Search Documents

To improve operational effectiveness of enclosed cab filtration systems. Background Enclosed operator cabs are widely used on mobile excavation equipment in the mining and construction industries. They protect the operator from bad weather, noise, and airborne dusts. The inside cab environment usually must be kept at very low dust concentrations because of quartz dust generated from the excavation of silica-bearing rock. Most cab designs achieve heating and air conditioning effectiveness by recirculating most of the interior cabin airflow, with a smaller portion of the outside air added to the cab as makeup air. Both the recirculated cab airflow and exterior makeup air added to the cabin should be efficiently filtered, with the makeup air positively pressurizing the cab interior. Ideally, operator cab air filters should provide at least 99% capture efficiency for dust particles as small as 0.3-pm aerodynamic diameters. These higher efficiency air filters provide good dust control for the equipment operator, but tend to accumulate dust more quickly than lower efficiency air filters.

Jan 1, 2001

To reduce equipment operator exposure to respirable dust in enclosed cabs by examining the effectiveness of retrofitting air pressurization and filtration systems on existing cabs.

Jan 1, 2001

Objective To reduce equipment operator exposure to respirable dust in enclosed cabs by examining the effectiveness of retrofitting air pressurization and filtration systems on existing cabs. Background Many types of heavy equipment are used in mining, construction, and agriculture. Most have enclosed cabs to protect the equipment operator from excessive dust and noise exposure. When the equipment is new, controls are normally implemented into the cab to keep these exposures at acceptable levels. However, as this equipment becomes older, many components of the enclosure deteriorate, such as gaskets and seals. This causes the effectiveness of the enclosed cab to be greatly reduced. Once this occurs, the equipment operator's dust exposure can increase to hazardous levels. In surface mining operations, elevated exposures to crystalline silica have caused an excessive incidence of silicosis. Approach A cooperative research study with a mining operation and a cab filtration company was conducted to evaluate the effectiveness of retrofitting an older surface drill with two controls to lower the drill operator's respirable dust exposure. These two controls were: (1) A good air filtering and pressurization system to ensure that clean air was delivered into the enclosed cab. Ideally, the incoming air filter should be 99% efficient in removing particles with an aero- dynamic diameter of 0.3 pm or greater from the airflow. (2) Sufficiently sealing the cab to develop a positive static pres- sure and ensure that dust was not leaking into the cab. This was done by plugging all holes and cracks and maintaining good gaskets and seals. To prevent wind from forcing contaminated air through holes in the cab, the cab's static pressure must be greater than the wind's velocity pressure. During the course of this research, it was found that a floor heater fan used in the drill during the winter months greatly increased the operator’s Respirable dust exposure. Problem Identification Four days of background dust levels were measured as a baseline for this research. These baseline measurements were taken in May 2000 when air temperatures ranged from 60° to 70° F. When this was completed, the two controls were implemented. The first control was to install an improved air filtering and pressurization system on the enclosed cab. This was composed of a two-stage prefilter, a blower, then the respirator-medium secondary filter. Since the secondary filter was on the positive side of the fan, all air delivered into the enclosed cab had to pass through this secondary filter. After the filtering system was installed, the cab was pressurized to a static pressure of0.01 inches of water (w.g.), which is still very minimal. The second control was to seal the cab. New door gaskets were installed, and all cracks and holes in the shell of the enclosure were plugged. This increased the cab pressurization to approximately 0.1 inches w.g.

