ADVERTISER PROFILE
The safest intervention in mining is the one that never happens
In mining, serious safety risks arise when unplanned and non-routine activities require intervention. When muck flow is interrupted, these situations introduce additional hazards in unpredictable and rapidly changing conditions. They can also become a significant source of operational delays.
“ Some of the biggest safety risks in
mining include working around stored energy, working at heights and ground control hazards. The potential for serious injuries or even fatalities is highest when controls are inadequate or when they fail,” says Jennifer Berger, Vice President, North America Sales Area at Normet.
A small issue that snowballs into high risks and increasing costs
One of the most common triggers behind these disruptions in muck is metal scrap – materials such as mesh, bolts, and steel that enter the process during the mining cycle.
“ As mines go deeper and rock stresses increase, we’ re installing more bolts screen and shotcrete to maintain stability,” Berger explains.“ When we blast, this ground support is damaged or completely torn out. As a result, it ends up in the muckpile along with ore and waste rock, creating downstream problems for mining operations.”
Scrap may seem minor, but if it enters the post-blast rock flow, its impact can be significant. As scrap moves through ore passes and fixed material-handling infrastructure, it can cause blockages, damage equipment and disrupt the flow.
Berger adds:“ As scrap makes its way through the material handling system, it can impact crushers, cut conveyor belts and cause hang-ups. And when that infrastructure is damaged, the result can be significant maintenance costs, downtime and lost productivity.”
If disruptions prevent mines from processing muck, they may need to store the material underground and re-handle it later. And every time mines move it again, they increase costs and reduce efficiency.
When disruption turns into a safety risk
In more severe cases, the impact extends well beyond the initial disruption.
“ Trying to catch up after losing hours, days, or even weeks is very difficult. It can impact not just daily production, but even an entire quarter. And this is not a muck circuit problem alone, as downstream processes are also affected. Crushing and processing systems are not designed to handle scrap steel, which leads to increased wear, more maintenance and sometimes complete stoppages,” Berger points out.
So, scrap can easily affect the entire muck flow, but the impact goes beyond productivity. The real danger begins when these disruptions require intervention. Clearing blockages or repairing damage means working in hazardous conditions that require risk assessments and specialised procedures.
“ Clearing blockages involves elevated risk due to changing conditions and the limited frequency of the task. Standard procedures may not fully address the increased risks involved,” Berger says.“ These situations can involve working at heights, stored energy and material that can release unpredictably.”
Preventing the problem early
The problem needs to be addressed before it escalates. Removing as much scrap as possible before it reaches grizzlies and passes, or other fixed infrastructure, becomes a critical factor in safe and efficient muck flow.
Many operations still rely on separate dedicated booms for oversized rock breaking and scrap handling, which increases the overall equipment footprint by requiring two separate systems.
“ Needing to switch between tools at the grizzly is slow, as equipment must be repositioned and tasks interrupted to alternate between scaling, picking and breaking activities. In some cases, scrap material may just be pushed through the grizzly instead of taking the time required to remove it,” Berger says.
A single-boom system equipped with interchangeable tools for both picking and breaking improves safety and operational efficiency by eliminating the need to switch between multiple machines. This streamlines material handling activities, lowers maintenance costs and simplifies operations. Having one boom with interchangeable tools makes it easier for operators to make the correct decision to remove scrap material, such as damaged rock bolts, screen and scrap, rather than forcing it through the rock handling and processing system. This promotes safer, more efficient muck flow and process stability.
“ With solutions like the Xquick quick coupler, you have access to multiple tools – such as a grapple or a magnet – and can choose the right one for the task. There is no need to switch between machines or maintain multiple pieces of equipment,” Berger explains.
The best outcomes are often invisible
When muck flows as intended and disruptions are prevented, muck flow stays on track.
“ When nothing happens, you don’ t hear about it. When everything runs as it should, you have the best possible chance of meeting your operational plans and targets,” Berger concludes.
Improving safety in mining does not rely on responding to risks but rather on eliminating them to the greatest possible extent. Preventing material flow disruptions as early as possible reduces safety risks, improves operational reliability and minimises costly downtime.
For more information visit: https:// normetxrock. com
International Mining | JUNE 2026 11