Scraper winch safety and alternative cleaning technologies in South African narrow reef hard rock mines

Scraper winches remain the primary machinery for moving broken rock in underground narrow reef hard rock mines in South Africa. Despite their longstanding use, significant safety hazards and risks associated with these systems remain. Recent analyses of scraper-winch-related accident data (2015 – 2024) confirmed that scraper winch ropes remain the main hazard and are often linked to insufficient situational awareness and task supervision. A review of scraper winch technologies and alternative broken rock cleaning systems revealed that most potential solutions were previously recommended through research initiatives like the Chamber of Mines Research Organisation, Deepmine, and Futuremine. The implementation of these potential solutions has been constrained by factors such as cost, reliability, and infrastructure compatibility. Key recommendations for improving safety in existing scraper winch operations include proactive rope condition monitoring, improved anchor point rigging, and the integration of proximity detection systems to reduce risks related to worker exposure to the moving parts of the scraper winch system. The implementation of alternative cleaning equipment such as waterjets for face cleaning and ultra-low profile dozers can further improve safety and production. However, the implementation of ultra-low profile dozers is limited by geological and infrastructure constraints. The above solutions focus directly on enhancing the scraper winch system or replacing it with alternative cleaning solutions. Alternatives that would result in the elimination of scraper winch hazards require a change in the mining method. Such solutions include mechanical, ropeless mining methods such as reef boring and reef cutting. Although these technologies offer safety advantages and a means to eliminate scraper-winch-related risks, their economic viability in the South Africa’s narrow reef tabular environments remains challenging.