Mar 1, 2001

Objective To reduce dust generated from soiled floors within enclosed operator cabs. Background Enclosed operator cabs are widely used on mobile excavation equipment in the mining and construction industries. They protect the operator from bad weather, noise, and airborne dusts. The inside cab environment usually must be kept at very low dust concentrations because of quartz dust generated from the excavation of silica-bearing rock. For cabs to be effective in controlling airborne respirable dust, they must have an efficient air filtration system, while providing a positive pressurization of the cab interior. Ideally, the recirculated and exterior makeup air filtration should provide at least 99% capture efficiency for dust particles as small as 0.3-µmaerodynamic diameters. Many of these enclosed cabs use heating units mounted or directed along the floor (see figure 1), which can cause dust entrainment problems. Prior studies by the National Institute for Occupational Safety and Health (NIOSH) of enclosed cabs have shown that these floor heaters can generate notable amounts of dust within the cab enclosure (see Technology News 486). Multiple-shift dust levels measured inside a drill cab increased on average from0.04 mg/m3 during the summer months to 0.68 mg/m3 during the winter months. Additional dust level measurements, made with optical particle counters during a nondrilling time period, verified that dust levels inside the cab increased from 0.03 to 0.26 mg/m3when the floor heater/fan was turned on. Dust levels within the cab also became greater than the ambient air dust levels outside of the cab when the floor heater was turned on during the nondrilling time period. This shows that the floor heater was a notable dust source problem. Cab floors are commonly soiled from operators tracking dirt inside the cab upon entering from the mine or construction site. Interior cab dust levels can be increased by (1) airflow disturbance of the soiled floor or (2) operator disturbance of the soiled floor. Approach During prior NIOSH surveys of surface coal mine drills, several drills with very low cab dust levels (#0.1 mg/m3) were observed to have floor sweeping compound spread out over the cab floor during the working shift. This initial observation led to a more controlled A-B study of the effect of the sweeping compound on the interior cab dust levels. This study involved dust sampling with and without sweeping compound inside the cabs of a bulldozer and two drills. Sweeping compounds commonly use sawdust or cellulose as the main bulk material, with oil or wax added for dust adhesion purposes. Sand is sometimes added to increase bulk density. Sweeping compounds with sand are commonly used to sweep up concrete floors. Those without sand (usually referred to as "gritless") are used to sweep up smooth finished floors. Most of the oils and waxes used for the adhesive ingredient are petroleum-base and can have an irritating odor. People sensitized to petroleum distillates could have allergic reactions to these sweeping compounds. A few companies offer non petroleum-base sweeping compounds, using either a natural oil or chemical additive for dust adhesion. During this study, it was decided that only the gritless sweeping compound (without sand) would be used, eliminating the addition of another potential silica source inside the cab. Since the sweeping compound would be applied on the enclosed cab floor for the duration of the shift, it was decided to use a canola oil-base sweeping compound to eliminate irritating odor from the petroleum-base sweeping compounds. The natural canola oil-base sweeping compound had a slight woody scent. The three pieces of equipment used in this study had notably different cab layouts. The bulldozer had a small cab with vents discharging air-conditioned or heated air from adjustable louvers at operator waist level and floor level. The bulldozer also had a cloth fabric seat and a carpeted floor. Drill A had a large cab with the heat directed from adjustable louvers at operator knee level and the air-conditioned air directed from cabin ceiling louvers. This drill had a vinyl fabric seat and a steel plate floor. Drill B had a small cabin with the heat directed across the floor (see figure 1) and the air-conditioned air directed down from the ceiling. It had a vinyl fabric seat and a worn rubber mat on a steel floor.

May 1, 2001

Background Carbon monoxide (CO) is an odorless, colorless gas that can cause illness and death by asphyxiation. Although the toxicity of CO is understood, CO exposure can occur from unrecognized sources. On April 2, 2000, a couple and their newborn infant were poisoned by CO migrating through the ground from blasting at a nearby coal strip mine into their home near Kittanning, Armstrong County, PA. They were treated at the hospital and diagnosed with CO poisoning. The infant had a carboxyhemoglobin level of 31%, the father 28%, and the mother 17%. Carboxyhemoglobin is the compound formed in the blood when CO is breathed. Persons not exposed to CO have carboxyhemoglobin levels of 0.3%-0.7%, and cigarette smokers have levels of up to 9%. Following release from the hospital, the family installed a CO detector in the basement of their home with the help of the local fire department. This Technology News briefly describes this incident to help increase awareness of the problem. It is discussed in more detail by Eltschlager et al. [2001]. Figure 1 shows the coal strip mine believed to have generated the CO. The initial suspect for the source of the CO was the furnace in the house. Only later did it become apparent that blasting at the nearby strip mine might be the culprit. A State investigation concluded that CO had migrated approximately 500ft from the blast, through the ground, and into the home. Figure 2 shows the locations and order of blasts at the mine. Initially, the mine did not plan to blast. Overburden generally consisted of weathered shale that could be dug without blasting. However, the mine decided to blast when hard sandstone that could not be dug out was encountered within 3 ft of the coal top. The blasting was intended to break up the sandstone. Blasting was done using bulk ammonium nitrate-fuel oil (ANFO) in 6.25-in holes 25-30 ft deep on a 16-ft by 16-ft pattern, with charge weights ranging from 17 to 170 lb. The closest blast to the home was 430 ft on April 17, 2000. The distance from the home to the blast area on the day when CO was first reported (March 31, 2000) was 500 ft. Twenty blasts were detonated at the mine between March 7, 2000, and April 20,2000. The blaster was careful to prevent fly rock since another home was only 150 ft away and a garage was 50 ft away. The quantity of explosive used in the blasts was sufficient to break the sandstone, but was less than would normally be used to blast overburden. The holes were typically one-third explosive and two-thirds stemming, with powder factors averaging 0.43 lb/yd3. Additionally, the muck was not immediately excavated after each blast. The heavy confinement on the explosive acted to prevent the typical release of blasting fumes into the atmosphere. Instances of CO migrating from blasts into homes have occurred before, but generally the distances involved were under 150 ft. It is believed that the blast design contributed to the confinement of CO in the ground, and discontinuities in the ground strata facilitated migration toward the residence. Upon inspection of the blast pitwall, a regular system of joints was observed. These joints are oriented roughly from the blast pit toward the house (figures 3-4).Blast-generated CO appears to have been driven into the joint system, displacing the air. When the joint system was saturated, the next succeeding blast pushed the CO into an uncased well next to the house (a high level of CO has been measured in the well shortly after a blast). From there, the CO entered the French drain system and then the basement of the house. The joints are vertical cracks through rock layers that occur on a regular spacing (figure 3). They are most common near valley slopes and are caused when valley walls converge as the stream cuts down through the rock layers. Often called hill seams, they roughly parallel the valley walls, but can curve and split, creating a pathway for gas movement (figure 5). These fractures are often encountered when underground mining proceeds close to outcrop. The system of fractures at the Kittanning blast pit was well developed and provided a path for transmission of CO both through the sandstone and up and through the overlying shales. Blasting engineers should be able to distinguish naturally occurring fractures from blast fractures and note the frequency, development, and orientation of the hill seams and their proximity to occupied houses. The limits of transmission of

