TITLE; ATTACHMENT REPORT

CANDIDATE NAME; HOPESON BANDA

ATTACHMENT PERIOD; 12 JANUARY 2015 to 31 DECEMBER 2015

COURSE NAME; MINING

COMPANY NAME

METALLON GOLD ZIMBABWE (PVT) LTD

Creating a golden future

HOW MINE

YEAR OF SUBMISSION; 2015

ATTACHMENT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE

REQUIREMENT OF A NATIONAL DIPLOMA IN MINING.
ACKNOWLEDGEMENTS

It gives me immense pleasure to present this report carried out at Metallon gold Zimbabwe
(How Mine) Limited in partial fulfillment of a national diploma in mining at Zimbabwe school
of mines. No work can be carried out without the help and guidance of various individuals. I
am happy to take this opportunity to acknowledge and express my profound gratitude to
those who have been helping me complete this report.

Firstly I would like to thank the lord Almighty for granting me this opportunity to be part and
parcel of Global Insurance Company Limited.

Secondly I would like to pass my gratitude to the following people who were inspiring in the
completion of my attachment programme and from whom I got to appreciate mining as a
whole, MrMoyo (The mine captain), my mentorMr N.Ndiweni (The mine training officer), all
the miners at how mine and lastly to the management staff of How Mine for giving me the
opportunity to proceed with my studies.

My gratitude also goes to the ZSM academic staffs who have imparted their vast knowledge
which has so much assisted me during my industrial attachment. It is through their
unwavering support that I was able to appreciate the theoretical aspects of insurance and
reinsurance Industry. Many heartfelt thanks for their unwavering support.

Lastly I would also like to thank my parents for their unconditional love and support and for
their financial support.

God bless you all.

Table of Contents
INTRODUCTION ........................................................................................................................... 4
INDUCTION.................................................................................................................................. 6
ORGANIZATIONAL STRUCTURE ................................................................................................... 7
FINANCE DEPARTMENT............................................................................................................... 9
HUMAN RESOURCES DEPARTMENT ........................................................................................... 9
REDUCTION DEPARTMENT ....................................................................................................... 10
ENGINEERING DEPARTMENT .................................................................................................... 10
TECHNICAL SERVICES DEPARTMENT ......................................................................................... 10
UNDERGROUND DEPARTMENT ................................................................................................ 10
ATTACHMENT PROGRAMME .................................................................................................... 12
ACITIVITY; GEOLOGY ................................................................................................................. 12
ACTIVITY; SAFETY HEALTH ENVIRONMENT AND QUALITY ........... Error! Bookmark not defined.
ACTIVITY; REDUCTION (PROCESSING PLANT) ........................................................................... 14
ACTIVITY; SURVEY ..................................................................................................................... 21
MINING ATTACHMENT PROGRAMME ...................................................................................... 22
ACTIVITY; LASHING.................................................................................................................... 23
ACTIVITY; PRODUCTION (TRAMMING) ..................................................................................... 25
ACTIVITY; SHAFT EXAMINATION AND SERVICING .................................................................... 29
ACTIVITY; PIPES, TRACKS AND VENTILATION (P.T.V) ................................................................ 31
JACKHAMMER DEVELOPMENT DRILLING ................................................................................. 34
ACTIVITY; LONGHOLE DRILLING ................................................................................................ 42
ACTIVITY; TRANSPORTATION, HANDLING AND STORAGE OF EXPLOSIVES .............................. 46
ACTIVITY; ROCK DRILL SHOP ..................................................................................................... 51
INTRODUCTION
COMPANY BACKGROUND

How mine is situated 30km southeast of Bulawayo in Matabeleland South Province. The mine
dates back to July 1941 when the How claims were first pegged as a virgin discovery by Mr. J
Howe.

August 1941 saw the How claims being transferred to the Halo Syndicate Milling which went
on to change its name and registered as Halo Company Limited in October 1943. By July 1944,
two quarries had been established with the southern quarry down to a depth of 30m. Milling
was being done by use of a 19-stamp mill. In 1950, the mine was put on option to Rhodesia
Gold Fields Development Company in the same period a diamond-drilling program totalling
2020m was undertaken and its result indicated a potential for a large tonnage operation.
Extraction difficulties and lack of funds stopped operations in 1953. Balart Mines Pvt. Ltd.
took over the mine in June 1954 and sank the main mineshaft between the two open pits.

The property was taken over by LONRHO in 1973, first under the name Rhodesian Gemstone
Pvt. Ltd., the Attica Mines, and eventually Independence Mines Pvt. Ltd. in 1986. Since 1970,
the mine has operated continuously and is the largest gold producer in Matabeleland
Province.

