PROGRAM OF RESEARCH

A SUMMARY OF RESEARCH

IN PROGRESS DURING FISCAL YEARS 98

Gregory R. Wagner, M.D.

Acting Associate Director for Mining
CONTENTS

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Spokane Research Laboratory Organizational Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Pittsburgh Research Laboratory Organizational Chart ................................................... 3

6SRNDQH 5HVHDUFK /DERUDWRU\

Mining Injury and Disease Prevention Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Control Systems for Drilling .................................................................... 5

Safety Enhancements for Rock Scaling Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Chemical Hazards at Active Metal/Nonmetal Mines .................................................. 7

Mobile Roof Support Technology ................................................................ 8

Engineering Controls for Reducing Surface Mining Health Hazards ..................................... 9

Skeletal Modeling for Protective Mine Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Accident Reconstruction and Training for Metal/Nonmetal Mines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Injury Prevention for Metal/Nonmetal Drilling and Bolting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Hazard Reduction in Surface Mining of Sand and Gravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Hazard Reduction for Surface Mining Haulage Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Catastrophic Failure Detection and Prevention Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Slope Stability Hazard Recognition for Metal/Nonmetal Mines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Design Analysis of Ore Passes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Mine Hoist and Elevator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Mining Under Adverse Geologic Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Safe Monitoring of Engineered Backfill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Warning Systems To Reduce Traumatic Injuries in Underground Mines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Mine Deformation Monitoring for Ground Hazard Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Methods for the Prevention of Mine Roof Support Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Total Mine Safety Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Surveillance of Mine Safety Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Communications and Technology Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Pittsburgh Research Laboratory

Hearing Loss Prevention Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Quiet-by-Design Engineering Noise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Technical Assistance for Hearing Conservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Hearing Conservation Communications/Technology Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Mining Injury Prevention Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Coal-Rock Interface Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Control Circuit Safety Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Control Systems for Mobile Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Operator Interfaces for Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Navigation and Guidance Systems for Mobile Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Equipment Safety Analysis Using Computer Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Human Factors of Extended-Cut Mining and Other Underground Coal Extraction Methods . . . . . . . . . . . . . . . . . . . 35

Human Factors Design for Machinery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Systems Approach To Reduce Manual Task Injuries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Intrinsic Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Geological Hazard Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Fire-Fighting Skills and Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Effective Emergency Warning, Escape, and Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Preventing Falls in Mining and Related Industries: A Systems Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CONTENTS—Continued

3DJH

Hazard Reduction for Surface Mining Powered Haulage Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Elevator Ascending Overspeed Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Wire Rope Hoisting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Maintenance Safety for Electric Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Electric Shock Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Circuit Protection—Underground Mining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Improved Safety for Small Mines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Worker Safety for Independent Contractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Hazard Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Disaster Prevention and Response Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Lightning Strike Hazard Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Analysis of the Impact of Extended-Cut Mining on Ground Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Evaluation of Highwall Stability Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Design of Mine Roof Support Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Innovative Geologic and Engineering Techniques To Reduce the Incidence of Mountain Bumps . . . . . . . . . . . . . . . 54

Ground Control for Pillar Extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Mitigating Ground Fall Hazards in the Stone Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Innovative Support Technologies for Gate Road and Bleeder Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Remote Methane Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Characterization and Mitigation of Mine Gas Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Toxic Fumes From Explosives and Blasting Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Seals for Explosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Safety of Waste Oil in Explosives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Malfunction of Explosives in Delay Blasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Detonator Transport Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Explosion Prevention and Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Mine Fire Detection Strategies and Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Mine Fire Preparedness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Prevention and Extinguishment of Mine Fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Effect of Airflow on Fighting Mine Fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Life Support: Survival and Mine Rescue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Lake Lynn Laboratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Multiple-Seam Technology Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Dust and Toxic Substance Control Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Influence of Coal Seam Properties on Dust Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Controlling Respirable Silica Dust During Underground Mining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Improving Dust Control Technology for Longwall Mining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Control of Respirable Dust in Noncoal Mines and Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Control of Silica Dust in Underground Metal/Nonmetal Mines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Surface Mine Dust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Improved Application and Monitoring of Dust Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Personal Dust Dosimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Methane Assessment in Auger Highwall Mining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Extended-Cut Air Delivery Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Effects of Airflow on Escaping Mine Fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Diesel Engine Emission Measurement and Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Respirable Dust Measurement and Analysis (Instrumentation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Surveillance, Statistics, and Research Support Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Extramural Coordination and Information Dissemination Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Directory of Project Personnel: Spokane Research Laboratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Directory of Project Personnel: Pittsburgh Research Laboratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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5

MINING INJURY AND DISEASE PREVENTION BRANCH

Control Systems for Drilling

Principal Investigators: Greg G. Miller, Wayne L. Howie,

Walter K. Utt, and Carl B. Sunderman

RESEARCH OBJECTIVES

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RESULTS TO DATE

Roof Strata Characterization

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Relocating roof bolter operators away from hazards using artificial intelligence.

Safety Enhancements for Rock Scaling

Personnel

Principal Investigator: Art Miller

RESEARCH OBJECTIVES

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Phase I. Problem Assessment

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7

Demonstrating the technical feasibility of a pneumatic scaling tool.

The obvious hazards of scaling loose rock.

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Phase II. Design Concepts for Safer Methods and

Equipment

• The technical feasibility of using a handheld, pneumatic tool

for rock scaling was demonstrated. The vertical wall of a

fractured basalt formation was scaled using an off-the-shelf

pneumatic scraping tool. Although a scaling bar is lighter

and more maneuverable, the pneumatic tool penetrated

fractures without the need to use the jabbing motion often

required to remove rock with the bar.

• A prototype scaler modeled after the pneumatic tool was

constructed. The tool was designed to minimize weight,

maximize reach, and allow chisel bits to be changed easily.

Chemical Hazards at Active Metal/Nonmetal

Mines

Principal Investigators: Pamela L. Drake and Russell L.

Levens

RESEARCH OBJECTIVES

To investigate and evaluate potential chemical hazards in

mining workplaces to enable development of control or

mitigation methods.

PROBLEM STATEMENT

Exposure to metals and organic chemicals in mining workplaces, in particular, milling and refining facilities, may

adversely affect thousands of workers. As one example, mercury is a hazardous metal associated with gold and silver in

many ore deposits in the Western United States. Mercury persists during processing and refining because the chemical

complexing and adsorption characteristics of mercury, silver,

and gold are similar. Silver is another metal to which refinery

workers are exposed. The potential for exposure to mercury

and silver is expected to depend on mercury and silver

concentrations in the ore, the processing steps employed at each

mine, and the engineering controls implemented to protect the

workers.
8

 Project personnel conducting spot checks for mercury vapor

during a pour of molten slag.

RESULTS TO DATE

Exposure to mercury vapor and silver dust and fumes are the

focus of this project. Site surveys have been conducted at two

gold and silver mines in Nevada. Air samples from “personal Recent years have seen a resurgence in pillar extraction in

breathing zones” and surrounding work areas were collected in underground coal mines where MRSs are being used for

the refineries and Merrill-Crowe processing facilities to detect support instead of posts. Approximately 40 U.S. coal mines

excessive exposures, if any, and to identify potential sources of have adopted this emerging new technology. It is estimated by

mercury and silver. Air velocity measurements were taken on major manufacturers that there will be 150 machines in

exhaust ventilation systems at the refineries with the purpose of operation by the end of 1998. With the increase in the number

assessing their effectiveness and making recommendations for of MRSs, MSHA has received requests to approve roof control

design changes where needed. The preliminary results from plans that involve novel approaches to the use of these mathese surveys have been forwarded to the participating mines. chines. MSHA does not have the technical information needed

Two alternate designs for ventilation hoods for the refinery at to approve these plans, nor is agency approval consistent from

one site were completed. The new hood designs were presented one subdistrict to another. As a result, MSHA requested that

to mine personnel as a relatively inexpensive means of reducing research be performed to (1) develop an understanding of how

worker exposures to silver during the ingot cleaning process. these machines interact with mine strata and provide support

An overview of the Chemical Hazards project was presented to during coal extraction and (2) acquire the data needed to

the Health and Safety Committee of the Nevada Mining develop guidelines for the safe use of MRSs. Topics of concern

Association in June 1997 in Winnemucca, NV. include optimum setting pressure, critical loading rates that

Mobile Roof Support Technology

Principal Investigators: John K. Owens and Wayne L.

Howie

RESEARCH OBJECTIVES

To assess how loading on mobile roof supports (MRSs) can

be used to indicate impending roof failure and to provide data

that MSHA can use to improve safety in retreat mining

operations utilizing MRSs.

PROBLEM STATEMENT

could signify imminent failure of the mine roof, and optimum

location of MRSs during specific operations.

Another problem that has arisen with the use of MRSs is the

lack of a warning system that would alert miners to dangerous

ground conditions. In the past, post and cap noises, displacement, and failure allowed miners to “read” unstable

ground, but with the increasing use of MRSs, such an early

warning system is no longer available. Thus, during the

investigation of a fatality that occurred in a mine section using

MRSs, the West Virginia Board of Coal Mine Health and Safety

requested that research be performed to determine the feasibility

of developing a warning system for MRSs that would alert

miners to unstable ground conditions during pillar removal so

that miners and equipment could be removed before a fall

occurs.