May 1, 2001

Objective To develop a passive, inexpensive technique for monitoring explosion overpressures within sealed areas in underground coalmines. Background From 1994 to 2000, seven explosions of methane and/or coal dust occurred within the worked-out, sealed areas (gobs) of underground U.S. coal mines. These explosions, believed to have been started by lightning, destroyed many seals and caused much damage external to the sealed area. One gob explosion went undetected until the mine operator reopened the sealed area and discovered the damage. Fortunately, these gob explosions did not cause any fatalities or injuries. Because lightning occurs in just about all mining areas, several questions arise. Could gob gas explosions be occurring in other sealed areas and going undetected? If so, what is the magnitude of the resulting explosion overpressures? The Pittsburgh Research Laboratory (PRL) of the National Institute for Occupational Safety and Health (NIOSH) undertook a study to identify and evaluate passive measuring devices to monitor and quantify the overpressures associated with such explosions. This work was done in parallel with full-scale explosion experiments for evaluating the strength characteristics of seals used for isolating areas in underground coal mines. Approach Evaluation studies were done in PRL's 20-liter explosion test chamber and in the full-scale Experimental Mine at Lake Lynn Laboratory to evaluate the response and accuracy of various commercially available automobile tire pressure gauges to overpressures generated from gas and dust explosions. The first series of tests was done in the 20-liter chamber, which is used to study the explosibility and inerting of fuel dusts and gases. Data from the tire pressure gauge tests were compared to the pressure-time data obtained from the 20-liter chamber 's traditional electronic strain gauge pressure transducer recorded on a high-speed data acquisition system. To evaluate the tire pressure gauges, the valved inlet (tip) of the candidate pressure gauge was removed and the body of the gauge was cemented with epoxy into a 0.25-in pipe elbow and attached to the outside of the test chamber. A second series of tire gauge evaluation tests was done at Lake Lynn during explosion-resistance testing of seals used in underground coal mines. Full-scale seals (20 ft wide by 8 ft high)were constructed as one wall of a 2,000-ft3 chamber and exposed to a series of methane explosions. Average overpressures ranged from20 to 80 psi. The seals were built with various strength materials ranging from 7 to 48 in thick. The modified tire gauges are attached on the outside of the chamber to a 0.25-in NPT pipe that extends into the chamber (figure 1). The axis of the gauge is mounted at a right angle to the plane of the seal to minimize the coupling of any seal movement to the stem of the gauge that may cause inaccurate readings. The internal explosion pressure history is recorded with a strain gauge pressure transducer mounted inside the chamber. Methane is injected into the chamber, mixed with air, and ignited with an electric spark located at the geometric center of the chamber. Maximum explosion overpressures are recorded and compared with the tire gauge pressure.

