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Objective: To provide a safe, practical, cost-effective method for measuring coal rib thickness during highwall mining.

Jul 1, 2008

Objective: To continuously monitor, display, and record concentration levels of respirable coal mine dust in mines to an accuracy of ±25% with a 95% confidence level for at least 30 days without servicing.

Jul 1, 1997

Objective: To help prevent squeezes, collapses, and other pillar failures through better pillar design, thereby enhancing safety for underground mine workers.

Jul 1, 1997

To provide longwall operators with a method to predict methane emissions from panels with increased face width.

Jan 1, 1997

Develop geophysical techniques suitable for enhancing miner safety. Specifically, to use geophysical methods to detect hazardous conditions in a rock mass in deep underground mines as well as to assess the mechanical integrity and monitor changes of the rock.

Jan 1, 1997

To provide an engineering solution to wood crib design and deployment strategies that will ensure safety for underground coal mine workers. This is accomplished by preserving necessary ground control requirements while minimizing support costs or by developing new support strategies to enhance ground support in difficult conditions. A secondary objective is to be able to quantify wood crib support performance to define support requirements for alternative support systems. These objectives have been achieved through a simple-to-use computer program called the wood crib performance model (wcpm).

Jan 1, 1997

Reduce haulage truck accidents resulting from blind spots, with a special emphasis on reducing accidents during backing operations.

Jan 1, 1997

Objective Develop a method to warn of hazardous conditions and enhance safety during operation and inspection of vertical mine shafts and hoists. Background Mine hoisting is the most critical and potentially the most dan¬gerous operation in underground mining. Many hazards are related to falls of miners and materials, ground instability, and malfunction or lack of safety devices. All have the potential to cause a cata¬strophic accident. A condition known as "slack rope" is particularly dangerous, expecially if it occurs without the operator's awareness. The most common occurrence of slack rope is in metal or nonmetal mines that have a history of ground control problems near the "haft. Approach Studies of hoist safety features and Mine Safely a and Heath Administration (MSHA) accident statistics suggests a need to measure wire rope tension, conveyance speed and position, and shaft guide misalignment. The most accurate data are obtained directly from the conveyance. Such data could warn of potentially dangerous situations during hoisting operations, as well as during inspections, maintenance, and lowering of large equipment. Figure I shows the concept for monitoring wire rope tension, conveyance position, and guide displacement. Progress to Date A conveyance-mounted system has been developed that monitors rope tension: hoist conveyance position, speed, and load; and shaft guide misalignment. A "flex-beam" load sensor mounted just above the- conveyance protects against slack and tight rope. The measurements are transmitted 60 times a second via wireless equipment from the conveyance to the hoist room. An encoder mounted on the conveyance eliminates the need to correct the position because of rope stretch. Figure 2 shows the encoder wheel and guide displacement sensors being mounted on a cage in¬spection deck. A potentiometer monitors misalignment of the shaft guides during inspections. Information about the cage or skip can be acquired by the shaft inspector using a hand-held indicator. Inspection can also he conducted remotely from a station or hoist room using the wireless link to a laptop computer. Figure 3 shows test results from a simulated slack rope condition. Patent Status NIOSH has a patent pending on this device entitled "Cable-Load¬Sensing Device." For More Information NIOSH is seeking cooperators to assist in further tests of this technology to improve hoisting safety. Additional information can he obtained by contacting Michael J. Beus, Steven Iverson, or Elaine Cullen, Technology Transfer Officer, NIOSH, Spokane Research Laboratory, Spokane, WA 99207 at (509) 354-8000.

Feb 1, 1998

Objective Develop field measurement and computer modeling methods to predict the potential for hang-ups and structural failures in underground mine ore paws. Background Analysis of Mine Safety and Health Administration (MSHA) accident statistics has identified ore pass hazards as a significant safety problem in underground metal mines in the United Stales. Recent ore pass failures have underlined the lack or ore pass design methods ant1 standards available to both MSHA and mine engineers. Injury and fatality data for the 20-ycar period between 1975 and 1095 show that nearly 75% of the injuries were directly or indirectly related to pulling or freeing ore pass chutes, the use of hand tools, falls or broken rock, and structural failures or chutes or gates and ore pass walls.

Feb 1, 1998

Objective: To develop and test a training program that enhances the hazard recognition skills of underground limestone miners. This program can help job performance and lead to enhanced safety in the underground workplace.

May 1, 1998

Objective: To evaluate the quantity of ventilation air reaching the face of a 40-ft box cut during a 40-ft, two-pass, extended cut and to examine ways to increase this quantity of air.

May 1, 1998

Background: The National Institute for Occupational Safety and Health (NIOSH) recently investigated ignition incidents resulting from drilling holes into sealed and filled plow frame sections. A farmer and farm worker were seriously burned in two separate incidents that occurred in the same county in New York under similar conditions. They had just penetrated sealed sections of their plow frames with electric drills when a roar of escaping gas at high pressure was heard, and the victims were thrown back by the gas jet and engulfed in flames. The flames were quickly extinguished ,but the victims suffered burns. NIOSH experts were asked to help find the cause of these hazardous incidents.

Jun 1, 1998

Objective: To devise a passive means to detect overheating insulators on mine trolley/track haulageways.

Aug 1, 1998

Objective: The Roof Monitoring Safety System (RMSS) provides a first step in roof behavior awareness. By understanding and measuring roof movement in an underground mine, the potential for injuries or fatalities to mine workers from fall of ground can be lessened. Also, officials at an underground mine with a history of data on roof movement are better prepared to make a decision on remedial actions if falls of ground become a problem. The RMSS provides a safer, simple, and inexpensive means for measuring roof movement.