RESULTS TO DATE

The most significant result has been the development of a

load rate monitoring (warning) system for MRSs. Spokane

Research Laboratory studies at room-and-pillar retreat

operations have shown that the loading rate on an MRS is

critical to the safe use of these machines and can be used as an

aid in determining when it is appropriate to remove miners and

equipment from an area. The system uses an embedded

processor that can monitor either the pressure inside the four

hydraulic jacks of the MRS or strain in the hydraulic cylinder

walls to determine loading on the MRS. The embedded

processor reads changes in cylinder pressure or strain in the

cylinder walls through four multiplexed data acquisition

channels. It then converts these pressure or strain changes to

loading rates, which in turn activates green, amber, or red

warning lights mounted on the MRS. Each light represents a
9

Components of load rate monitoring system.

Mobile roof support in the laboratory.

different loading rate on the machine. A strobe light also

flashes when the yield pressure of the hydraulic cylinders is

reached, and an alarm sounds at high loading rates. A computer

program was also developed that allows for easy in-mine

adjustment of loading rates based on the geologic and

geotechnical conditions present at the mine. 

A prototype system was tested on a Fletcher MRS threestage cylinder at the Pittsburgh Research Laboratory using its

mine roof simulator loading frame. The system performed as

designed, with rapid response time to changing load rates. The

tests showed that the most accurate MRS loading data were

obtained by strain gages attached to the wall of the top stage

cylinder. Because of the success of the testing at Pittsburgh, a

field-ready MSHA-permissible loading rate monitoring system

was fabricated. The system will be sent to Triadelphia, WV,

early in FY98 for MSHA permissibility tests and approval.

Plans are to test the system at mines having the range of

conditions typically found where MRSs are used to develop a

protocol on how to use the system as a tool for alerting miners

about dangerous conditions during pillar removal and to collect

the data needed to develop guidelines for the safe use of MRSs.

 Project updates have been given periodically to MSHA and

members of the West Virginia Board of Coal Mine Health and

Safety. MRS manufacturers are actively participating in the

research by supplying the machines and multistage hydraulic

cylinders to test the system, furnishing blueprints of their

machines, assisting in system installation, and locating mine

sites at which to test the system.

BIBLIOGRAPHY

Owens, J.K.

 Field Study of Mobile Roof Supports. Presentation at

technology transfer seminars on New Technology for Ground

Control in Retreat Mining (Norton, VA, April 8, and Pikeville,

KY, April 10, 1997). 10 pp.

Engineering Controls for Reducing Surface

Mining Health Hazards

Principal Investigators: Fred R. Biggs and Richard Miller

RESEARCH OBJECTIVES

To devise and promote the use of engineering controls in

metal/nonmetal surface mines to eliminate or minimize health

hazards related to dust, noise, diesel emissions, jarring and

jolting, and blasting agents.

PROBLEM STATEMENT

Engineering control technologies can be applied to

metal/nonmetal surface mine environments to eliminate or

minimize long-term health hazards. For example, equipment

noise in mining environments is pervasive. In the past few

years, there have been significant developments in noise

attenuation and active noise cancellation technology that could

be applied to mining environments. Another example is worker

exposure to respirable crystalline silica, which has prompted

MSHA to propose a rule regulating miner exposure to this

health hazard. A third example is related to back injuries and

multiple sprains and strains; between 1986 and 1995, 35% of

the lost-time injuries in surface haulage were back injuries

caused by jarring and jolting. Spokane Research Laboratory

personnel’s engineering expertise can be applied to
10

MTS IMPACT test machine.

 Average noise exposure in decibels per year for a churn drill

operator. The use of engineering controls is one approach to

reducing noise exposure in mines.

characterizing jolting and jarring on mining equipment through

bench and field testing and isolating those elements that could

lessen shock loads to equipment operators.

RESULTS TO DATE

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Skeletal Modeling for Protective Mine Gear

Principal Investigator: Marc T. Filigenzi

RESEARCH OBJECTIVES

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Principal Investigators: Robert McKibbin, Greg Miller,

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Miller

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Hazard Reduction in Surface Mining of Sand

and Gravel

Principal Investigator: C. M. K. Boldt

RESEARCH OBJECTIVES

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13

 Doppler radar backup alarm being tested on 240-ton class mining

truck.

Hazard Reduction for Surface Mining Haulage

Equipment

Principal Investigators: Ron Backer and C. M. K. Boldt

RESEARCH OBJECTIVES

To investigate, evaluate, and develop technological tools to

reduce haulage-related accidents and injuries at surface coal and

metal/nonmetal mines.

PROBLEM STATEMENT

In the past 5 years, powered haulage accounted for 43% of

the fatalities in surface mines and was among the top five a tendency to generate false alarms. Efforts to identify and

sources of injuries. Limited visibility from the large trucks was customize proximity warning systems for surface mine haulage

cited as a major cause of these accidents. vehicles will continue. It was determined that special mirror-type

Accidents and injuries can be reduced by improving ways to systems (Fresnel lenses) are no longer available from any source.

recognize hazards, providing restraint devices for operators of Video cameras are being installed on some trucks as an accessory

haulage trucks, finding better ways to enter and leave the to mirrors and backup alarms on large trucks. Problems asequipment, and providing feedback to operators when driving. sociated with camera use include in-cab monitors that are difficult

Equipment manufacturers are working to incorporate alarms, to view because they are not clear enough and they do not have

improve vision, and improve ergonomics on large pieces of enough resolution to distinguish what is being viewed. Also,

equipment. Other approaches involve the development of existing camera lenses are not capable of staying clean under the

remote-controlled or autonomous vehicles for specific, ex- dirty conditions associated with mining. 

tremely hazardous, repetitive, or simple tasks. Improvements Studies of the effects of jarring and jolting on the operators

in sensing technology, such as radio frequency, radar, laser, and of large haulage trucks were initiated. Work will concentrate on

infrared devices, offer another opportunity to introduce tech- developing instrument packages to evaluate the impacts of such

nological improvements to vehicle operation and/or control. shocks. The instruments were tested on an MTS machine in the

There is little in the literature quantifying costs associated laboratory and then installed on several service vehicles. A

with various methods of truck dumping procedures (end- mine has agreed in principle to cooperate in this research. The

dumping materials over a spoil pile versus dumping and next step is to install the instruments on trucks of various

bulldozing the materials over a dump edge). The latter pro- sizes so that they can be tested under conditions of loading,

cedure is considered safer, but it is intuitively more expensive hauling, and dumping in operating mines.

because it requires a bulldozer and its operator in addition to

haulage trucks and drivers. However, intuition may be misleading because a bulldozer and operator may already be

spending time on the dump constructing dumping berms.

Knowing what is actually involved in various procedures would

give safety professionals a more measurable means of

evaluating the true costs of an activity and incorporating safety.

RESULTS TO DATE

The project addresses three issues: hazard recognition,

operator safety, and the economics of safety. Project personnel

participated on an MSHA-sponsored task force of industry and

equipment representatives chartered to improve the safety of

large, off-road haulage trucks used in surface mines. Brochures

describing the best practices for 11 different problems have

been developed as training handouts. In addition, researchers

reviewed and provided input on two MSHA training videos

dealing with stockpiles and waste piles.

The hazard recognition task included an evaluation of warning devices that could alert a driver to obstacles that could be

run into or run over, mirrors and/or Fresnel lenses that could

improve operator vision, and video cameras and monitors.

Available proximity warning devices (Doppler radar and radio

frequency tags) have operating characteristics that do not quite

meet the requirements of mining haulage trucks at surface mines.

Only two manufacturers of the Doppler radar devices could be

found in the United States, and only one of these devices

demonstrated reasonable performance. Radio frequency technology shows promise, but current systems are too expensive and do

not have the range or coverage desired for large haulage trucks

with their many blind areas. In field tests, the Doppler radar

alarms were found to be difficult to mount, adjust, and aim, with
14

 Truck buried in highwall failure that resulted in one fatality and

one nonfatal injury.

Economic studies of various dumping practices (enddumping versus short-dumping) have been initiated. This work

is being coordinated with the Pittsburgh Research Laboratory.

End-dumping materials over a spoil pile exposes the driver to

greater danger than dumping and bulldozing the materials over

a dump edge. Some operators may be reluctant to switch from

end-dumping because they feel short-dumping is more costly.

Results from this study will define the costs and benefits of

modifying current dumping practices.

BIBLIOGRAPHY

Boldt, C.M.K., and R.R. Backer.

Surface Mine Truck Haul Safety—Where Are We?

Presentation at the 28th Annual Institute on Mining Health,

Safety, and Research. Aug. 25-28, 1997.