Jun 1, 2001

Objective To develop safety training tools for mine health and safety trainers that fill gaps in currently available materials and help capture the wisdom and knowledge of “expert miners.” Background NIOSH began a series of stakeholder meetings in 1998 to determine what research was needed to improve miner health and safety. One of the more common concerns among stakeholders was a critical lack of appropriate training materials applicable to metal/nonmetal mining. Participants provided many insights into what effective training materials should include and how materials could best reach both new and experienced miners. The most important factors were that any materials be realistic and interesting and that some way must be found to capture the wisdom of expert miners before they retired. Approach NIOSH researchers chose videos as the best means of achieving these training goals. Over the past 3 years, NIOSH has produced three training videos that present information on safe work practices in underground mines: handling explosives, recognizing roof hazards and using proper scaling techniques, and installing ground supports. The last two videos, “Rock Falls—Preventing Rock Fall Injuries in Underground Mines” and “Miner Mike Saves the Day—or—Ground Support…It’s Important,” have won Alice Hamilton awards, NIOSH’s highest recognition of Excellence in Occupational Safety and Health, in the Educational Materials category. Two new videos are now being released. Both of these videos were shot completely in operating underground hard-rock mines and used expert miners to tell the story. Hazards In Motion The first, “Hazards in Motion,” deals with the dangers of working around mobile equipment in an underground mine. Ben, a new trainee, refuses to pay attention in his 40-hour New Miner Training class, and when the class takes its first trip underground, he wanders off and finds himself in many dangerous situations. He encounters many experienced miners who both chew him out for his unsafe attitude and give him advice and information on how to survive around mobile equipment. Many common pieces of equipment are shown, including haulage trucks, LHD=s, tracks and trains, slushers, skips and hoists, and air doors. The dangers of ignoring signals and of horseplay are also included. After nearly losing his life numerous times, Ben learns his lesson with the help of the Safety Angel, an experienced miner who looks suspiciously like his safety trainer. Ben’s Safety Angel saves his life repeatedly, teaches him how to work safely around these common conveyances, and introduces him to experts who have specific safety tips. Ben learns the error of his ways and vows to be the safest miner in the mine. “Hazards in Motion” is approximately 30 minutes long. Hidden Scars The second video is the first in the NIOSH “Expert Miner” series. “Hidden Scars” is a narrative interview with Don Capparelli, a miner and supervisor at the Sunshine Mine in north Idaho. This video captures the story of a fatal rock burst in May 1994, when Don was seriously injured and his long-time partner, Jimmy Findley, was killed. “Hidden Scars” is a very powerful story. Don Capparelli shares the physical and emotional pain he lives with daily as he relates the events leading up to the rock burst that took the life of his best friend and partner. This video is an excellent reminder of the human cost of uncontrolled accidents and the hidden scars that survivors must deal with for the rest of their lives. It runs approximately 25 minutes.

Jun 1, 2001

Pillar design is the first line of defense against rock falls—the greatest single safety hazard faced by underground coal miners in the United States and abroad. To help advance the state of the art in this fundamental mining science, the National Institute for Occupational Safety and Health organized the Second International Workshop on Coal Pillar Mechanics and Design. The workshop was held in Vail, CO, on June 6,1999, in association with the 37th U.S. Rock Mechanics Symposium. The proceedings include 15 papers from leading ground control specialists in the United States, Canada, Australia, the United Kingdom, and the Republic of South Africa. The papers address the entire range of issues associated with coal pillars and have a decidedly practical flavor. Topics include numerical modeling, empirical design formulas based on case histories, field measurements, and post failure mechanics.

Jan 5, 1999

Objective To develop safety training tools for mine safety and health professionals that fill gaps in currently available materials. Background Over the past 4 years, NIOSH has developed and released a series of training videos targeted at underground mine safety. These videos were developed in close cooperation with the mining industry and safety training professionals and were intended to provide realistic, interesting, effective training to both new hires and experienced miners. The videos cover the mining cycle, starting with the breaking of the rock (Handling Explosives in Modern Mines), making certain the work area is safe after a blast (Rock Falls— Preventing Rock Fall Injuries in Underground Mines), installation of ground supports and recognition of failed supports (Miner Mike Saves the Day), and hauling both ore and materials in the mine (Hazards in Motion). A separate video (Hidden Scars) captures the story of a fatal rock burst through an interview with a miner who nearly died and who lost his partner in the accident. These videos have been extremely popular in the mining industry and are being used across the nation as well as in 18 other countries. Two of them, Rock Falls and Miner Mike Saves the Day, have won Alice Hamilton awards, NIOSH’s highest recognition for Excellence in Occupational Safety and Health, in the Educational Materials category. Approach A recently completed independent evaluation of the SRL mining videos identified five themes that mine safety trainers consider necessary for successful training materials: high quality, credibility, accurate content, effectiveness, and an engaging nature. All of the NIOSH videos were rated very high for each theme. Using these measures of effectiveness, a more difficult challenge has been undertaken. Much has been written in the mining industry about the coming turnover in employment. The average age of miners in the United States is approaching 50, and many of the “experts” will be leaving the industry as they reach retirement age. The mining industry, like many industries involving skilled labor, relies heavily on a master-apprentice relationship between new hires and older miners. New hands learn from experienced miners. Their learning falls into three primary categories—they learn what’s important to know, they learn how to do things correctly and safely, and they learn the culture.

