’s safety committees and forums. Safety intervention effectiveness can only be measured with time and data assimilation which can prove fruitful for understanding where the areas of improvement exist upon which the necessary implementation changes can be expeditiously executed.
The fall of ground and transport and machinery agencies contribute significantly to the fatal incidents in the industry. Fall of ground related fatalities accounted for 131 in 2003 and the number steadily declined to 25 in 2012. There was a notable drop in fall of ground fatalities in 2022 with 6 fatal incidents compared to 20 in 2021. Transportation and mining have also experienced a reduction in fatalities over the years and this can be partially attributed to efforts towards traffic management improvements and other interventions by the industry. The specific Trackless Mobile Machinery (TMM) regulations that were promulgated in December 2022 also assisted the industry in accelerating the operational and technological readiness of their TMMs, however, there are understandably many technical complexities and challenges that require resolution on a case-by-case basis.
The Minerals Council and its members have implemented a Fall of Ground Action Plan (FOGAP), which, along with previous measures, has significantly reduced fatalities from one of the historically major causes of underground deaths. This initiative is in progress and has already produced great learning outcomes for industry adoption. Additionally, the Minerals Council and members are tackling the risks associated with trackless mobile machinery, another primary source of fatalities and injuries through the dissemination of the first comprehensive Collision Prevention System (CPS) guidance documentation as leading information for the industry both nationally and internationally. This was in progress prior to the TMM 2015 regulatory upliftment, and the new CAS regulations promulgated in December 2022,1 and encompasses work from all stakeholders including EMESRT (Earth-Moving Equipment Safety Round Table), original equipment/technology providers, University of Pretoria, mining companies, educational institutions and others.
The Minerals Council South Africa’s Modernisation and Safety Team is busy with a detailed analysis of these trends given that this year is a 10-year milestone year for the South African Mining Industry’s safety performance. The analysis entails a detailed assessment of the fatalities and injuries in the industry and further insights into the outcomes shall be shared at a later stage. The ultimate objective is to develop a portfolio for the industry as a look-ahead for the next ten years and the core pillars of the Khumbul´ekhaya strategy that would evolve to a second version of our strategy for adoption by the mining industry. The trends and lagging indicators are important for us to understand where we are as an industry. We are doing extensive work on safety leading indicators as we believe that further proactive learnings can be derived from analysing high potential incidents and injuries for the development of recommended transitional implementation of improved controls, processes and technological interventions where applicable.
Emerging trends/innovations
Overall, emerging trends and innovations in mining safety focus on utilising technology including artificial intelligence (AI), implementing advanced training programs, and adopting sustainable practices to enhance worker safety, protect the environment, and promote sustainable development in the mining industry. These advancements aim to minimise hazards, improve safety protocols, and create a safer and more sustainable mining environment. The Minerals Council MOSH (Mining Occupational Safety and Health) Team have developed industry risk bowties as per the ICMM (International Council of Mining and Metals) critical control management approach. The effective management of barriers/controls for risk management is a fundamental measure to proactively protect people from an operational standpoint. Figure 2 below encompasses and summarises some of these trends, however with the Fourth Industrial Revolution upon us, there is much room for the inclusion of other innovations.
I imagine a futuristic South African mining operation having a fully-fledged workforce (i.e. no workforce reduction – should include redeployment and upskilling due to technology implementation), trained to operate machinery from a remote centre, where control failures in risk areas are continuously monitored, flagged and corrected (possibly via an artificial intelligence module that practically governs agency bowties “live”). Machine data, people movements and fall of ground risk are rigorously tracked and predictive capabilities are so accurate that timeous design changes can be instituted at a fast pace such that the risk probability to personnel is minimal. Such a mine would also have the potential for optimised mineral production with Zero Harm realised through a people-centric, technological and sustainability make-up that leaves no room for error and resultant lost lives. Many mines are heading in this direction and do possess some (percentage portion) of the elements mentioned. In time, this outlook can become a strong reality for our mining sector that has high potential given our critical mineral wealth and our inherent South African tenacity.
Figure 2: Technology trends in mining. Supplied by Minerals Council South Africa
Threats and Challenges
Some of the threats and challenges in the industry include the following:
Deep-level mining:
As shallow mineral deposits are depleted, mining operations are extending to greater depths, where the risk of rockfalls, seismic activity and high temperatures increases. Ensuring safety in these conditions requires advanced engineering solutions and robust monitoring systems. The implementation of technology is never a “silver-bullet” solution and requires a system engineering approach.
Aging infrastructure:
Older mines often suffer from outdated infrastructure, which can compromise safety. Regular maintenance, upgrades and the adoption of modern technologies are essential to mitigate these risks.
