Building a Culture of Safety, Sustainability, and Dust Control

In the coal mining industry, balancing operational safety and sustainability with effective dust control is no small feat. Dust-A-Side Australia has been involved in a significant project at a major coal mining site in Australia for over 13 years, implementing a comprehensive approach to haul road and mine dust management. Here’s an in-depth look at the project’s journey, the challenges faced, and the team’s achievements through their steadfast commitment to safety and innovation.

Situation: Building a Safety and Dust Control Culture

One of the primary challenges in this project was fostering a culture centred on safety and efficiency. The Dust-A-Side Australia team not only implemented technical solutions but also focused on understanding the client's needs, adapting to them, and promoting a robust safety culture. From the outset, this project involved breaking old habits and setting new standards in dust control, particularly around the traditional reliance on water carts for dust suppression.

Driven by a commitment to innovation, the Dust-A-Side Australia team invited managers from the coal mine to South Africa, where the Dust-A-Side brand was first established. The visit offered a unique opportunity to observe Dust-A-Side’s operations and learn from methodologies applied there. This visit provided valuable insights into reducing water dependency and optimising road maintenance strategies. Initial discussions concentrated on replacing water-based dust suppression on haul roads with more effective, long-lasting solutions.

The Solution: Implementing Bitumen Emulsion and HydroTac for Comprehensive Dust Control

Dust-A-Side Australia's signature dust control binder, DAS Product, has proved to be an invaluable solution at this busy open-cut coal mine. DAS Product is an emulsion of bitumen in water, specifically designed and formulated to physically bind road materials together and suppress dust on haul roads.

Upon application, the emulsion breaks, allowing the bitumen to cure and bind the wearing course together, forming an impermeable seal that resists water ingress and prevents wheel-generated dust. One of the key benefits of DAS Product is its resilience in all weather conditions, allowing treated areas to recover quickly from heavy rain and remain dust-free during dry periods. 

The client required an effective solution for suppressing dust across their haul road network, and our Full-Service package provided not only the bitumen emulsion application but also the necessary assets, personnel, and ongoing site management.

The results were remarkable, achieving significant reductions in dust levels, water usage, plant operating costs, and other key metrics:

• 95% reduction in wheel-generated dust and a noticeable reduction in visible dust on the haul road.
• 75% reduction in water usage, leading to savings in water infrastructure costs and a reduced likelihood of heavy vehicle-related incidents.
• 15% reduction in plant operating costs and maintenance costs from graders and water carts.
  

The improved road conditions have further enhanced safety and production, with the binding properties of DAS Product providing good traction and reduced road roughness, lowering the risk of tyre damage and increasing operational efficiency.

As the project progressed, Dust-A-Side Australia’s team trialled HydroTac, a dust control binder designed for heavy-duty applications, applying it on both light vehicle (LV) and heavy vehicle (HV) roads to enhance durability and dust suppression efficiency. As part of a holistic dust control approach beyond roads, this solution extended to critical areas within the mine, such as the Coal Handling and Preparation Plant (CHPP) and Run-of-Mine (ROM) stockpiles, with targeted dust suppression systems installed at each transfer point to manage airborne dust effectively.

This comprehensive dust control approach, combining DAS Product, high-pressure mist systems, and HydroTac, along with a strong focus on training and safety, laid the foundation for a significant cultural shift in the workplace. From the beginning, emphasis was placed on reducing dust emissions, improving road conditions, and cultivating a new mindset among the workforce.

Task: Fostering a Robust Safety Culture

Creating a safety culture is more than establishing protocols; it’s about ensuring the entire team believes in and adheres to these principles. For the past 13 years, this project has maintained an impressive record of zero lost-time injuries (LTI), a testament to the team's deep-rooted commitment to safety. Dust-A-Side Australia’s Site Manager emphasises that safety is not merely a process, but a belief system shared by everyone. The guiding motto is clear: the goal is for everyone to go home alive, uninjured, and happy.

The team has prioritised separating personal stresses from work responsibilities, fostering an environment where workers can fully focus on their tasks. The site manager acknowledges the hard work and dedication of both past and present team members in building a stable safety culture. As a leader, he exemplifies these values, guiding the team with a strong focus on safety and well-being.

Key Achievements

The success of this project demonstrates the value of both technological advancements and cultural alignment. Key accomplishments include:

• 13 Years LTI-Free: The team’s commitment to safety has resulted in 13 consecutive years with zero LTIs, underscoring the project’s focus on safety-first operations.
• Reduction in Water Cart Dependency: With the introduction of HydroTac and other dust control strategies, the project has eliminated the need for two water carts, saving resources, reducing road grading requirements, and freeing up an additional road crew to focus on other areas.
• Improved Road Conditions: Through comprehensive dust control measures, the project has minimised rolling resistance on haul roads, enhancing equipment efficiency and reducing operational costs.
• Team Recognition and Appreciation: Celebrating milestones and individual contributions has been essential. The Dust-A-Side Australia team recently organised a farewell for Steve, a valued team member with 12 years on the project, to honour his commitment. Recognising dedication and contributions is integral to fostering a positive work culture and building morale.
  

A Lasting Impact

This Dust-A-Side Australia project exemplifies how a holistic approach to dust control and safety can yield long-lasting results. By focusing on both the technical aspects of dust suppression, through products like DAS Product and HydroTac, and the human element of safety culture, the team has created a resilient environment that prioritises well-being and operational efficiency. Their achievements over the past 13 years set a high standard in the mining industry, demonstrating that a safety culture thrives only when it is genuinely embraced.

The Dust-A-Side Australia team remains committed to sustaining this legacy, ensuring that safety, efficiency, and sustainability continue to guide their work at the coal mine site and beyond.