Mar 1, 2002

Objective The main purpose of this video is to teach mine rescue personnel certain aspects of rescue work that are not traditionally taught. These include the strain caused by working continually under adverse conditions; the "survivor guilt" that occurs from being spared the fate of one's deceased cohorts; and the posttraumatic stress that may be experienced during the sometimes lengthy task of recovering the victims' bodies. Background On November 20, 1968, an explosion rocked the Farmington No. 9 Mine in northern West Virginia (figure 1). The explosion killed 78 of 99 miners who were working in the mine, including all but one member of the mine's rescue team. Some 30 years after the event, researchers from the NIOSH Pittsburgh Research Laboratory (PRL) conducted a video interview with Danny Kuhn (figure 2), the only Farmington No. 9 mine rescue team member who was not working that day and who did not die in the explosion. According to the Mine Safety and Health Administration (MSHA), there are about 80 underground coal mine rescue teams in the United States, and according to the National Mining Association, there are more than 850 underground coal mines. This represents a significant decrease in both over the past decade. The low number of rescue teams is a concern because serious incidents, though fewer, still happen, and if a disaster occurs, there will be fewer rescue teams to respond. This would result in an increased need to use available human resources very efficiently. Much training to prepare these rescue teams still takes the form of what educators call "teaching to the test." In other words, teams practice in order to win mine rescue contests. This test-oriented approach has traditionally been augmented by interactions with others who have responded to real situations or by participating in actual incidents. Given few incidents and fewer rescue teams from whom to derive enrichment, the preparation of coal mine rescue personnel becomes a problem. Recently, more emphasis has been placed on active learning, such as working out problems in smoke. These sessions more nearly simulate the actual conditions that today's team members might rarely encounter. To properly prepare and retain the current coal mine rescue personnel who are left in the workforce, it is necessary not only to offer such hands-on experience, but also to replace the learning narratives that once were passed from team to team. The present video is intended to contribute in that capacity. Approach NIOSH researchers first learned of Mr. Kuhn in the fall of1998. Mr. Kuhn was contacted and agreed to an interview. An oral history interview was conducted with Mr. Kuhn in early November1998. After reviewing the videotape of the interview, researchers determined the content to be so rich as to warrant a second interview in a more formal setting. The second interview was done in early December 1998. During this interview, Mr. Kuhn spent about 2 hours describing the Farmington disaster, including the workplace climate leading up to the explosion, the events that took place in the 10 days after the explosion, and the nearly 10-year effort to safely and successfully recover most of the victims' bodies. The videotape of the second oral history interview with Danny Kuhn was reviewed and edited by NIOSH researchers for content. Careful attention was used to ensure that valuable information was presented, but within a reasonable timeframe. A detailed map of the Farmington No. 9 Mine was edited into the final video and used to highlight critical features as they were being described by Mr. Kuhn. Results and Accomplishments A 60-minute videotape and instructor's guide for use in safety training or other settings was completed. The target audience consists of all those who work in underground coal mines. This training video will help safety instructors better prepare mine rescue team members for the situations that they will encounter when engaging in extended rescue and recovery work. As a result of this expectations training, team members will be more likely to serve their

Mar 1, 2002

Experience, it is said, is the best teacher. Some experiences, however, should be shared so that no one else will ever have to live through them again. The fire at the Sunshine Mine is one such experience. ?Hard-rock mines don?t burn.? The Sunshine Mine near Kellogg, ID, was the nation?s premier silver producer for many years. In 1972, the mine was nearly 6,000 feet deep, contained hundreds of miles of worked-out areas, and employed nearly 500 people. Because of its depth and the type of host rock for the silver (unburnable quartzite), the general thinking of the day was that fires in mines such as the Sunshine were impossible, because ?hard-rock mines don?t burn.? What wasn?t really considered was that timber supports, foam insulation, and mining equipment do burn and that the carbon monoxide gas produced by burning is far more deadly than fire itself. Thus, no one was prepared when, on May 2, 1972, a fire of un-known origin broke out below the 3100 level of the mine. Before long, 173 miners on the day shift were trapped by thick, black smoke. By the time the fire was out, 91 miners had died, and the Sunshine Mine Fire became known as one of the worst mine disasters of the 20th century. It became the catalyst for passage of the Metal/Nonmetal Health and Safety Act of 1977, which applied the same federal safety standards to hard-rock mines as those regulating coal. Mandated safety training, mine inspections, and equipment standards were brought into force.

Aug 1, 2002

To determine the effectiveness of multiple types of fire sensors for early and reliable mine fire detection. Background The National Institute for Occupational Safety and Health (NIOSH) has evaluated the effectiveness of multiple types of fire sensors for early mine fire detection and nuisance signal discrimination. Reliable early fire detection in underground mine can be hindered by false fire alarms produced by carbon monoxide (CO) and smoke particulate emissions from diesel equipment, welding, and metal-burning activities. Another false fire alarm source is the cross-interference of hydrogen (H2) produced by battery-charging operations with a CO sensor's chemical cell. Workers can learn to ignore repetitious "false" alarms associated with these emissions. This jeopardizes their safety in the event of a mine fire.