CATASTROPHIC FAILURE DETECTION AND PREVENTION BRANCH

Slope Stability Hazard Recognition for Metal/

Nonmetal Mines

Principal Investigators: Jami M. Girard, Russ Levens, Ron

Mayerle, Ed McHugh, and Mark Larson

RESEARCH OBJECTIVES

To minimize hazards associated with unstable mine slopes

through an aggressive approach involving research on engineering controls, geotechnical design, advanced monitoring

equipment, computer models, and hydrogeologic conditions.

PROBLEM STATEMENT

Whether underground or on the surface, unanticipated rock

movements create the potential for a mine catastrophe.

Through the first three quarters of 1997, separate accidents have

claimed the lives of two miners because of falls of highwalls at

open-pit mines in the United States. Between 1992 and 1996,

nearly 14% of surface mine fatalities were related to slope

failures. In addition, a comparative study of fatal and nonfatal

accidents over the last 5 years indicated that slope failure

accidents in surface mines were 12 to 30 times more likely to

result in fatalities than other types of accidents in these mines.

With U.S. surface mine production reaching new highs in States

such as Nevada and Arizona, the potential for surface-minerelated accidents is likely to increase. This project at NIOSH’s

Spokane Research Laboratory was initiated early in 1997 with

an objective of reducing injury and fatality incidence rates

associated with slope failures.

There are four types of slopes that may fail at an open-pit

mine—highwalls, dumps, stockpiles, and tailings embankments.

An understanding of slope failures related to mining and the

technology available to prevent these types of failures will assist

engineers in designing the best preventive measures for unstable

ground. Better design and control of slopes will reduce the

number of fatalities and injuries. Results of this research can be

transferred to a number of other engineering situations,

including the design of roadcuts, railroad beds, canals, refuse

disposal sites, and earth dams, as well as landslide control.

RESULTS TO DATE

Project personnel have visited a number of surface mine

operations to observe current slope control practices and solicit

input from mine geotechnical engineers. A database of

documented slope failures and back-analysis information has

been created. Several potential new technologies for slope

monitoring and design have been selected for further research.

BIBLIOGRAPHY

Overview of Surface Mining Research at Spokane Research

Center, presented by F. Michael Jenkins at the Pacific

Northwest Metals and Minerals Conference, Spokane, WA,

April 24-25, 1997.
15

 Conducting field test on ore pass chute and

gate assembly.

Design Analysis of Ore Passes

Principal Investigators: Michael J. Beus and Bill Stewart

RESEARCH OBJECTIVES

To improve ore pass design criteria to prevent hangups and

structural failure and provide enabling technology for detecting

and remediating blockages in ore passes in hard-rock mines.

PROBLEM STATEMENT

The ore pass design project seeks to develop safer mine ore

passes and ore pass structures. Current work is focused on

particle flow computer analyses and the installation of sensors

on ore pass chute and control gate assemblies. This work will

enable researchers to determine actual static and dynamic loads

that cause structural failure.

RESULTS TO DATE

Safety analyses and surveillance studies are ongoing.

Accidents related to ore passes are being identified, and a

method to determine the extent of miner exposure to ore pass

hazards is being developed. Field surveys have been conducted

at five large underground metal mines in four States to assess

the scope of existing and potential safety problems around ore

passes. These surveys also helped in refining a fault-tree

analysis that allowed the project team to focus its research and

identify cause-and-effect relationships of which they had

previously been unaware.

Construction of a full-scale mockup of an actual ore chute

support structure was completed to test a new approach for

determining loads on ore pass gates. Strain gages were installed

on the support bolts, and hydraulic jacks are being used to apply

test loads. Procurement, assembly, and debugging of data

acquisition systems to take static and dynamic measurements

have also been completed. Closed-form calculations for

dynamic forces have been validated by ball-and-beam drop

tests. Test problems incorporating a computer program using

the particle flow codes PFC and PFC have been developed. 2d 3d

A one-third-scale ore pass, storage bin, and chute and gate

assembly have been designed and are currently under

construction. Prototype sensors for the one-third-scale chute

and gate assembly have been built, and tests of the design are

underway.

A field test was completed on an ore pass chute and gate

system at the Lucky Friday Mine in northern Idaho. Thirty-two

weldable strain gages were installed on the eight support bolts

from which the chute and control gate are suspended. Tensile

strains were averaged to obtain a measurement of the total

vertical force acting on the structure as material was dumped

into the ore pass. Fourteen loads averaging 5,000 to 6,000 lb of

material each were dumped from a load-haul-dump (LHD) unit

into the ore pass. Preliminary analyses indicate that dynamic

loads were reduced significantly by offsetting the chute and

control gate support structure from directly below the dump

point at the top of the ore pass. This allowed a cushion of

material to pile up at the base of the ore pass and absorb the

initial impacts from the leading edge of the falling column of

material. The data also show that energy losses from collisions

among particles and between particles and the walls are

considerable, resulting in much lower impact forces than

predicted by theory. Static loads were in line with predictions.

Tests are continuing at the mine to refine the approach and

validate the particle flow computer models.

BIBLIOGRAPHY

Beus, M.J.

Sensor-Enhanced Test Platform Will Refine Safety Measures

in Underground Mines. Research and Development, Sensors,

The Journal of Applied Sensor Technology, Vol. 14, No. 8,

1997, p. 14.

Stewart, B.M.

Poster session presented at the National Occupational Injury

Research Symposium, Morgantown, WV, Oct. 15-17, 1997.

Mine Hoist and Elevator Safety
16

Shaft conveyance monitoring system.

Principal Investigator: Michael J. Beus 

RESEARCH OBJECTIVES

To improve the safety of hoist and elevator operations by

using sensor and computer technology to increase the amount

of information and efficiency of information flow available to

hoist operators and inspectors.

PROBLEM STATEMENT

This project was initiated at the request of MSHA because of

increasing concern about hoist and elevator safety.

RESULTS TO DATE

A state-of-the-art hoisting and ore pass research facility has

been constructed. This facility will allow assessment of mine

hoisting and elevator safety and control systems, including

hoisting machinery (hoist room controls, motors and gear

boxes, and winders) and shaft infrastructure (support

frameworks, guides, wire ropes, and skips and cages). Sensors

and real-time data acquisition interfaces to monitor hoisting

operations have been developed. Limit switches have been

designed and will be installed on the hoist headframe and in the

loading pocket. A Windows-based program called Wonderware

and a flat panel touch-screen monitor are used for process

control and automation. A “flex-beam” load cell has been

developed to measure rope tension and is being patented. These

systems allow personnel to assess critical hoist operating

parameters, such as hoist position, speed, and acceleration;

conveyance loads; rope tension; and shaft guide alignments.

This newly developed conveyance load sensor and data

transmission scheme will advance hoist and conveyance

monitoring.

Validation of various data protocols is complete. A

computer program written in Visual C++, called “On-board,”

has been developed for data collection and visualization on a

stand-alone process screen that can be used with laptop or

handheld computers.

Further integration of a customized signal processing board

to minimize size and increase transmission speed is underway.

In-shaft charging methods and modification of modems to

transmit voice and data will be designed and tested. Ways to

integrate conveyance monitoring data into the hoist room

computer at the test facility are being studied.

Field tests were completed in deep shafts in the Sunshine and

Lucky Friday Mines to test wireless transmission methods for

monitoring mine shaft conveyances. One shaft is a 5,000-ftdeep escape shaft and has two 5-ft-square hoisting

compartments with timber lagging. The other shaft is a

concrete-lined, 6,000-ft-deep production shaft. It is 21 ft in

diameter with steel sets. Error-free transmission was achieved

in both shafts from a depth of approximately 1,900 ft. It is

anticipated that distances can be improved by the use of

repeaters and better antennas.
17

 Skip inside headframe at test facility. See diagram

above for location of data acquisition equipment.

 Breakout of borehole walls indicates high stress

and elevated ground control safety hazards.

BIBLIOGRAPHY

Beus, M.J., and T.M. Ruff. 

Development of a Mine Hoist and Ore Pass Research

Facility. NIOSH Report of Investigations 9637, 1997, 12 pp.

Beus, M.J., and T.M. Ruff.

Development of a Research Facility To Improve Mine

Hoisting and Ore Pass Safety. Technology News 458, May

1997, 2 pp.

Beus, M.J., T.M. Ruff, and W.G. McCoy.

Conveyance Monitoring To Improve Mine Hoisting Safety.

Paper in Conference Record of the 1997 IEEE Industry

Applications Conference, Thirty-Second IAS Annual Meeting

(New Orleans, LA, Oct. 5-9, 1997). Vol. 3, pp. 2091-2098.

Mining Under Adverse Geologic Conditions

Principal Investigators: Jeffrey K. Whyatt, Jami M. Girard,

Brian G. White, and Timothy J. Orr

RESEARCH OBJECTIVES

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18

Prototype of video borescope.

RESULTS TO DATE

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19

 Mining through backfilled cross-panel and entry pillars in the

 8-Right longwall panel at the Foidel Creek Mine.

