The Lonmin Fall of Ground Journey - Presented by: Charl Viljoen and Victor Ndlovu
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The Lonmin Fall of Ground Journey Presented by: Charl Viljoen and Victor Ndlovu
Lonmin FOG Journey: Presentation overview
• What we did to improve from an LTIFR of 18.1 to 3.34
– Systems , technology and behavior
• Our future FOG strategy
• Woman in Mining
Our journey started in 1990 when the first roof-bolts were installed
Industry Approach to FOG - Before
Clearly unsafe
Lonmin Mining Lease Area
ROWLAND
SD: 1032
f
SC: 200 000
f
PANDORA SHALLOWS
MO: est. 2050 #
HOSSY SD: (Feasibility study)
f
SAFFY
SD: 489 SC: 120 000
SD: 804
SC: 120 000 MO: est. 2052
SC: 200 000
MK3 SHAFT MO: est. 2042
f MO: est. 2044
K5 SHAFT VP-WESTERNS
K4
SD: 1331 PANDORA DEEPS
MK2 SHAFT
SC: 225 000 f
MO: est. 2062 f VP-EASTERNS+PANDORA
33E 31E
HW SI PANDORA SHALLOWS
K4 SHAFT
33E
33W
32W
32E
32E
30E
31W
31W
31E 31E
29E U17
30W
30W 7E
8E
30E
30E
29W 6E
28E
27E 5E
26E OP
UTCR
10E
f 4E
25E
9E 2O
28W
10W UG
U16
HW V
24E
19W
K3
23E 22E 9W
27W
18W 18E
24W
20W 24E 21E
17E 3E
19W 26W 17W
LATILLA
SAFFY SHAFT
23W
21W
23E ROWLAND SHAFT 20E
16W
16E
E3 INC SHAFT
SD: 809
18W 25W 15E
22W
17W 22E
19E
15W f
8W U15
24W 14E
16W 14W
23W
21E
18E 13E 9E 7W
22W 13W
20E
15W 6W U14
SC: 290 000
17E 3W
K3 SHAFT
21W 12E 8E
HOSSY
19E 14E 12W
16E 9W 5W
18E 14W
20W 13E 11W 11E 6E 4W
7E
19W 12E 10E 8W
9E
14W 17E 15E
f SHAFT13W
11E f
7W
E2 INC SHAFT
5E
4E U14
MO: est. 2033
18W 15W 10E 8E
16E 10W
E1 INC SHAFT
12W 9E 6W
17W 3E
12E 9W
13W 15E 7E
16W 8E 5W
11W
14E 11E 6E
12W 5E
8W f U13c
1 SHAFT
13E 10E 7E 4W U13c
7W 3W
10W
6E 4E
12E 9E 6W
12W 8E 5E U13a U13b
7W
9W
10W 11W 11E
11W
10E 7E
9W 8W
NEWMAN 4E
5W
4W 3W 3E
U13
E3 BELT
3E
INC SHAFT
10W9E
6W
5E U12
LEGEND
5W 9W 8E 7W
8W
6W U11
8W 7E
4W 7W
(INCLUDING
4E 5W
6E
4B INC SHAFT 5E
5W
4W
3W
U10
UG2
OUTC
ROP
U2
3W
4E
4W
3E
3W
U9a
3E
U9B
f
E2 BELT PANDORA JV) SD Shaft Depth below Collar
E1 BELT
2W U7 U8 U9
2W 2E
U4 U7a
KEY U3
U5
U5
U6
SD: 345 SD: 349 SC Shaft Capacity (Reef Tonnes)
NEWMAN SD: 396
Shallow inclines SC: 80 000 SC: 80 000 SC: 80 000 MO Expected to be Mined Out by
SD: 396 MO: est. 2025 MO: est. 2040
1st generation
1 SHAFT SC: 120 000 MO: est. 2013
4B INCLINE UG2 GEOLOGICAL DOMAINS
verticals SD: 322
SD: 445 MO: est. 2018 ¥ Mining Legend Strategic Domains
SC: 90 000
VP Area of Responsibility
2nd generation SC: 160 000 MO: est. 2013 5W
Development
Normal Reef Facies
verticals MO: est. 2023
4W 3W
Stoped out face Split reef facies
3rd generation Geological Structures High Risk Domain
verticals Outcrop
0 Km 1 Km 5 Km 10 Km Slump
* Marikana Shaft Overview Oct 2012 Major Faults
f
# Includes Middelkraal Mineral Reserves Dykes FY13 MINE EXTRAC_SHAFT OVERVIEW
SCALE Surface Aeromagnetic anomaly
¥ Excludes Newman Merensky Mineral Reserves 24 OCT 2012
4
Ground Control Interventions
Lonmin Ground Control Milestones
1990 In stope bolting Karee
1996 Grout packs E2
1998 Pre stressing units E2
1999 PSUs/ Grout Packs Rowland
2002 PSUs Karee
2003 In stope bolting E2/ Grout packs E3
2005 In stope bolting and Grout packs Marikana
2008 Systematic bolting
2009 PSUs Marikana
2010 Improve Entry Examination
2010 UG Pulltests
2010 Rockstar & Rock hazard training
2011 Support of T/ways
2011 In-Stope bolting Newman
2011 In-Stope nets on Rowland, Newman, Saffy
2011 Phase in Cempacks on Karee (improved grout pack)
2012 Introduce improved temporary face support at WPL
2012 Rollout on resin bolting on Karee
2012 New support system (Cempack) and layout Saffy
2012 Pilot ALLeRT (Tarp) at Newman
2013 Stope nets role out Marikana
2013 Rollout ALLeRT Marikana
2013 Develop RockIT system
2014 Rollout RockIT system, IT and ug integration
Hazard awareness 2014 Rollout Greasebox Camlok (temp support)
2010 Rock hazard training