Sep 1, 2002

To improve the air quality in large-opening stone mines by developing better ventilation techniques, including appropriate fan selection in conjunction with air-coursing methods. Background Stone mines are the most common underground large-entry mines in the United States. Data from the Mine Safety and Health Administration (MSHA) for the year 2000 indicate that there were 162 active nonmetal underground mines in the United States, of which 117 were stone mines. Many underground stone mines are drift mines developed from previous quarry operations. Typically, these room-and-pillar mines have entries that are 20 ft or higher and at least 40 ft wide. These large dimensions lead to a very small ventilating pressure loss, even when significant air quantities move through the mine. This is especially true of drift mine operations where ventilating pressure losses of <0.25 in w.g. are common. Underground stone mines with shafts that are<200 ft deep typically have ventilating pressure losses that are <2 in w.g. The pressure losses through these mines are much lower than those of a typical coal mine or deep metal/nonmetal mine. Therefore, the ventilation techniques and principles are quite different. In addition, because of new MSHA regulations that limit the concentration of diesel particulate matter, these mines may need to greatly increase their ventilation airflow. Therefore, large-opening mines need a fan that can move large air quantities and operate at low static pressures. There are three fan types for mine ventilation: centrifugal, axial vane, and propeller. Centrifugal fans are uncommon in underground stone mines as they are often associated with mines requiring the highest of ventilation pressures. Axial vane fans are widely used in all types of mining operations. They are the most common fan type currently found in underground large-opening stone mines. However, they typically do not operate at low static pressures with high efficiency. Propeller fans are currently uncommon in underground stone mines. They are designed for low static pressures and large air quantities at higher efficiency. This fan type best suits the ventilation needs in large-opening stone mines?they produce large air quantities at low pressure losses. Mines with air shafts<100 ft long and at least 12 ft in diameter have fairly low mine static pressures and may also benefit from propeller fans.

Dec 1, 2002

To improve the ventilation of large-opening under-ground stone mines by using stoppings made from stone left in place. Background Underground stone mines typically use large room-and-pillar openings with little ventilation control. Stone miners may be exposed to contaminants that include silica dust, diesel particulate matter (DPM), exhaust gases, nuisance dust, and face shot (blasting) fume gases. The health risks from breathing these fine particles and toxic organic materials are well documented. Although contaminants such as dust or diesel exhaust can be some-what controlled at the source, the escaping contaminants are often diluted and removed from work areas using ventilation with minimal controls. In many cases, current mine ventilation practices use trial-and-error techniques to improve ventilation. The growing realization of the importance of a healthy work environment along with increased regulations will require many stone mines to implement new ways to improve ventilation. In-place stone stoppings are one option. Mine air flows from one point to another because of a pressure differential between those points. This pressure differential is established using a mechanical fan in conjunction with separations (stoppings) between high-pressure (intake) and low-pressure (return) airways. The separation of intakes and returns is an important concept that is used in most other types of mines. Normally, air moves through underground stone mines with minimal control technology. Fans are placed in locations where they are thought to be most beneficial, and intakes are not separated from returns. In a few smaller underground stone mines, proper ventilation can be achieved with a few strategically placed fans. However, as these mines increase in size, moving adequate quantities of air through-out the mine becomes harder, and separation of intakes and returns becomes a problem. Building traditional mine stoppings to separate the intake and return airways in entries with a cross-section area often exceeding 800 ft2 is difficult. The stoppings must be able to withstand both the dynamic pressure from face shots and the static pressures created by the fans. Construction and maintenance difficulties, as well as high costs, are the main factors preventing these traditional mine stoppings from gaining wide acceptance by the stone mining industry.

Dec 1, 2002

Objective To accurately measure very low air velocities (0-100 ft/min) in U.S. large-opening underground metal/nonmetal mines. Background Hundreds of metal/nonmetal underground mines operate throughout the United States. They extract commercial products from deposits such as limestone, salt, and gypsum. Mining generates a wide variety of gases and dusts, such as silica, diesel exhaust, radon, blasting byproducts, and perhaps even methane. If these substances become airborne, they can adversely affect the health and safety of underground workers. Many metal/nonmetal mines have large cross-sectional airways that could be 60 times larger than an average underground coal mine entry. These large airways require adequate volumes of fresh air to dilute, make harmless, and exhaust the toxic and, at times, explosive byproducts. However, in some underground mine sections, air movement is barely perceptible. The technology of measuring very low air velocities will become increasingly more important for operators of large-opening stone mines in order to monitor miner exposure to diesel particulate matter. Conventional anemometers (e.g., vane) are capable of accurately measuring air velocities only above 100 ft/min. Thus, it was necessary to investigate other anemometry technology to detect low air velocities in the range of 0-100 ft/min. Two different portable ultrasonic anemometers were tested. Actual testing was done in an underground limestone mine with openings about 51 ft wide by 29 ft high. Ultrasonic Anemometers Vane-type anemometers are commonly used by engineering personnel throughout the underground coal mine industry. They work well in measuring air velocities >100 ft/min. However, a separate technology, e.g., portable ultrasonics, is needed to measure air velocities much below 100 ft/min at various places within the large mine opening. Laser-doppler technology was also considered for this application, but was ruled out because of its high cost and other technical limitations. With no moving parts, the portable ultrasonic anemometers are claimed to be accurate down to about 1or 2 ft/min. The first type of ultrasonic anemometer that was examined underground is manufactured by Gill Instruments Ltd., Hampshire, U.K. The U.S. distributor is IN USA, Needham, MA. The Gill Instruments Solent Volometer (figure 1) is a battery-powered, single-axis anemometer meant for measuring low to medium air flows up to1,999 ft/min. It uses the ultrasonic "time of flight" principle where pulses of high-frequency sound are transmitted along the air flow path and the time taken to reach the receiver is measured. The faster the air speed, the quicker the pulses reach the receiver. The second ultrasonic anemometer that was examined under-ground is manufactured by Airflow Developments Ltd., Buckinghamshire, U.K. The U.S. distributor is Airflow Technical Products, Inc., Andover, NJ. The Anemosonic UA-6 (figure 2) is a battery-powered, handheld instrument with digital display. It measures air velocity (0 to 9,999 ft/min) or volume flow, flow turbulence intensity, and air temperature. Neither device is considered to be intrinsically safe for use in underground gassy coal mines. A comparison of salient specifications of both instruments is shown in table 1. The total suspended weight includes the instrument (Gill) or instrument probe (Airflow) plus about 35 ft of connecting cable attached to the pole. This combination of instrument plus cable length allows two operators to measure air velocities up to about 30 ft above the mine floor. Figures 1 and 2 show how each unit would be attached to an extensible, graduated fiberglass rod in order to position the sensor probe at a certain spatial point (centroid of the quadrate) within the underground large opening.

