After the installation of the longwall in October 2006, it became apparent that due to the increase in width of the support (2m) the difference in stride patterns required to walk along the longwall was having an adverse impact on Ulan operators.
Various members of the longwall crews reported sore feet, ankles, heels and knees.
After trialling high-leg leather boots unsuccessfully, Ulan tradesmen Craig Underwood and James Wormald along with longwall operator Gary Robbins developed a higher order control measure – a step guard to cover the gap between the 2m wide roof support shields, creating an even walkway.
The design and fabrication of the Underworm Pontoon Plate was undertaken in consultation with the OEM and was then implemented across 12 roof support shields.
The complete longwall at Ulan, with the exception of an Eickhoff shearer, was supplied by Joy Mining Machinery, boasting a number of Australian firsts, including 198, 2m wide roof supports, operated by a revamped RS20s Roof Support Control System.
“Longwall supports have been used by the mining industry for a considerable period of time and a simple, low cost idea has eliminated hazards associated with walking over relay bars between the roof support feet,” the Underworm developers said.
The cost of each Underworm plate is $200, and with 197 plates required for the Ulan longwall, the safety innovation cost the mine $39,400.
Using the Underworm, Ulan operators can now pass along the longwall face at whatever stride pattern is comfortable for the individual:
- Reducing the likelihood of ankle rollovers between pontoon feet;
- Eliminating inadvertent stepping onto the relay bar between the pontoon feet; and
- Reports of sore feet and knees from longwall crews have ceased.
The Underworm was recently one of 10 finalists entered into the NSW Minerals Council OHS Innovation Awards 2007, taking home the People’s Choice Award.
The Underworm concept is fully transferable across the underground longwall mining industry utilising longwall roof supports with a front of support walkway and an exposed central relay bar.