2012 ALLeRT (Apply Lonmin Life Rules and Triggers)
2014 RockIT system
5
The Journey
BEFORE AFTER
The Most Dangerous thing you can do is not to avoid RISK
6
Zero FOG
INJURIES
Lonmin’s FOG Journey
In stope bolting
1990
7
Zero FOG
INJURIES
Lonmin’s FOG Journey cnt.
Grout packs and
pre stress units
2002
In stope bolting
1990
8
Zero FOG
INJURIES
Lonmin’s FOG Journey cnt.
Systematic
bolting in all
dev. 2008
Grout packs and
pre stress units
2002
In stope bolting
1990
9
Zero FOG
INJURIES
Lonmin’s FOG Journey cnt.
Entry
Examination
MOSH
Systematic
bolting in all
dev. 2008
Grout packs and
pre stress units
2002
In stope bolting
1990
10Zero FOG
INJURIES
Lonmin’s FOG Journey cnt.
Entry
Pull tests Examination
MOSH
2010
Systematic
bolting in all
dev. 2008
Grout packs and
pre stress units
2002
In stope
bolting
1990
11Zero FOG
INJURIES
Lonmin’s FOG Journey cnt.
Entry
Examination
MOSH In stope nets
Pull tests 2011 MOSH
2010
Systematic
bolting in all
dev. 2008
Grout packs and
pre stress units
2002
In stope
bolting 1990
12Zero FOG
INJURIES
Lonmin’s FOG Journey cnt.
ALLERT
TARP 2012
MOSH
In stope nets
2011 MOSH
Entry
Pull tests
Examination
2010
MOSH
Systematic
bolting in all
dev. 2008
Grout packs and
pre stress units
2002
In stope
bolting 1990
13Zero FOG
INJURIES
Lonmin’s FOG Journey cnt.
ALLERT Rock IT 2013
TARP 2012 MOSH initiative
In stope nets
Pull tests 2011 MOSH
Entry
2010 Examination
MOSH
Systematic
bolting in all
dev. 2008
Grout packs and
pre stress units
2002
In stope
bolting 1990
14Zero FOG
INJURIES
FOG Journey: The Future
2015
Drilling and
blasting practices
ZERO HARM - Balancing Behavioral Based Safety (BBS)
with KPI’s for safe and efficient working processes
Efficient delivery of production targets - Re- emphasizing
the importance of the Safety Business Review process to
enhance, compliment and sustain continuous
improvement systems
Deliver through a competent and empowered workforce
and reward for high performance - Improving productivity
by heightening behaviour performance
15Zero FOG
INJURIES
FOG Future Journey
ZERO HARM - Balancing Behavioral Based
Safety (BBS) with KPI for safe and efficient
working processes
Efficient delivery of production targets - Re-
emphasizing the importance of Safety
Business Review process to enhance,
compliment and sustain continuous
improvement systems
Deliver through a competent and Behavioural
leadership
empowered workforce and reward for high
intervention
performance - Improving productivity by 2016 Drilling and
heightening Behaviour performance blasting practices
2015
16Zero FOG
INJURIES
FOG Future Journey
Permanent aerial
ZERO HARM - Balancing support 2017
Behavioral Based Safety (BBS) with
KPI for safe and efficient working
processes
Efficient delivery of production
targets - Re- emphasizing the
importance of Safety Business
Review process to enhance,
compliment and sustain
continuous improvement systems Behavioural
Deliver through a competent and leadership
empowered workforce and intervention
2016
reward for high performance - Drilling and
Improving productivity by blasting practices
heightening Behaviour 2015
performance
17Zero FOG
INJURIES
FOG Future Journey
Mechanization
2020
Permanent aerial
ZERO HARM - Balancing support 2017
Behavioral Based Safety (BBS) with
KPI for safe and efficient working
processes
Efficient delivery of production
targets - Re- emphasizing the
importance of Safety Business
Review process to enhance,
compliment and sustain
continuous improvement systems Behavioural
Deliver through a competent and leadership
empowered workforce and intervention
2016
reward for high performance - Drilling and
Improving productivity by blasting practices
heightening Behaviour 2015
performance
18Milestones: Systems
Milestones: Behaviour
Milestones: Lonmin Ground Control
