RISK ASSESSMENT ON THE VIDEX MECHANICAL ROOF BOLT
RISK ASSESSMENT ON THE VIDEXMECHANICAL ROOF BOLT
Contents Section 1 - Summary. . Section 2 - Objectives . Section 3 - Risk Analysis Method .
Identification the possible system hazards.
Determination of the level of risks.
Definition and description of the system controls and barriers.
Assessment of the acceptability of the controls .
Documentation of the study process and results . Section 4 - Results . Section 1 - Summary Introduction
Management of Videx Mining Products requested a risk assessment on the Mechanical Roof Bolt manufactured by the Company. The Risk Assessment Team prepared and submitted a Risk Analysis on the Videx Mechanical Roof Bolt. Key Findings
Mechanical Roof Bolts must be installed according to the mine's support and instal ation code ofpractice as well as standards.
Gloves, eye protection and foot protection should be worn while handling Bundles of Mechanical RoofBolts.
Hazard awareness training should be given to all workers who are required to handle/transportMechanical Roof Bolts.
Only trained and competent workers should handle and instal Mechanical Roof Bolts.
Mechanical Roof Bolt/s should not be used to lift up heavy equipment/machinery. but other suitableequipment should be used.
Section 2 - Objectives
The objectives of the risk assessment are as follows.
Operational Risk Analysis
To identify the potential hazards/threats, prioritise the risks associated, and highlight the controls required toeliminate and or minimise the risks related to the Videx Flexible Eyebolt and Wedge thereby ensuring allreasonable precautions are taken to either eliminate the risk of injury to the workforce, asset damage andproduction delay. Section 3 - Risk Analysis Method
The risk analysis followed the standard Risk Assessment method. All risk analyses follow a general scheme. which can be described as follows.
r nalysis (including equipment, personnel procedures work environment,
management and supervisory systems etc.).
Identify loss scenarios (i.e. sequences of events leading up to potential or actual losses i.e incidents oraccidents) in the form of hazards, potential productivity interruptions, asset damage events. environmental contamination issues etc.
Evaluate the risks of each loss scenario by determining the relative likelihood of each ever t, and therelative consequence of each event.
Evaluate the currently planned controls, barrier and safeguards.
identify additional, potential controls, barriers and safeguards.
In the current exercise, a select team of Videx Mining Products employees accomplished these steps The team followed the subsequent risk analysis framework. Defining the operational system
The exercise was scoped to review risks related to potential failure of the Mechanical Roof Bolt. To this end theMechanical Roof Bolt was broken down into component parts using the failure modes and effects and criticalityanalysis (FMECA) technique. In addition, the activity of installation of the Coupling Bolt was analysed. focussingspecifically on the Mechanical Roof Bolt and not peripheral hazards. An operational flow chart highlighting theinstallation activities was derived.
Identification the possible system hazards
This step postulated the maximum reasonable consequence of loss scenarios (i.e. of circumstances leading upto or resulting in hazards. The consequences were classified as losses to people (health & safety), productiondelays, equipment damage, and environmental damage or combinations of these losses.
Determination of the level of risks
Risks associated with each failure and step in the installation flow chart were considered. This was achieved byconsidering the event frequency or probability, and the event severity or consequence. The Videx RiskAssessment Team has established a standard ranking system that has been used on previous analyses, andhas been acknowledged by international authorities as an acceptable means of prioritising and ranking riskbased information during team exercises.
The ranking system used is described below, where:
Risk is defined as the product of probability and consequence.
Probability categories
Probability categories were defined as follows. A = C'ommon B = Has happened C = Could happen D = Not likelyE = Practically impossible
Consequence categories
Consequence categories were defined for various loss categories as follows.
Health & Safety
1 Fatal/ fatalities 2 Permanent Disability 3 Reportable Injury 4 Disabling Injury 5 No lost time injury
Risk categories
Risk categories were defined by combining the probability and consequence categories a
4 10 14 18 21 23 5 15 19 22 24 25
enotes the highest (most significant) risk, a risk score of 25 denotes t
Definition and description of the system controls and barriers
This step identified existing controls and barriers, and also considered planned and possible additional controls and barriers, which could be used to manage the operational risks. Controls and barriers i nclude engineering devices, operational methods and practices, management actions and principles, and environmental and system amendments that the team agrees appropriate to consider.
