Case Study

Newlands Mine Rockfall Control

Located in the central Bowen Basin, Xstrata’s Newlands mine was developing a new punch longwall operation, requiring underground access from the base of a 70m highwall. The mine required a rockfall control system to be design and installed over an extensive area of a particularly hazardous working environment. Stornoway undertook the works, meshing in excess of 50,000m2 over a five month period, making it one of the largest rockfall control projects undertaken in Australia in recent years.

Challenge

Xstrata had commenced the development of a new punch longwall coal mining operation at it’s Newlands Mine in Queensland’s central Bowen Basin. The operation involved underground access from the base of a particularly hazardous 70m highwall. The rockface continuously shed surface rock, including blocks the size of small cars. Hot days followed by nighttime cooling exacerbated the instability of the surface rock, ensuring that each day presented a whole new set of hazards.

In seeking a contractor to undertake the works, Xstrata had to be confident of not only the technical capability but also the safety management culture and systems to ensure the work could be completed without injury or fatality.

Solution

Stornoway successfully bid for the work, demonstrating technical expertise, value for money and a strong safety track record. In particular, Stornoway recognised that the dynamic nature of the highwall meant continuous risk assessment would be required for the project duration. As a result, a process of daily “wall walks” was instigated in which a geotechnical engineer would accompany the entire work crew on a visual inspection and assessment of hazards presenting in the target work area. Major hazards were identified and control plans implemented, including the establishment of exclusion zones where risks were considered too high for personnel to work.

The solution was a system combining flexible double twisted rockfall mesh draped over the face with rock bolts drilled into the face to minimise the risk of block failure. RiBS (Reinforced Banding System) were installed in major fault zones.

Results

In excess of 50,000m2 of was protected over a five month period without injury to Stornoway or mine personnel.