Lonmin Ground Control Milestones
1990 In stope bolting Karee
1996 Grout packs E2
1998 Pre stressing units E2
1999 PSUs/ Grout Packs Rowland
2002 PSUs Karee
2003 In stope bolting E2/ Grout packs E3
2005 In stope bolting and Grout packs Marikana
2008 Systematic bolting
2009 PSUs Marikana
2010 Improve Entry Examination
2010 UG Pulltests
2010 Rockstar & Rock hazard training
2011 Support of T/ways
2011 In-Stope bolting Newman
2011 In-Stope nets on Rowland, Newman, Saffy
2011 Phase in Cempacks on Karee (improved grout pack)
2012 Introduce improved temporary face support at WPL
2012 Rollout on resin bolting on Karee
2012 New support system (Cempack) and layout Saffy
2012 Pilot ALLeRT (Tarp) at Newman
2013 Stope nets role out Marikana
2013 Rollout ALLeRT Marikana
2013 Develop RockIT system
2014 Rollout RockIT system, IT and ug integration
2014 Rollout Greasebox Camlok (temp support)Safety Achievements to Date
Lonmin - Section / Unit Highest FFS
4B/1B Shafts 8 000 000*
Marikana Mining Operations 6 000 000*
Karee Mine (K4, K3, 1B & 4B) 4 000 000*
Hossy Shaft 3 000 000*
Western Platinum Mine 3 000 000*
K3 Shaft 2 000 000*
Rowland Shaft 1 000 000*
Saffy Shaft 1 000 000*
Newman 1 000 000*
FALL OF GROUND FATALITY FREE
SHIFTS
Lonmin 17 000 000
Rowland Shaft 14 000 000
Karee operations 10 000 000
Lonmin 8 000 000*Lonmin Safety Achievements
Mine Safe 2014
William Kgasi
JT Ryan Award
2014 Third Year in a row
Lonmin – working 1 year fatality free
23Zero Harm – Roof Support Installations
“ZERO HARM” – Roof support installationsZero Harm – Development End Net Installation
Zero Harm - Stope Net Installation
Zero Harm: Safety Net at Work
Zero Harm: Safety Net at Work
Video – Newman RDO Mr DambuzaZero Harm – Stope Net Installed
“ZERO HARM” – To Everyone Everywhere Everyday
Lonmin Women in Mining Journey
The Lonmin WIM team and Safety team strive to provide PPE for women:
That fits correctly (size and design), and is comfortable
SABS & MHSC (SANS 511:2011 for women workwear) compliant with reference to material and design
Lonmin WIM PPE Project Stages
Manufacturers Re-design the Stakeholders Finalize women
Assessment of
engagement (WIM PPE; new designs engagement & PPE Policy &
current PPE (WIM
team and Safety completed and testing (1-2 rolling out; target
Committee)
dept.) ready for testing months) February 2015.Women in Mining PPE: The Realities
Original design has not taken into account
the needs and requirements of women
clothing has not been designed with safety and comfort of a
women in mind
ergonomics of the clothes impacted on productivity and efficiency
clothes did not reflect the femininity of the women in mining
the practicality of dressing and changing was never taken into
consideration
the material used was not practical to the female physique, it was
too heavy and tight , and the colour was not complementary
PPE for expecting mothers was never taken into consideration
the foot sizes and proportion of leg length was not considered for
calf size
boots was not designed for female walking action, shoe size
Beanis where not designed for safety of women with long hairNew modified Women PPE
New designs completed and
ready for testing
Body Protection (Women Overall)- (1 Piece)
Made of light material
Inner wear sewn into the trousers
Easy to undress
White top & navy pants
Body Protection (Women Conti-suit)-(2 Piece)
Jacket -extended length
Trouser with high waist –skin is not
exposed when bending
Women’s cut provide comfort
Foot Protection (Women Gumboots and
Safety Shoes)
Calf extended gumboots
Small size safety shoes size available
Bandana / Beanies to cover hairLonmin WIM: PPE for expecting Women Empowered Women
Thank you
“there is no better tool for development and productivity
more effective than empowerment of women”You can also read