Controls were assessed for hazards with a risk rank of 1-7 ("high" risks) and for risk ranks of 8-16 ("medium" risks). "Low" risks (17-25) were also included in this exercise.
Assessment of the acceptability of the controls
The acceptability of the nominated controls in terms of design devices, management and operational practices and system amendments was reviewed by the team to ensure that additional scope for risk reduction has not been overlooked within the time available. At this stage the risk analysis team formally closed its participative exercise.
Documentation of the study process and results
The report is presented so that the mine can review t
implementation plan to incorporate additional approved controls established through the risk analysis. Analysis of logistics
The risk analysis was conducted on 20th of April 2000 at the premises of Videx Mining ro
Johannesburg with a selected risk review t
eam participating in the exercise. Participants a
Section 4 - Results
The risk analysis exercise generated a structured set of results presented in this section
Format for results
The analysis team developed a format for results based on the components of the equipment and the flow chartof installation activities.
Tables of results are presented below in the following sequence.
Component failure mode list Mechanical Roof Bolt
1. Shank (Tensile strength, Shear Stress, Chemical/ Metallurgical)
The Flow Chart Risk Assessment Of The Videx Mechanical Roof Bolt POTENTIAL HAZARD/ ACCIDENT CURRENT CONTROLS ECOMMENDED CONTROLS
1Aa) Mechanical Roof Bolts are stored in
1. Units are manufactured using 14,5mm high
adverse conditions (with corrosive chemical),
extensively, which could effect their strength
leading to local support failure causing a fall
1Ab) A bundle of Mechanical Roof Bolts are
Mechanical Roof Bolts. 2. Gloves and eye protection and footprotection should be worn while handling bundles of Mechanical Roof Bolts.
personal injury while handling them.
2. The supplier's qualified and competent instructors
Mechanical Roof Bolts. 2. Gloves and eye protection and footprotection should be worn while handling the Mechanical Roof Bolts.
1 Units are manufactured using 14.5mm high tensile
not be stored underground for longer than
acidic water), for lengthy periods of time
one (1) month before being installed.
allowing the units to rust, which could effect
proper installation, leading to local support
personal injury while handling them.
2. The supplier's qualified and competent instructors
Mechanical Roof Bolts. 2. Gloves and eye protection and footprotection should be worn while handling the Mechanical Roof Bolts. POTENTIAL HAZARD/ ACCIDENT CURRENT CONTROLS RECOMMENDED CONTROLS
1. Hazard awareness training should be given
to workers who are required to handle and
effectively done before the Mechanical Roof
Bolt is installed, leading to possiblefall of ground resulting in personal injury.
2. Adhere to Mines making safe procedure as well as all relevant Mine standards.
3a) The hole/s are not drilled to intersect all
1. Mines support and installation codes of
1. Hazard awareness training should be given
leading to a possible fall of ground resulting in
2. The supplier's qualified and competent
instructors provide initial on site job training.
2. Where possible holes should be drilled under supervision to ensure geological conditions and disturbances are intersected.
3. Random checks should be done to determine the direction of the holes.
3b) The hole/s are drilled too short and will not C
1. Mines support and installation codes of
1. The hole must be drilled to exceed the full
accommodate the full original length of the
original length of the Mechanical Roof Bolt.
Mechanical Roof Bolt resulting in failure to
2. The supplier's qualified and competent
tension the Mechanical Roof Bolt, which could
instructors provide initial on site job training.
2. If hole/s are drilled too short they should
lead to local support failure causing a fall of
ground resulting in personal injury.
3c) The diameter of the hole/s are drilled too
1. Mines support and installation codes of
1. The hole diameter is critical, the appropriate
expansion shell to be utilised for the diameter of
Mechanical Roof Bolt cannot be activated and
2. The supplier's qualified and competent
tensioned properly, which could lead to local
instructors provide initial on site job training.
support failure causing a fall of ground
2. If hole/s are drilled to incorrect diameter they
3b) While drilling the hole a piece of rock could C
1. Mines support and installation codes of
1. Hazard awareness training should be given
be dislodged or falls from either the hanging
to workers who are required to handle and
wall or the sidewall resulting in personal injury.