Regulatory compliance:
Ensuring compliance with stringent safety regulations can be challenging, especially for smaller mining operations. Continuous engagement with regulatory bodies and investment in compliance technologies are necessary to navigate this complex landscape.
Opportunities for improvement
The “Art of the Possible” through collaboration and partnerships between mining companies, technology providers, local communities and regulatory bodies can drive innovation in safety solutions. Partnerships with tech-companies can facilitate the integration of cutting-edge safety technologies.
Engaging local communities in safety initiatives can promote a culture of safety and responsibility. The technical, social and behavioural aspects that are embedded in the foundation of a strong safety culture is key to enabling and instilling the care and team-spirit that is required to sustain safe operations. These factors coupled with investing in research and development can lead to the advancement of new safety technologies and methodologies as research institutions and universities can play a pivotal role in advancing mining safety.
The Mindshift Conference hosted this year by MEMSA (Mining Equipment Manufacturers of South Africa) highlighted the importance of stakeholder collaboration within the South African Mining Industry. The Minerals Council through the special project on “Industry Alignment on TMM Regulations” had succeeded in hosting workshops to drive the localisation of technology. These workshops involved bringing together supplier competitors, mining companies, governmental bodies and others into the “same room” to co-create solutions towards potentially manufacturing components within South Africa. Key outcomes from the workshop were that competitors can collaborate within the boundaries of competition law; advanced engineering design skills do exist in our country together with other core competencies and advanced manufacturing capabilities are also available. The main message is that collaboration between all stakeholders is a fundamental requirement to share knowledge and resources that ultimately lead to safer working environments and more sustainable practices.
Conclusion
As we gear up for Electra Mining Africa 2024, the focus on safety remains unwavering. By leveraging technological advancements, enhancing training programs and stimulating collaboration, the mining industry in South Africa can continue to improve its safety record. The Minerals Council South Africa’s proactive strategies and the active involvement of suppliers will be instrumental in driving this positive change. The supplier community have an abundance of technical know-how due to the composition of their vast engineering competence and knowledge. Engineers are the reason for this rich knowledge base as they innovate, test, design, work in multi-disciplinary teams and spend long hours introspecting on the design details to solve problems. We need to tap into this supplier body of knowledge and strategise on how to use this innovational thinking to find solutions and opportunities for accelerating the Zero-Harm journey. Ensuring the safety of our miners is not just a regulatory requirement but a moral imperative that defines the future of mining in South Africa.
Reference:
The 2015 regulations governing trackless machines were uplifted, and the Mine Health and Safety Act Trackless Mobile Machinery Regulations for collision avoidance systems promulgated.
| Introducing Dushendra Naidoo:
Dushendra Naidoo holds both a bachelor’s and master’s degree in mechanical engineering from the University of Natal and is a certified Professional Engineer with ECSA. Recently, he obtained a postgraduate diploma in management development from GIBS. He has acquired certificates in project management, financial management, value engineering and behavioural based safety. Naidoo spent some time in Germany where he acquired specialised knowledge from experts on miscellaneous plant equipment. Naidoo’s career began at the CSIR’s Mining Technology Division as a research engineer where he was involved in a variety of research projects including underground mine support design, Mine Health and Safety Council projects and technology driven initiatives for over five years. He obtained a merit award for successful project outcomes for a mining project at the CSIR. This was followed by five years in the manufacturing arena at Joy Mining Machinery as a senior mechanical engineer where he led aspects of a special project that involved developing a hard rock continuous cutting machine and obtained a design patent for the rock-breaking system. At Thyssenkrupp Industrial Solutions he was a lead engineer for multi-million-rand projects for over five years including the design and construction of the first vertical lime kiln in Zambia. He also managed proposals for a brief period in the petrochemical department. Thereafter he joined Fermel as a design office engineering compliance manager where he was responsible for mine vehicle certifications, design compliance and quality assured outputs from a design team. His passion for training young engineers and design led to him winning the first phase of the Isidingo Drill Challenge that was an initiative hosted by the Mandela Mining Precinct. He spent some time at Bosch Projects in the Sugar and Industrial Department as part of a leadership team and was involved in major projects including the design of one of the largest rotary cascade sugar dryers in the world for a client in Thailand. His technical know-how also led to him having a brief involvement in a major expansion project at Tronox Minerals Sands. He was the principal adoption specialist for the Minerals Council’s MOSH Transport and Machinery Team for over two years where he was able to express his passion for engineering, safety, and the mining industry through the many safety initiatives that he is responsible for. He was promoted to the head of Safety and Sustainable Development at the Minerals Council South Africa. |
 Dushendra Naidoo, head |