Jan 1, 2003

Objective To develop safety training tools for mine safety and health trainers that can be used for both new-miner training and annual refresher training. Background For the past 3 years, NIOSH has been developing training materials for mine safety trainers in response to gaps identified during stakeholder meetings. Most materials have been directed to the hazards of underground mines, but the recent passage of Part 46 of CFR 30 required new-miner and annual refresher training in aggregate operations. One result was the identification of another audience needing basic information about safety in mining. Trainers characterized trainees in this segment of the industry primarily as young males, many of whom had little work experience. Approach Training specialists from the Arizona State Mine Inspector’s Office approached NIOSH researchers early in2002 about the possibility of a collaborative project to develop safety training materials for new trainees in aggregate operations. A preliminary search of MSHA accident statistics identified over a dozen common hazards that could be targeted in a training video. A storyline was developed for review by safety specialists in the aggregate industry, and a script was written to cover the selected hazards. Although the target audience was primarily new hires, the finished video was also to be relevant to more experienced workers.

Jan 1, 2003

Develop tools that mine personnel can use to comply with 30 CFR,Part 47. Background The new MSHA rule, 30 CFR, Part 47 (also known as the HazCom rule), requires all mines to develop a written program to track hazardous chemicals at their sites. More specifically, the rule requires that mines list all chemicals and determine which are hazardous; develop a written Hazard Communication Program; label all containers used to store hazardous chemicals; obtain or develop Material Safety Data Sheets (MSDS) for all chemicals stored or produced; provide miners with training in working around hazardous chemicals; and make information about hazardous chemicals available to all workers. All mines with six or more employees must have complied with the new rule by September 23, 2002, and mines with five or fewer employees will have to be in compliance by March 21, 2003.

Mar 1, 2003

Introduction The Coal Mine Roof Rating (CMRR) is a roof classification system. It was first introduced to the mining community in 1994.The CMRR filled a longstanding need to quantify geologic description of coal measure rocks into an engineering value that could be used for mine design. It has now been written to a user-friendly visual basic code that can be run on any PC with a Windows operating system. Background Rocks that form the roof of coal mines can vary widely and quickly in composition, extent, and defects. This results in an equally broad range of rock properties that can substantially affect the ability of the rock mass to form a stable mine roof. The CMRR was designed to evaluate the properties of the coal mine roof rock mass that contribute to its weakness and convert them into a relative strength rating from 0 to 100. These properties include the cohesion and frequency of discontinuities like bedding, slips, shears, and joints; uniaxial compressive strength (UCS); and moisture sensitivity. With simple lab and field tests and observation, the CMRR can be calculated by technical and operating personnel with a minimum of training. The CMRR has been widely accepted in both U.S. and international coalfields. As a result, a number of roof control applications have been found for the CMRR. It is currently used as an input component in the Analysis of Longwall Pillar Stability(ALPS) program, which is used to design longwall chain pillars. Incan be used as a criterion for determining the appropriate width of mine entries. It has also been used to indicate the appropriate length of cut in weak ground. The CMRR can be used as a strength parameter to characterize inter burden between mined seams in the numerical modeling of subsidence effects. In any area where an estimation of coal measure rock mass strength is required, the CMRR can be adapted to fill this need. How It Works Originally designed to be used with underground exposures, the CMRR can also be calculated from core. The chisel test for bedding cohesion and the ballpeen hammer test for UCS are inappropriate for core. These tests have been replaced by point load testing both axially and diametrally. Two other measures that are common to standard core logging—Rock Quality Designation (RQD) and fracture spacing—are also used to estimate rock weakness. With these easily obtained parameters, the CMRR can be calculated from core and used in the mine planning and exploration phase. The input screens allow calculation of the CMRR for both underground exposure and core. The CMRR is reported both as a “dry" value and as a groundwater-adjusted value for moisture-sensitive rocks. There is a graphical output report featuring a lithologic column with annotated unit ratings and a roof bolt symbol representing the height of the bolted horizon. Another important feature is an AutoCAD interface. This feature allows the export of located CMRR data directly to an AutoCAD layer in XYZ form. In this way, drill hole data can be inserted directly to a base map.