Aug 1, 1998

Objective A cable bolt can be a strain-measuring device as well as a supporting device in underground mines. Placing instruments on a cable bolt allows certain characteristics of a rock mass, such as high strain and load, to he evaluated during mining and provides a means for mining engineers and mine inspectors to forecast a potential roof fall. Background Thousands of cable bolts are installed in U.S. mines each year. Studies performed by NIOSH researchers show that support loads can exceed the yield point of the steel, which can result in unstable ground conditions that pose direct safety hazards for underground workers. Rock falls can also create secondary hazards, such as caved escape ways and blocked ventilation passages. Development of methods and tools to assist in the evaluation and selection of rock supports could reduce the number of unplanned rock falls significantly. Approach Instrumented cable bolts developed at NIOSH’s Spokane Research Laboratory were used along with existing ground control systems to monitor rock mass loads and movement Axial and shear loads on the cables are determined as these loads are transferred to strain gages embedded in the king wire. In longwall, room-and-pillar, or underhand cut-and-fill mines, rock mass loads and movements can be detected down to microstrains of stress or millimeters of movement. By detecting such small amounts of ground movement and support load, early intervention to prevent a roof fall is possible, and miner safety and health are increased. How it Works Up to 10 strain gages are embedded in the king wire at whatever locations a mine ground control engineer may specify. The gages m either be set in pairs in the same plane to detect shear or set at 90° angles to detect loading in three dimensions. The cables are up to 5 meters long if they arc to be grouted with resin or up to 15 meters: if they will be grouted with cement. They arc capable of holding m ultimate lend of 214 kN and produce reliable readings to 178 kN, as shown in the calibration curve. The cables are fitted with an instrument plug for monitoring the gages and a special head for insertion into the rock. A data acquisition system, such as a Vishay strain indicator box, Campbell Scientific, or Omnidata system, is required to obtain the data for load and displacement calculations.

Nov 1, 1998

To address the safety of programmable electronics-based mining systems before this technology proliferates in the mining industry.

Jan 1, 1999

To design an apparatus that advances the state of the art in gas content testing equipment. The goal of the design is to incorporate improvements in testing sensitivity/accuracy, durability, and ease of operation over existing equipment. It is also desirable for the new design to successfully perform gas content determinations of multiple chemical species from a rock sample.

Jan 1, 1999

Develop a means of determining both the fill level of material in an ore pass or bin and the location of bridging material causing a blockage.

Jan 1, 2000

To provide a practical method to reduce hand and arm injuries during roof bolting operations.

Jan 1, 2000

Objective The Roof Monitoring Safety System (RMSS) introduced in late 1997 has been modified to improve durability and simplify the measurement of roof or rib movement. Greater knowledge about the stability of roof and rib rock is expected to result in safer conditions for the mine worker. Developing safety tools and methods is part of NIOSH’s mission to prevent work-related injuries and deaths. A mining operation with a proactive approach to control ground conditions is in a better position to make essential decisions related to mine development and take remedial actions in the event of roof or rib falls. Background Falls of roof and rib rock are responsible for a high number of mining injuries and fatalities. Visual inspections and the sound of breaking or cracking rock are often relied upon to indicate unstable roof conditions. In some mines, roof bolt holes are checked for separations or gaps with a scratch tool; this provides further information about the stability of the roof. Monitors such as the RMSS can confirm roof movement that was surmised only by eye or ear, or potentially detect movement that was missed by these means. An added safety feature of the RMSS is the capability of locating the measurement station at a distance from where the monitor is placed in the roof. Stone and other industrial minerals are the basic raw materials used in construction. Continuing economic growth and highway building in particular have resulted in record demand for stone. This high demand, coupled with increasing constraints on surface mining, have caused many new .stone mines to be developed underground. These new mines in many cases will be employing new and inexperienced miners who may not have the ability to recognize unstable ground conditions using just sight and sound. From the initial introduction of the RMSS, it was anticipated that improvements and modifications would occur. We correctly assumed that, once miners and operators were exposed to the monitor. suggestions would evolve. In one case, the RMSS was used to determine if an impact hammer used on a mechanical scaler was causing or increasing instability of roof rock. The test showed little or no movement resulted from this method of scaling under the particular conditions at this mine. In another instance, an operator needed to monitor the stability of a haulageway in a benched area that had very high ceilings. The RMSS requires a 2-in-diam hole for installation; however, only roof bolt holes of a smaller diameter were available, and it was impossible to drill new holes at that height. The operator attached a 2-in collar at the roof line and was able to install the RMSS. These examples illustrate the potential for further enhancements of this tool. NIOSH continues to seek additional candidate sites for use of the RMSS. As usage increases, we anticipate further refinements and additional applications. How It Works The new RMSS, cable, and read-out box are shown in figure l. The read-out box has a green light that stays lit until battery replacement is needed. The red light is set to conic on to indicate movement. The red light can he adjusted for increments of movement as low as .010 inches. The RMSS red light should not be considered as a primary or only means of determining the stability of roof or rib. It is intended to serve as a supplement to existing methods or procedures for determining stability. An overview of the RMSS components is shown in figure 2. Movement of rock layers within the mine roof is measured relative to a fixed-point calibration at the monitor housing. The housing contains a potentiometer, roller switch, plastic rack, and spur gear. Movements are detected by the transfer of electromotive forces

Jun 1, 2000