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Safe Monitoring of Engineered Backfill

Principal Investigators: J. B. Seymour, D.R. Tesarik, and

T.J. Williams

RESEARCH OBJECTIVES

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Warning Systems To Reduce Traumatic Injuries in Underground Mines

Principal Investigator: Todd Ruff

RESEARCH OBJECTIVES

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Mine Roof Evaluation Sensor

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21

 The collision avoidance sensor is mounted on a frontend loader while the tag is worn on the pedestrian

worker’s belt.

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0,51

Navigation and Warning Aids for Mobile Equipment

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The scope of this task has been limited to one particular

problem area because of limited funds. Rock bursts in the

Coeur d’Alene Mining District raise concerns for the safety of

miners, especially as mines reach deeper levels in the earth. A

system is being tested to provide instantaneous information

about a rock burst, including its location, so that rescue personnel can be sent to the area immediately and assist workers

who might have been injured. The first phase of this project has

been to determine the most effective means of detecting and

locating a rock burst in a stope. Three sensors were tested,

including an air velocity gauge to detect the air blast from a

rock burst, a dust sensor, and an accelerometer that measures

localized vibrations. The past year has been spent evaluating

the effectiveness of each sensor. The dust sensor has proven to

be the most reliable; however, one drawback is that, because the

time it takes for the ventilation system to blow dust past the

sensor after a rock burst, the signal is delayed. An alarm system

was built based on the dust sensor and will be tested during the

next fiscal year. Other sensors will also be evaluated.

Mine Deformation Monitoring for Ground

Hazard Assessment

Principal Investigators: Peter Swanson, Mark Larson, and

Doug Scott

RESEARCH OBJECTIVES

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22

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hazard reduction.

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23

Methods for the Prevention of Mine Roof

Support Failure

Principal Investigator: Steve Signer

RESEARCH OBJECTIVES

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Total Mine Safety Systems

Principal Investigators: Tom Brady and Jeff Whyatt

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25

Taking manual extensometer readings of displacement in

an underground mine to evaluate pillar stability.

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BIBLIOGRAPHY

 Filigenzi, Marc T.

 Simplified Pre- and Post-Processing Technique for Performing Finite-Element Analysis of Deep Underground Mining. In

Proceedings of 16th International Conference on Ground Control in Mining, ed. by S.S. Peng and C.T. Holland (Morgantown, WV, Aug. 5-7, 1997), pp. 320-328.

SURVEILLANCE OF MINE SAFETY HAZARDS

Surveillance Team: Chuck Kerkering, Denise Rains, Eric PROBLEM STATEMENT

Zahl, John Norberg, Ted Lowe, Tom Brady, Russell

Levens, Carolyn Takeuchi, and Fred Biggs

RESEARCH OBJECTIVES

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27

 Teachers on tour in a deep underground mine

in northern Idaho during a session of the

Northwest Natural Resources Teacher’s

Workshop.

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Council, Health Improvement Partnership, Partnership for

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Resources Festival. Employees provided educational opportunities at “outdoor education days” at Camp Reed and Camp

Spaulding, Riverside High School’s Career Day, Bear Lake

Outdoor Education Day, and Tekoa Natural Resources Camp.

More than 3,600 students were reached during these activities.
28

PITTSBURGH RESEARCH LABORATORY

HEARING LOSS PREVENTION BRANCH

Quiet-by-Design Engineering Noise Control

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Technical Assistance for Hearing

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29

Conducting an acoustical survey in a silica plant.

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30

Schematic of infrared-based, coal-rock interface detection system.

MINING INJURY PREVENTION BRANCH

Coal-Rock Interface Detection Systems

Principal Investigator: Gary L. Mowrey

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31

Control Circuit Safety Analysis

Principal Investigator: John J. Sammarco

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Control Systems for Mobile Equipment

Principal Investigators: Chris Jobes, William Monaghan,

Tim Lutz, Tim Matty, and William Schiffbauer

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33

Control of a cutter from a remote location.

Graphical operator interface for machine control.

Operator Interfaces for Remote Control

Principal Investigators: Ed Fries, Chris Jobes, and George

Schnakenberg

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 Awkward postures adopted in the performance of mining tasks

may lead to increased risk of musculoskeletal injury.

BIBLIOGRAPHY RESULTS TO DATE

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Injuries

Principal Investigator: Sean Gallagher 

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Principal Investigator: William K. McKewan

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48

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monitored in the field tests.

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Maintenance Safety for Electric Motors

Principal Investigator: Gerald T. Homce

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Electric Shock Prevention

Principal Investigators: Gerald Homce and Peter Kovalchik

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Work on overhead line hazards this year has included data

collection and preliminary data analysis. Detailed accident

investigation reports have been obtained for 75 overhead line

contacts that occurred at mining operations between 1980 and

1996. Initial analysis has shown that about two-thirds of these

contacts occurred in noncoal mines. Direct worker contact was

the most common factor, followed by crane operation.

Four separate dynamic tests using an optical time domain

reflectometer were conducted to measure the temperature of

electrical conductors in a mine trailing cable.

Circuit Protection—Underground Mining

Principal Investigator: Michael R. Yenchek

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Improved Safety for Small Mines

Principal Investigator: Robert F. Randolph

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Fowkes

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 Frequency of lone lightning strikes fits a power function extremely well.

DISASTER PREVENTION AND RESPONSE BRANCH

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Principal Investigator: Dennis Dolinar

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Innovative Support Technologies for Gate

Road and Bleeder Entries

Principal Investigators: Thomas Barczak and Gregory J.

Molinda

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Remote Methane Measurements 

Principal Investigator: C.D. Litton

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 Remote optical methanometer evaluated at the Pittsburgh

Research Laboratory.

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BIBLIOGRAPHY

Franks, R.A., J.J. Opferman, G.F. Friel, and J.C. Edwards.

A Second-Generation Remote Optical Methanometer.

NIOSH Report of Investigations 9640, May 1997, 9 pp.

Franks, R.A., J.J. Opferman, G.F. Friel, and J.C. Edwards.

A Second-Generation Remote Optical Methanometer. Paper

in Proceedings of the 43rd International Intrumentation

Symposium (Orlando, FL, May 4-8, 1997), pp. 527-536.

Characterization and Mitigation of Mine Gas

Emissions

Principal Investigators: W.P. Diamond and Steven J.

Schatzel

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61

 Installation of an automated gas sampler in an instrument

housing at a bleeder fan site. Tracer gas (SF ) released dur 6 ing a

field study migrates through inaccessible workings and is monitored

at all potential migratory pathways by the sampler unit.

R&D 100 Award

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Toxic Fumes From Explosives and Blasting

Agents

Principal Investigator: Richard J. Mainiero

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 Test chamber constructed in PRL’s Experimental Mine for

measuring toxic fumes from blasting agents.

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Seals for Explosion Control

Principal Investigator: Eric S. Weiss

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 Full-scale, reinforced cementitious seal instrumented with transducers and accelerometers to

measure displacement of the seal during an

explosion.

ANFO samples used in thermal stability tests.

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Safety of Waste Oil in Explosives

Principal Investigators: Thomas Ruhe and T.S. Bajpayee

RESEARCH OBJECTIVES

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62

 Rift compression fixtures for ranking ruggedness of explosives

and detonators.

Malfunction of Explosives in Delay Blasting

Principal Investigator: Michael S. Wieland

RESEARCH OBJECTIVES

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(QJLQHHUV/#&OHYHODQG/#2+/#SS1#54405541

Detonator Transport Containers

Principal Investigator: Lon Santis

RESEARCH OBJECTIVES

To establish guidelines for evaluating the safety of detonator

container boxes on mining vehicles.

PROBLEM STATEMENT

Over 4 billion lb of explosives are transported over U.S.

public highways (often in quantities in tens of thousands of

pounds) to mines and construction sites each year. A separate

container is needed when detonators and explosives are transported on the same vehicle to prevent the inadvertent initiation

of a detonator so that it does not set off the entire explosive

load. However, nine mixed-load fire incidents resulted in four

mass detonations on public highways since 1977. The mining

laws on this situation are inconsistent and poorly defined and

were developed without tests or consideration of fire hazards.

Researchers on this project seek to quantify how much

protection the mining standards for hardwood offer. They will

also examine other barrier materials, including composite

materials. MSHA will use the results of this study to clarify and

possibly revise its ambiguous legal mandate. The Institute of

Makers of Explosives is also considering revising its standard

for public highways after NIOSH suggested safety improvements based on test observations.
63

 A detonator is sent skyward and a 25-ft-tall fireball erupts

during a test.

RESULTS TO DATE PROBLEM STATEMENT

Sixteen detonator boxes were tested in bonfires. Eight

thermocouples were used to monitor each test, and each test was

recorded on video. Barrier tests on various laminated and

hardwood partitions have been completed and will be reported

in FY98.

BIBLIOGRAPHY

Santis, L.D.

Fire Protection Provided by Detonator Containers. Presentation at 23rd annual conference on Explosives and Blasting

Technique, Las Vegas, NV, Feb. 2-5, 1997.