2. Adhere to Mines making safe procedure as well as all relevant Mine standards. POTENTIAL HAZARD/ ACCIDENT CURRENT CONTROLS RECOMMENDED CONTROLS
4a) The diameter of the drilled holes is larger
1. The supplier's qualified and competent
1. Mine should select suitable expansion shell
instructors provide initial on site job training.
which could lead to local support failure
2. Different expansion shell sizes are available
2. Drill bits to be correct size for selected
causing a fall of ground resulting in personal
4b) The hole/s are drilled too short and will not
1. Mines support and installation codes of
1. Hazard awareness training should be given
accommodate the full original length of the
to workers who are required to handle and
expansion shell Mechanical Roof Bolt, this will
2. The supplier's qualified and competent
prevent the Bolt from being tensioned as
instructors provide initial on site job training.
2. Only trained and competent workers should
designed, which could lead to local support
handle and instalI Mechanical Roof Bolts.
failure causing a fall of ground resulting in personal injury.
4c) The Mechanical Roof Bolt/s are installed
1. Mines support and installation codes of
1. Hazard awareness training should be given
without their tensioning washers (face plates),
to workers who are required to handle and
this will prevent the Bolt from being tensioned
2. The supplier's qualified and competent
as designed, which could lead to local support
instructors provide initial on site job training.
2. Only trained and competent workers should
failure causing a fall of ground resulting in
handle and instalI Mechanical Roof Bolts.
4d) The plastic sleeve is not removed from the C
1. Mines support and installation codes of
1. Hazard awareness training should be given
to workers who are required to handle and
2. The supplier's qualified and competent
tensioned as designed, which could lead to
instructors provide initial on site job training.
2. Only trained and competent workers should
local support failure causing a fall of ground
handle and instalI Mechanical Roof Bolts.
1. Mines support and installation codes of
1. A T-Spanner or tensioning tool approved by
local support failure causing a fall of ground
2. Only trained and competent workers should handle and instalI Mechanical Roof Bolts. POTENTIAL HAZARD/ ACCIDENT CURRENT CONTROLS RECOMMENDED CONTROLS
The Mechanical Roof Bolt is used to lift up
1. Mechanical Roof Bolt/s is designed to
1. Mechanical Roof Bolt/s should not be used to
lift heavy equipment/machinery, but other
cause the Mechanical Roof Bolt to break,
which could result in personal injury. Failure Mode And Effect Analysis On The Videx Mechanical Roof Bolt. COMPONENT/ FAILURE/MODE URRENT CONTROLS RECOMMENDED CONTROLS
a) Mechanical Roof Bolt/s 1. Steel suppliers conduct Mechanical and metallurgical/chemical
analysis tests on each batch of steel before delivery and issues Videx
2.Videx give the steel requirement specifications to the mill that then
manufacture the steel for Videx as per the specifications and provide
3. CSIR has conducted Tensile strength tests and issues Videx with certification thereof.
4. All certificates and test results of each batch are kept on file for future reference.
5.Mechanical Roof Bolt/s are manufactured according to ISO 9002 Quality Management procedures.
6. Mines support Code of Practice is designed to prevent Tensile strength failures. COMPONENT/ FAILURE/MODE CURRENT CONTROLS RECOMMENDED CONTROLS
1b) Shear stress failure caused by a) Mechanical Roof Bolt/s 1. Steel suppliers conduct Mechanical and metallurgical/chemical
analysis tests on each batch of steel before delivery and issues Videx
2.Videx give the steel requirement specifications to the mill that then
manufacture the steel for Videx as per the specifications and provide
3. CSIR has conducted Tensile strength tests and issues Videx with certification thereof.
4. All certificates and test results of each batch are kept on file for future reference.
5.Mechanical Roof Bolt/s are manufactured according to ISO 9002 Quality Management procedures.
6. Mines support Code of Practice is designed to prevent Tensile strength failures. COMPONENT/ FAILURE/MODE CURRENT CONTROLS RECOMMENDED CONTROLS
a) Mechanical Roof Bolt/s 1. Steel suppliers conduct Mechanical and metallurgical/chemical
analysis tests on each batch of steel before delivery and issues Videx
2.Videx give the steel requirement specifications to the mill that then
manufacture the steel for Videx as per the specifications and provide
3. CSIR has conducted Tensile strength tests and issues Videx with certification thereof.
4. All certificates and test results of each batch are kept on file for future reference.
5.Mechanical Roof Bolt/s are manufactured according to ISO 9002 Quality Management procedures.
6. Mines support Code of Practice is designed to prevent Tensile strength failures.
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RISK ASSESSMENT ON THE VIDEX