Apr 1, 2003

Introduction Research has shown that when an emergency occurs, work-ers often do not get the information they need to take appropriate action. Important information about incidents is either not com-municated effectively or not at all to those affected by the event. The "Emergency Communication Triangle" safety talk focuses on the content of emergency warning messages. It presents a procedure using mental cues that can be used by senders and receivers of emergency warnings. The talk includes graphics for use during the presentation, as well as references for more information. Background Interviews with 48 miners who had escaped one of three different underground mine fires revealed that warning information provided to them was inadequate. Either insufficient information was provided to miners inby the fire areas or they failed to ask the questions needed to let them plan and execute an effective escape. Most of the miners who evacuated from these three mines did not have information that would allow them to make decisions about efficient escapes. The communication breakdown came from two directions: (1) the individuals providing the warning did not offer details about the situations even though some were known and (2) the individuals who received the warnings did not ask for clarification of the situation. The lack of information allowed miners to continue attempting to place cues into normal frameworks after they should have evaluated the situation as abnormal and threatening. The uncertainty created by the lack of information influenced their decision-making and therefore their actions. Approach Researchers at the NIOSH Pittsburgh Research Laboratory have developed a training intervention that can be used by senders and receivers of warnings during a mine emergency. This material was developed for use in short safety training sessions such as start-of-shift safety talks. The information can be presented in about 15 minutes. Although the illustrations were taken from the underground coal mining industry, the training can be tailored to any work setting by substituting appropriate examples. How It Works During the safety talk, miners learn about the six categories of critical information that should be provided during emergency communications: Who, Where, What, Miners, Event, and Response. • Who: When reporting an emergency or receiving a warning, the first thing a miner must do is identify himself or herself. This is important because people react differently based on who gives them information. • Where: Giving or finding out the location of the problem is important. Of the 48 miners interviewed about their escape, only 2 knew where the fire was located. However, this information was known by either the dispatcher or the person who discovered the fire. • What: Miners must tell or ask exactly what is happening. At one mine fire, miners near the phone heard the message to evacuate and went to gather the others on their crew. One worker shouted to a machine operator: "Come on down to the mantrip. We&apos;re going out." Because it was close to quitting time, the machine operator thought they were just leaving the section a little early and went through his normal end-of-shift routine, wasting valuable time. After giving or obtaining the three initial pieces of critical information, miners can then give or obtain details about the response in progress. • Miners: Is anyone hurt? Has everyone been accounted for? When and where was a missing person last seen?

Sep 1, 2004

Coal miners, especially roof bolter and continuous miner operators, work in a hazardous underground environment where they are often exposed to poor roof conditions. Nearly 500 rock fall injuries are reported each year, and 99% of them are caused by rocks falling from between the roof bolts. These loose rocks that injure miners are usually just a few inches thick, but on average weigh 280 pounds. NIOSH has found that most rock fall injuries can be prevented by installing roof screen during the bolting cycle. Roof screen is a sheet made of steel wires in a grid pattern. When screen is bolted up against the mine roof, it provides far more coverage than any common surface control used in the mines today. Because more mine roof is covered, there is less chance that a rock will fall and injure a miner. The facts about roof screen are shown in the new NIOSH video entitled “Make It Safer With Roof Screen.” Using extensive underground footage, the 7-minute video shows how well screen keeps loose rock from falling in difficult roof conditions. Techniques for installing screen from both outside-controlled and walk-thru roof bolting machines are shown. The video also provides safe handling tips, best practices, and information about machine technology that can greatly improve material handling. Throughout the video, a coal mine safety manager and a shift foreman talk about the tremendous difference that roof screen has made at their mines. An instructional booklet supplements the video with additional information. It presents compelling data from mines that have practically eliminated rock fall injuries with a roof screening program. Other sections of the booklet discuss in greater detail roof screen installation, tips for manual screen handling, a material handling system for roof screen, and use of the personal bolter screen, which can be easily handled by one person. Screen specification and custom ordering are described, including the sizes of screen, grid sizes, reinforcing (indicator) wires, edge cut options, and screen strength. A list of additional sources of information is also provided. Nearly every mine eventually encounters poor roof. Screen is one of the most powerful control techniques available. This new video will help make mine managers aware of screen, and it can help them in developing a roof screen installation program. It also serves as an information source and teaching tool for safety managers and trainers. The video can easily be integrated into new miner training programs or annual refresher training.

Mar 1, 2005