Explosion Prevention and Suppression

Principal Investigator: Kenneth L. Cashdollar

RESEARCH OBJECTIVES

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64

 Dust explosion in PRL’s 20-liter laboratory

chamber.

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338306:6;,1

Mine Fire Detection Strategies and

Technology

Principal Investigator: J. C. Edwards

RESEARCH OBJECTIVES

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65

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66

In-mine diesel fuel fire.

 Mine rescue team member wearing the

Carins Iris thermal-imaging camera.

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Mine Fire Preparedness

Principal Investigator: Ronald Conti

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Fire suppression facility at Lake Lynn Laboratory.

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Effect of Airflow on Fighting Mine Fires

Principal Investigator: C.D. Litton

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Principal Investigator: John Kovac

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Inspecting SCSRs for long-term performance in the field.

Lake Lynn Laboratory

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72

 Effect of dry air loss moisture in coal on both dust cloud electrostatic field and airborne respirable dust.

DUST AND TOXIC SUBSTANCE CONTROL BRANCH

Influence of Coal Seam Properties on Dust

Generation

Principal Investigators: John A. Organiscak and Jeff Listak

RESEARCH OBJECTIVES

To determine the effects of coal seam composition on airborne respirable dust generation and to evaluate the rock matrix

petrographically to determine the effects of grain size and

shape, degree of cementation, and mineral composition on the

generation of airborne respirable silica dust.

PROBLEM STATEMENT

About 120,000 miners are employed in the U.S. coal mining

industry and are potentially exposed to airborne respirable coal

dust. NIOSH’s Coal Worker’s X-Ray Surveillance program

showed that at the current coal mine dust standard of 2.0 mg/m ,3

the prevalence of pneumoconiosis among coal workers at the

category 2 level or greater was 10% for workers with 30 years

of exposure. A NIOSH criteria document recommended that

the dust standard be reduced to 1 mg/m . Prior research shows 3

that underground airborne dust generation is correlated to coal

seam type. Understanding the effects of coal seam and rock

composition on respirable dust generation could identify new

avenues for suppressing coal mine dust.

RESULTS TO DATE

In laboratory experiments, five ranks of bituminous coals

were crushed to study the various factors influencing airborne

respirable coal dust generation. The results of these experiments indicate that a combination of several factors is associated with the generation of airborne respirable dust (ARD).

The most likely factors are (1) the coal rank, which affects the

amount of coal dust particles in the product, and (2) the effect

of air dry loss moisture in the coal seam on the electrostatic

charge in the dust cloud. The resultant effect of these factors is

that different percentages of coal particles <10 μm are dispersed

as airborne respirable dust. The higher ranked bituminous coals

from the eastern regions of the United States produced more

dust particles, greater electrostatic fields in the dust cloud, and

lower percentages of airborne respirable dust per amount of

<10-μm particles in the fines than the lower ranked coals of

western regions. Future research should focus on determining

if coal dust charging properties can be exploited by using

surfactants to improve water spray dust suppression and if

pneumoconiosis is in part influenced by the greater dustcharging properties of higher ranked coals.

Five different shale samples and one sandstone sample were

also crushed during laboratory experiments to study the various

factors influencing airborne silica dust generation. The results

from these experiments show that the proportion of silica in the

rock material is not indicative of the proportion of silica present

in the dust generated. The amount of silica dust generated in

the laboratory seemed to be more related to the compressive

strength of the rock. Notable inconsistencies in the amount and

size distribution of silica dust generated by the roll-crushing

apparatus and continuous mining machines in the field indicate

differences in the rock-breaking mechanisms of these two

machines. Extracting rock with a continuous mining machine

is postulated to involve more grinding than the roll crusher

apparatus.
73

 Proper positioning of the operator can control exposure to

respirable silica dust.

Controlling Respirable Silica Dust During

Underground Mining

Principal Investigator: Gerrit V.R. Goodman

RESEARCH OBJECTIVES

To develop methodologies for controlling respirable silica

dust exposures during underground coal mining.

PROBLEM STATEMENT

The Federal Coal Mine Health and Safety Act of 1969 limits

the amount of respirable coal mine dust to a permissible

exposure limit (PEL) of 2.0 mg/m for a working shift. If the 3

dust sample contains more than 5% silica by weight, the dust

standard is reduced. This is equivalent to a PEL for silica of

0.1 mg/m . In a recent NIOSH criteria document, it was 3

suggested that the recommended exposure limit (REL) for

respirable coal dust be reduced to 1 mg/m . The current REL 3

for respirable silica is 0.05 mg/m . According to recent MSHA 3

statistics, approximately 40% of the samples collected from

operators and helpers on continuous miners exceeded 5% silica.

Furthermore, roughly 25% of the samples from underground

workers in the remaining (nonbolting) occupations had silica

percentages in excess of 5%. Such levels represent an

unacceptable health risk to U.S. coal miners and suggest that

available methods are unable to control silica dust exposures

during underground coal mining. Research must therefore

focus on development of new control technologies or

improvements in older ones.

RESULTS TO DATE

Work during this fiscal year examined the effectiveness of

water sprays in confining the dust under the cutting boom of a

continuous mining machine. With the help of a cooperating

mine, two water sprays were mounted on the left and right sides

of a continuous miner near the scrubber inlets. These sprays

induced additional airflow along the sides of the miner to improve confinement of the dust cloud. The results of this study

showed that the sprays reduced the dust flowing back over the

continuous mining machine to the remote operator location.

A second task emphasized the importance of proper positioning of the operator of the remote mining machine during

deep cutting. Dust rolling back over the machine to the remote

operator was measured. At one operation using an intake curtain, the exposure of the operator was nearly four times the

intake dust level. This was attributed to the operator’s leaving

the fresher airflow behind the curtain and walking into higher

dust levels that flowed over the mining machine. To reduce

personal dust exposures, it is recommended that this worker

stay within the mouth of the blowing curtain. At a second

operation where an exhaust curtain was used, exposure of the

mining machine operator was nearly five times the intake dust

level. This also was attributed to the miner operator’s entering

the high dust levels rolling back over the continuous mining

machine. To reduce personal dust exposure, the operator

should be positioned away from the rollback and outby the

mouth of the exhaust curtain. 

A final task addressed the control of dust exposures on a

miner-bolter. Unlike regular continuous miners, a miner-bolter

often operates with an independent mobile loading machine. In

a typical operation, coal is cut, dumped on the mine floor, and

then transferred into shuttle cars by the loading machine.

Dumping and loading both generate additional dust that flows

back over the miner and bolter operators. A study at a minerbolter operation showed that dust levels were affected more

during the loading phase of the mining cycle. Exposures were

greatest for the bolter operator on the exhaust tube side of the

continuous miner.

BIBLIOGRAPHY

Jayaraman, N.I., L. Erhard, and G.V.R. Goodman.

Optimizing Air Curtains for Dust Control on Continuous

Miner Faces: A Full-Scale Model Study. Applied Occupational

Environmental Hygiene. Vol. 11, No. 7, 1996, pp. 838-844.

Goodman, G.V.R.

Control of Silica Dust in Underground Coal Mining Operations. Presentation at Second Health and Safety Seminar for

Small Mines, Somerset, PA, Aug. 1997.
74

 Summary of respirable dust levels measured during cutting

passes at 13 longwalls.

Improving Dust Control Technology for

Longwall Mining

Principal Investigator: Jay F. Colinet

RESEARCH OBJECTIVES

To determine the state of the art of longwall dust control

technology in the United States, identify particularly effective

dust control practices, investigate application of new control

technology to reduce worker exposure, and disseminate this

information to the mining industry.

PROBLEM STATEMENT

Over the last 15 years, longwall production has increased

fourfold, and recent compliance sampling indicates that over

27% of shearer operator samples exceed the 2.0 mg/m3

standard. The potential for increased dust generation and the

proximity of mine workers to multiple dust sources exacerbates

the problem of dust exposure in longwall mining operations.

Past advances in longwall dust control technology have been

tempered by significant production gains. Improvements in

longwall dust control technology must be developed to reduce

the exposure of longwall workers to respirable dust.

RESULTS TO DATE

Data obtained from surveys at 13 longwall operations were

analyzed to determine the state of the art of longwall dust

control technology. These data indicate that the effectiveness

of control technology varies widely throughout the industry, but

in general, ventilating air and spray water are being applied now

at higher levels than ever before on longwalls. Studies also

show that “basic” control technology has not been universally

applied throughout longwall operations and that technology

transfer efforts need to be more effective in disseminating

control technology information.

The application of two-phase (water and compressed air)

spray nozzles for an external spray system on longwall shearers

was evaluated at PRL’s full-scale longwall gallery. Results of

these tests indicate that dust reductions with the two-phase

spray system were similar to those obtained with conventional

sprays. However, the two-phase spray system reduced water

consumption by over 30%.

Two-phase spray nozzles were also evaluated on a simulated

longwall face at the Pittsburgh Research Laboratory’s Experimental Mine. Two-phase spray manifolds were positioned at

25-ft intervals along the simulated longwall face in an attempt

to maintain a “clean” air split in the worker walkway. Dust was

sampled to determine their effectiveness. Preliminary results

indicate that the manifolds would need to be placed closer together to improve air splitting down the length of the face.

Closer spacing of the manifolds would require a greater number

of manifolds and higher quantities of spray water and compressed air, making the system less feasible at operating faces.

BIBLIOGRAPHY

Colinet, J.F., and R.A. Jankowski.

Ventilation Practices on Longwall Faces in the United States.

Paper in Ventilation ‘97 (Ottawa, Ontario, Sept. 15-17, 1997).

Colinet, J.F., E.R. Spencer, and R.A. Jankowski.

Status of Dust Control Technology of U.S. Longwalls.

Ch. 55 in Proceedings of the 6th International Mine Ventilation

Congress (Pittsburgh, PA, May 18-22, 1997), pp. 345-351.

Control of Respirable Dust in Noncoal Mines

and Mills

Principal Investigators: Andrew B. Cecala and Robert J.

Timko

RESEARCH OBJECTIVES

To determine effective control technology to reduce worker

exposure to silica and other harmful contaminants in mineral

processing plants.
75

 Instruments sampling respirable dust concentrations near pebble mill in portland cement

plant.

PROBLEM STATEMENT

This research program adddresses one of the priority re- performed at a dry-processing plant during the previous year.

search areas specified in the National Occupational Research The results are being finalized, and all information will be

Agenda (NORA): to provide the basis for reducing chronic compiled into a report.

obstructive pulmonary disease. Dust such as crystalline silica Work began on a new project to determine the impact of

is harmful because it causes progressive deterioration of the structural design on respirable dust concentrations inside mill

lungs once it has become embedded in tissue. Within the last buildings. U.S. Silica’s plant in Berkeley Springs, WV, was

year, the International Agency for Research on Cancer has surveyed in September 1997. This plant is one of the largest

classified crystalline silica as a human carcinogen. MSHA’s silica sand operations in the country. Numerous locations in the

records have shown that since 1974, more than 82,000 of the screening tower and pebble mill buildings were sampled to

134,000 full-shift air samples collected by inspectors in the monitor dust levels during 72 hr of operation. The screening

metal/nonmetal mining industry have contained at least 1% tower is constructed of block and the pebble mill of brick.

quartz. The occupations with the highest exposures in the entire Results of the monitoring will enable researchers to evaluate

surface metal/nonmetal mining industry were bagging and whether the design has an effect on dust levels.

packing, and cleanup.

RESULTS TO DATE

In February 1997, a dust survey was completed at a wet- eter of 10 )m or less) is harmful to workers because of its

processing portland cement operation in western Pennsylvania.

The objective was to determine respirable dust concentrations

at various locations throughout the plant. Thirteen sampling

locations were monitored continuously for 70 hr. This work

was a followup study to an identical evaluation performed in

July 1996. This work allows a comparison of dust levels during

the two extreme weather conditions. A similar analysis was

BIBLIOGRAPHY

Cecala, A.B., R.J. Timko, and A.D. Prokop.

Bag and Belt Cleaner Reduces Employee Dust Exposure.

Rock Products, Vol. 100, No. 3, March 1997, pp. 41-43.

Silica Dust Control in Metal/Nonmetal Mining. Presentation

at Second Health and Safety Seminar for Small Mines,

Somerset, PA, Aug. 13, 1997.

Controlling Silica Dust Hazards in Mining. Short course

presentation at 28th Annual Institute on Mining Health, Safety,

and Research, Salt Lake City, UT, Aug. 28, 1997.

Control of Silica Dust in Underground

Metal/Nonmetal Mines

Principal Investigators: Andrew B. Cecala and Robert J.

Timko

RESEARCH OBJECTIVES

To develop control technology to provide a healthier work

environment for underground metal/nonmetal miners.

PROBLEM STATEMENT

All respirable dust (particles having an aerodynamic diamability to get into the alveolar regions of the lungs. Some dust,

like crystalline silica, is even more harmful because it causes

progressive deterioration of the lungs once it becomes embedded in the tissue. The goal of this research is to determine
76

 MSHA’s compliance dust records showing underground metal/

nonmetal occupations with the highest percentage of samples

exceeding the permissible exposure limit.

effective control technology to reduce worker exposure to silica current control technologies and sources of occupational dust,

and other harmful dusts in underground metal/nonmetal mines.

RESULTS TO DATE

This project began in the spring of 1997. An extensive literature search was completed to identify previous work in this

area. Discussions were held with other NIOSH laboratories to see

if any additional information could be obtained on related work.

In addition, we have had meetings with MSHA, the National

Mining Association, and a number of labor unions to discuss this

new program area. Our goal is to determine the most critical

areas of worker exposure to silica and other harmful dust in

underground metal/nonmetal mines. A substantial amount of

communication among the various partners is needed to establish

a plan of action for this research. We anticipate visiting a number

of operations to observe problems in the underground

environment and determine high-exposure job functions, as well

as key factors in or sources of these high exposures. Abatement

control research will be initiated in the most critical areas found

during this preliminary investigation.

Surface Mine Dust Control

Principal Investigators: Steven J. Page and John A.

Organiscak

RESEARCH OBJECTIVES

To provide a broad-based approach toward the eradication of contact with the ground. Tests consisted of comparing the shroud

silicosis in surface mining operations through evaluation of

representative sampling, and testing of new control technology.

PROBLEM STATEMENT

From 1988 to 1992, the average concentration of respirable

crystalline silica in samples collected by MSHA inspectors and

mine operators was greater than the permissible exposure limit

(PEL) established by MSHA at 0.1 mg/m for all surface oc- 3

cupations combined. Exposures of drillers and drill helpers to

respirable crystalline silica are of particular concern. Average

concentrations ranged from 0.15 to 0.51 mg/m , up to 70% of all 3

samples exceeded MSHA’s PEL, and up to 82% exceeded

NIOSH’s recommended exposure limit. In 1992, NIOSH reported 23 cases of silicosis in rock drillers ranging from 25 to 60

years of age who had between 3 and 20 years of drilling experience. Most of these cases involved operators in their 30's and

40's, indicating that high silica exposure levels were associated

with their occupation. A recent study of 91 surface coal mine

drillers found an additional 7 cases of silicosis. Further

examination of surface miners has shown that the incidence of

lung abnormalities is not limited to drillers.

RESULTS TO DATE

To address these problems, the project is divided into two

phases. The first phase will assess silica dust sources and current

control technology at surface mines. Dust source surveys will be

conducted at mines having both poor and good dust compliance

sampling histories; these mines will be selected with the

assistance of MSHA health specialists at district offices. The

sampling focus will be on sources associated with occupations

historically identified by NIOSH as having a high incidence of

silicosis and/or identified by MSHA as having a high risk of

exposure to quartz. These sources are likely to include drills,

dozers, pans, and trucks. During the surveys, dust control

methods and their operating parameters will be documented. The

effectiveness of dust control methods used at the various

operations will be analyzed.

The second phase of the project will investigate those areas

where dust control technology is deficient. Because rock drills

are expected to be the most significant source of silica, the focus

is likely to be on reducing the amount of silica dust generated by

the drilling operation.

On June 18-19, 1997, a deck shroud on a surface coal mine

drill at the Sky Haven Mine, Clearfield, PA, was evaluated. The

shroud is unique in that it is circular in design, has no open seams,

and is capable of being hydraulically raised and lowered to make

in full contact with the ground to the shroud partially
77

 Circular drill shroud was more than 99% efficient in reducing

airborne respirable dust.

raised to simulate a leak. Respirable dust concentrations were

less than 0.5 mg/m and 52 mg/m for the two conditions, 3 3

respectively, yielding dust reduction efficiencies greater than

99%.

BIBLIOGRAPHY

Surface Mine Dust Control Technology. Presentation to

Ingersoll-Rand, Garland, TX, Oct. 24, 1996.

Technology To Reduce Silica Dust Exposure of Surface

Drill Operators. Presentation to Holmes Safety Association,

Oakland, MD, Oct 26, 1996.

Silica Dust Control on Surface Coal Mine Drills.

Presentation at joint labor-industry briefing, Jasper, AL, June 3,

1997.

Best Practices for Surface Drill Dust Control. Presentations

at Regional Silicosis Conference, National Mine Health and

Safety Academy, Beckley, WV, Aug. 4, 1997; and Logan

County Community College, Logan, WV, Aug. 5, 1997.

Silica Dust Control on Surface Coal Mine Drills. Presentations at Regional Silica Conference, MSHA District 3, Morgantown, WV, Sept. 4, 1997; MSHA District 7, Pineville, KY,

Sept. 10, 1997; and MSHA District 7, Hazard, KY, Sept. 11,

1997.

Silica—It’s Not Just Dust. Joint NIOSH-MSHA-OSHA

Bulletin, 1997.

Improved Application and Monitoring of Dust

Control Parameters

Principal Investigator: Jay F. Colinet

RESEARCH OBJECTIVES

To evaluate the interactions and effectiveness of ventilating

air and spray water for longwall dust control and to quantify the

impact of recent changes in flooded-bed scrubber operations on

dust collection capability.

PROBLEM STATEMENT

The most recent results of the X-Ray Surveillance program

for underground coal mine workers indicate that approximately

8% of those workers with 20 to 24 years of experience contract

coal worker’s pneumoconiosis. Prevention of worker exposure

to excessive levels of respirable dust remains a primary concern

for the coal mining industry. MSHA sampling results indicate

that at any given time, 25% of operating longwalls are out of

compliance with the applicable dust standard. Water spray systems and delivery of suitable quantities of ventilating air are the

primary means used by operators to limit worker exposure to

respirable mine dust. Water and air systems must be improved

to reduce dust generation and afford adequate protection to

mine workers under a variety of operating conditions.

RESULTS TO DATE

An experimental test program and sampling protocol were

developed to evaluate the effects of changes in face ventilation

levels, water quantities, and water pressures on respirable dust

levels for shearer drum and external spray systems, spray

systems design, mining height, and cutting direction in longwall

operations. In phase 1 of the project, 90 tests were completed

in PRL’s longwall test gallery, which had been configured to

represent a 7-ft mining height and the shearer cutting in a headto-tail direction. The gallery has been configured to simulate

tail-to-head cutting, and tests will resume as soon as modifications to the gallery ventilation system are completed.

It is suspected that panels in which density has been reduced

by as much as 75% are allowing greater quantities of respirable

coal and silica dust to pass through the scrubber, increasing exposures of mine workers. Laboratory tests were conducted with

six different filter panels to quantify silica collection efficiency.

Results indicate that the least dense panel can allow over 40%

of respirable silica to pass through the scrubber. In contrast, the

most dense filters remove over 90% of silica, and these panels

are recommended for improved silica dust collection.
78

Efficiency of filter panels in collecting respirable silica.

BIBLIOGRAPHY PROBLEM STATEMENT

Colinet, J.F. Assessing respirable dust levels in mining workplaces is

Silica Collection Efficiency of Filter Panels for Flooded-Bed personal dosimeter would permit more frequent sampling with

Scrubbers. Presentation at 1997 National Conference To results immediately available to the worker. More timely dust

Eliminate Silicosis, Washington, DC., Mar. 25-26, 1997. exposure information may improve the chances that dust levels

Colinet, J.F., and J.P. Flesch.

Exposure to Silica Dust on Continuous Mining Operations

Using Flooded-Bed Scrubbers. NIOSH Pub. 97-147, Aug. A personal dust dosimeter has been fabricated based on the

1997. correlation of increasing differential pressure across a filter with

Colinet, J.F., and R.A. Jankowski. porous foam to collect the nonrespirable fraction of the dust and

passes the respirable dust to the filter across which pressure is

Dust Control Considerations for Deep-Cut Faces When measured. The foam preclassification device was evaluated at

Using Exhaust Ventilation and a Flooded-Bed Scrubber. SME NIOSH’s Hamilton Laboratory using the aerodynamic particle

preprint 97-48. Presentation at SME annual meeting, Denver, sizer to match foam penetration characteristics with those of a

CO, Feb. 24-27, 1997. 10-mm nylon cyclone. It was determined that the best approxiPersonal Dust Dosimeter

Principal Investigators: Jon C. Volkwein and Steven J.

Page

RESEARCH OBJECTIVES

To develop an inexpensive personal dust monitor based on

the correlation of increasing differential pressure across a filter

with increased mass loading of the filter.

currently time-consuming and expensive. An inexpensive

will be reduced promptly to avoid repeated dust overexposure.

RESULTS TO DATE

increased dust mass loading. The device uses a section of

mations of cyclone performance was a 4-mm-diam, 25-mmlong section of foam operating at a face velocity of 35 cm/sec.

Tests of the dosimeter in parallel with conventional personal

dust sampling filters have been completed. Six different coal

dusts were aerosolized in a laboratory dust chamber, and 118

triplicate observations were obtained. For individual coal types,

the correlation coefficients were between 0.90 and 0.97. The

precision of the two methods was similar; the personal samplers

had a coefficient of variation of 11.83%, and the new detector

had a coefficient of variation of 13.96%. For all coal types

tested, the data were best described by a power function where

y=1.43x with a correlation coefficient of 0.73. The method 0.85

became more accurate at higher dust loadings, so that all

laboratory data with mass loadings greater than an equivalent

concentration of 2 mg/m fell within ±25% of the power 3

function. Assessment of the method under field conditions has

begun with the results from two underground mines agreeing

well with the laboratory data. A patent application has been

filed on the invention.

Provisional Patent Application

Dust Detector Tube, Jon C. Volkwein, Steven J. Page, and

Harry Dobroski, Jr. Filed July 3, 1997, CDC Ref. No. I-004-

9710.
79

 Dust detector tube to be used with a lowflow-rate pump that displays differential

pressure continuously.

 Measuring explosive gas concentrations in augered mining holes

using a wireless transmitter.

Methane Assessment in Auger Highwall

Mining

Principal Investigator: Jon C. Volkwein

RESEARCH OBJECTIVES

To develop a method to assess methane concentrations in

augered mining holes where the rotating auger’s drill string

prevents the use of conventional methane monitors and hardwired communication with the operator.

PROBLEM STATEMENT

Auger highwall mining machines are increasingly encountering exposive quantities of methane gas. Use of conventional

monitoring technology is impossible because extending the

electrical cable that carries the monitoring signal through the

auger’s drill string is not practical. 

RESULTS TO DATE

Tests in PRL’s Safety Research Coal Mine have

demonstrated that data can be transmitted using a multiplefrequency radio signal through a 6-in-diam, 100-ft-long hole

that contains an auger drill string. This system uses an

inexpensive radio transmitter and receiver to send the signal,

which includes data on gas concentrations. A mineworthy

transmitter has been purchased and coupled with the methane

monitor.

BIBLIOGRAPHY

Volkwein, J.C.

Control and Monitoring of Gas in Blind Auger Headings.

Paper in Proceedings of the 6th International Mine Ventilation

Congress (Pittsburgh, PA, May 20, 1997), pp. 165-168.

Extended-Cut Air Delivery Systems

Principal Investigator: Charles D. Taylor

RESEARCH OBJECTIVES

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Methane gallery used for extended-cut ventilation tests.

PROBLEM STATEMENT BIBLIOGRAPHY

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Effects of Airflow on Escaping Mine Fires

Principal Investigator: Robert J. Timko

RESEARCH OBJECTIVES

detected by developing a hazard evaluation program for operating coal mines, and to expand the level of fire detection at

hazardous locations by improving fire detection methods or

increasing the quantity of fire detection devices in those areas.

PROBLEM STATEMENT

An underground fire is perhaps the most hazardous emergency confronting miners because it can generate tremendous

quantities of both gaseous and solid contaminants in a very

short time. Typically, ignitions that occur without witnesses

become more fully developed before they are positively identified and therefore are more difficult to extinguish. Because it

is impossible to eliminate all fires, it is important to identify and

catalog potential fire sources, as well as the detection methods

that are already in place. Many hazards are normally

unsupervised, including power centers, rectifiers, conveyor

belts, belt drive mechanisms, and air compressors. Locating

these sources and describing techniques for reducing their

potential as fire hazards, either by adding redundant detection

devices or improving alarm response time, will reduce the

likelihood of fires at these sources becoming well developed

before they are detected.

RESULTS TO DATE

An examination of historical mine fire data found that fires

occurring in belt entries were the most likely to cause injuries,

while those in main haulageways were responsible for the

highest number of fatalities. Fires in main haulageways were

also the most likely to require that the immediate area be sealed

before the fire could be extinguished. A study that looked more

closely at fire detection at various underground locations found

that redundant detection methods existed, but that these varied

from place to place within a mine. Face, near-face, and belt
81

locations had the highest levels of redundant safety devices diesel particulate matter (exhaust aerosol) and nitrogen dioxide

because (1) more time was spent in designing methods that (NO ), are considered of prime importance. This work and

could continuously monitor and rapidly extinguish an ignition development of diesel controls through directed contact work

in these areas and (2) miners spent a larger portion of their have contributed to MSHA’s current efforts to develop a diesel

workday in these areas, which tended to make an ignition more particulate standard.

likely to be witnessed and more quickly and safely extinguished. Conversely, haulageways had the lowest level of redundancy because miners are present less often and the types of

equipment located in haulageways are so varied that it is more

difficult to design detection strategies for specific pieces.

In FY97, efforts were concentrated on identifying the locations for potential fire in haulage entries. Because of the wide

variation in haulage entries in different mines, this has been a

more complex problem than originally thought. It now appears

that corporate philosophy relative to mine engineering has a lot

to do with mine haulage design. In other words, if a power

center is vented to the return in a specific way in one mine

owned by a specific company, it is likely that other mines

owned by the same company will have similar designs. If this

proves to be the case, hazardous locations may be able to be

modified through general management decrees rather than mine

by mine.

This project was terminated at the end of FY97.

Diesel Engine Emission Measurement and

Analysis

Principal Investigators: Bruce Cantrell and Emery Chilton

RESEARCH OBJECTIVES

To reduce worker exposure to diesel emissions in

underground mines.

PROBLEM STATEMENT

NIOSH’s Current Intelligence Bulletin 50 published in 1988

recommended that “whole diesel exhaust be regarded as a

‘potential occupational carcinogen,’ as defined in the Cancer

Policy of the Occupational Safety and Health Administration.”

NIOSH further stated that “though the excess risk of cancer in

diesel-exhaust-exposed workers has not been quantitatively

estimated, it is logical to assume that reduction in exposure to

diesel exhaust in the workplace would reduce the excess risk.”

The International Agency for Research on Cancer also

classified diesel exhaust as “probably carcinogenic to humans.”

In addition, MSHA received a recommendation from an advisory committee to establish a diesel exhaust aerosol standard

and to establish regulations to minimize exposure to all diesel

pollutants in underground coal mines.

Measuring worker exposure to toxic agents is the first step

in determining the exposure-dose response relationship and

quantifying the associated risk. Exhaust components, such as

2

RESULTS TO DATE

This work addresses both measurement and control of diesel

emissions. Comparisons of sampling and analytical methods

for diesel particulate were conducted in an underground survey

in a Canadian nickel mine and in an ongoing cooperative effort

with MSHA. Analytical methods investigated included a sizeselective sampling method, a respirable combustible dust (RCD)

method, and NIOSH Method 5040, for elemental carbon and

total carbon. Results from 81 comparison samples in the Canadian mine survey show that each measurement technique is appropriate for diesel exhaust aerosol. Size-selective sampling

and RCD gave identical results for diesel particulate concentrations, and both elemental carbon and total carbon correlated

highly with these measurements. At this mine, elemental carbon accounted for 50% of the measured total carbon.

Method development for diesel exhaust aerosol was advanced by issuance of a contract to produce a commerical

version of a NIOSH-developed size-selective sampler. Evaluation of the commerical prototypes will be conducted in FY98.

In addition, a round-robin test of diesel aerosol particulate

analysis using both the NIOSH 5040 and the European elemental carbon test protocols was completed. This test included

laboratories in the United States, the United Kingdom, and

Europe. Results show that total carbon measured by these

methods agree very well, but that elemental carbon is methoddependent.

Passive samplers for measuring NO exposure, developed in 2

a cooperative program with MSHA, were used in six mine surveys. These samplers included Palmes-type tube samplers and

a sampler using dust-type cassettes developed by the Pittsburgh

Research Laboratory. Twenty sampler pairs were used in each

mine. The mean comparison ratio is 1.16 ± 0.38. The large

variance is suspected to result from sampler handling errors in

the field. These tests and work with electrochemical, solid-state

sensors, and chemiluminescence detectors are continuing.

Under contract, the University of Minnesota Center for

Diesel Research (CDR) defined maintenance procedures for

underground diesels using emissions measurements. MSHA

has distributed these procedures in a report on an emissionsassisted maintenance procedure for diesel-powered equipment.

This procedure uses measured exhaust CO and CO to 2

determine the state of a diesel engine and whether or not

it needs repair. Other work on diesel control technique characteristics includes the use of aftertreatment devices, alternate

fuels, and modern engine technology in modifying diesel engine
82

Size-selective submicrometer fraction compared to RCD analysis for diesel aerosol.

exhaust to reduce worker exposure. Currently, the CDR and

NIOSH are conducting a study in a Canadian nickel mine to investigate the effect of a 50% soy-methyl-ester, low-sulfur diesel

fuel mixture on particulate and gas emissions from a diesel

load-haul-dump vehicle.

BIBLIOGRAPHY

Cantrell, B.K.

Diesel Exhaust Aerosol, Review of Measurement Technology. Paper in Proceedings of the CANMET, DEEP Steering

Committee, Canadian Ad Hoc Diesel Committee (Toronto,

Ontario, Canada, 1997), pp. 7.1 to 7.9.

Cantrell, B.K.

Diesel Emission Control Research at the National Institute

for Occupational Safety and Health. Presentation at Western

Mining Conference, Denver, CO, Feb. 2-5, 1997.

Spears, M.W.

An Emissions-Assisted Maintenance Procedure (EAMP) for

Diesel-Powered Equipment. Contract USDI-1432 C0369004,

Univ. of Minnesota Center for Diesel Research, Oct. 1997,

84 pp.

Respirable Dust Measurement and Analysis

(Instrumentation)

Principal Investigator: Kenneth Williams

RESEARCH OBJECTIVES

To reduce worker exposure to hazardous respirable aerosols

in the mining workplace through improved measurement and

control technology.

PROBLEM STATEMENT

Prolonged inhalation of respirable coal mine dust can cause

coal worker’s pneumoconiosis (CWP). Between 1968 and

1990, CWP caused the deaths of 55,467 U.S. coal miners. Accurate measurement of respirable dust is crucial to reducing dust

exposures and eliminating this disease. Real-time dust monitoring is the most effective way to locate areas where dust

controls are needed and, subsequently, to determine how well

these controls are working. Silicosis, which is caused by quartz

in mine dust, is another genuine concern for the U.S. mining

workforce. The National Coal Workers Autopsy Study records

that 12% of miners have silicosis lesions. Other studies show

that >5% of surface mine workers have silicosis. Better ways

to measure quartz will enable the health and enforcement

community to pursue improved epidemiology, describe doseresponse relationships in detail, and verify the effectiveness of
83

Prototype dust monitor.

 control technology. This project directly addresses the NORA than the P-7 method. Different ways of calculating

priority research area of “exposure assessment methods” by spectroscopic results or preparing analytical standards may be

developing technology to measure respirable dust. causing this systematic variation. Further research is expected

RESULTS TO DATE

A dust monitor that measures respirable dust continuously analytical method to proceed more rapidly by reducing the need

was developed. This sensor uses the inertial behavior of a to manipulate the samples by hand.

specially tapered, vibrating tube to measure the mass in a

sample of dust. By drawing air through the tube, the sensor collects dust from the mine air on a filter. The more dust on the

filter, the greater the mass, which decreases the frequency of Cantrell, B.K.

oscillation of the tube. By measuring changes in frequency, the

amount of dust can be determined. Phase 2 evaluations of Continuous Respirable Mine Dust Monitor Development.

prototypes have been completed in two mines. Laboratory and Paper in Proceedings: 6th International Mine Ventilation Conin-mine tests have shown that a properly designed sensor based gress (Pittsburgh, PA, May 16-22, 1997), pp. 11-17.

on this technology can operate successfully in the underground

coal mine environment and provide accurate, continuous meas- Cantrell, B.K., K.L. Williams, S.W. Stein, D. Hassel, and

urements of respirable dust concentrations. A field test protocol H. Patashnick.

for 10 monitors was written and presented to participating

mines. The production monitors will be evaluated first in Continuous Respirable Mine Dust Monitor Development.

laboratory tests and then in underground coal mines as they Paper in Proceedings of the Twenty-Seventh Annual Institute on

become available. Mine Health, Safety and Research (Blacksburg, VA, 1997),

Another technology for measuring the mass of sampled pp. 91-102.

respirable dust is the resonant filter membrane mass monitor

(RFM3). In this approach, a filter membrane is stretched taut Williams, K.L., and B.K. Cantrell.

and made to vibrate. As the filter collects dust, resonant frequencies of vibration decrease. Those changes in frequency can Machine-Mounted Continuous Respirable Dust Monitor.

be related to the mass of dust collected. NIOSH sponsored Technology News 463, 1997, 2 pp.

early research on the device and is now cooperating with the

developer by evaluating prototypes at the Pittsburgh Research

Laboratory. The monitor’s dust sampling capabilities and the

effects of humidity on the instrument’s output were tested;

although the RFM3 agreed with gravimetric measurements to

within ±25% for mass loadings above 0.5 mg, it was shown that

humidity affects the glass fiber filters currently used. When

sampling dust-free air at 23(C and 60% relative humidity, the

monitor indicated a mass gain of more than 50 mg.

NIOSH has developed a method for analyzing the quartz

content of coal mine dust samples directly on the collection

filter using Fourier transform infrared spectroscopy. Twentyfive field samples of coal dust on 37-mm PVC filters were

analyzed first by the on-filter method and subsequently by the

established P-7 method. The correlation between the two

methods is extremely high; however, the on-filter method

consistently reports quartz mass values about one-third higher

to resolve this question. Under contract, Spectros Associates

wrote specialized software to automate on-filter quartz analysis.

Once perfected, the software will allow refinements of the

BIBLIOGRAPHY
84

 Fatal injuries per 100,000 workers for mining commodities and

all industries by year.

SURVEILLANCE, STATISTICS, AND RESEARCH SUPPORT ACTIVITY

Principal Investigator: Deborah Landen

RESEARCH OBJECTIVES

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DISSEMINATION ACTIVITY (ECIDA)

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