October 2002 saw LONRHO relinquish ownership of Independence Gold Mining to Metallon
Corporation a South African based mining and finance company. Metallon Gold Zimbabwe is
a subsidiary of Metallon Corporation and it holds a lease that covers the area occupied by the
How claims as well as that of other mines belonging to the group which are Acturus, Mazowe,
Redwing and Shamva mines
MISSSION STATEMENT

To be:

The safest mine in the country.

Providers of attractive working conditions and competitive benefits.
A global leader in low cost production in an environmental friendly manner.

OPERATIONAL STATEMENT

To conduct all the mining, processing and service operations in a safe, efficient, cost
effective and environmental acceptable manner.
Training and technical services support plays an important part in realizing the stated
goals.
The company shall develop and maintain high standards for all aspects of our mining
and processing operations and aim to continuously improve on them.

VISION

The mission is to mine gold in a manner designed to increase profits whilst

considering social and environmental responsibilities.
 INDUCTION
(12-01-15 TO 21-01-15)

Department Responsible Department Responsible

Day 1 Security Officer Day 2 Human Resources
Human resources Manager
SECURITY Induction to Managers
Security checks and procedures office
SHE Labour control functions
Safety standards and procedures Recruitment Procedure
Arrangement and issue of PPE Senior SHE Officer Code of conduct
Clinic(Medicals)
Community and social
activities
Day 3 Finance Manager Day 4 Metallurgical
Administration Plant Manager
Accounts ,stores, buying office, Visit to tailing dams
creditors Surface engineering
Technical services Technical Services Going through the plant
Geology, Survey ,Assay Manager Metallurgical accounting
and
reporting
Transport
Day 5 U/G Manager Day 6 Human Resources
Mining Human resources take Manager
Underground employee to relevant
Engineering department
Development
Stopping operations
Tramming
ORGANIZATIONAL STRUCTURE

GENERAL
MANAGER

HUMAN TECHNICAL
METALLURGICAL UNDERGROUND FINANCE ENGINEERING
RESOURCES SERVICES
MANAGER MANAGER MANAGER MANAGER
MANAGER MANAGER
The general manager heads the company. There are six departments within the company and
the departmental heads all report to the mine manager. He then reports to the Metallon
Gold Zimbabwe head offices in Harare. Together with the departmental heads, the mine
manager plans the long-term strategies of the mine.
FINANCE DEPARTMENT

Finance Manager

Deputy Finance
Manager

Accountant

Creditors, IT Officer
Buyers

Storekeeper
This is a department responsible for the management of cash flow. The departmental head
works with the mine manager towards the working out of the company budget, and
suggesting the need of cutting costs while trying to gain high returns. In essence, the
department is actually headed by the mine manager.

HUMAN RESOURCES DEPARTMENT

Human Resources

Manager

Human Resources Human Resources Health Officer

community officer
Officer

This is a department responsible for the management of manpower. This department ensures
that the strategic objectives of the organisation are met with adequate professionalism. It
also looks at personnels grievances and personnel and industrial relations. The health and
safety of employees is important to any organisation and is dealt with within this
department.

Within this department is the security department which is classified under the Human
Resources department although its head, the Security Officer reports to the Mine manager.
This deals with the local security also making sure there is a minimum loss incurred.
REDUCTION DEPARTMENT
The department deals with ore reduction to give the ultimate product, gold bullion bar ready
for the market. The Metallurgical Manager heads the department. As a departmental head,
the Metallurgical Manager along with the Assistant Metallurgical Manager plans and
organises the strategies towards meeting production targets. The metallurgist works on
procedures to be followed towards the meeting of departmental goals and also carries out
assessment of the running procedures and offers immediate response to un-normalcy in the
plant.

He hands down his procedures to plant operators who supervise, and see to it that the
procedures are precisely followed. There is also a lab in which all test work is done with
samples being prepared for gold assaying. The results are used to determine if they are any
deviations from normalcy and rectification of procedures is done based on these results

ENGINEERING DEPARTMENT
The engineering department directs and strategizes all engineering activities. The department
is further divided into surface and underground engineering sections. The surface engineer
works with the reduction officer on planning the maintenance schedule for the plant and
surface works. The section engineers report to the underground manager for the
underground section engineer and the Metallurgical Manager for the surface section
engineer. Overall, the section engineers report to the Engineering Manager.

TECHNICAL SERVICES DEPARTMENT

The department has several sections within it. The geology section which is responsible for all
exploration works and these are carried out in line with the Mines Exclusive Prospecting
Order (E.P.O.). They direct mining works hence work closely with the underground
department. The geology section is serviced by the assay laboratory, which assays the
samples collected by geologists either confirming a gold rich belt. The assay laboratory also
services the reduction department, assaying samples collected in the plant as well as the
bullion after smelting there by giving its gold fineness. The environmental officer makes sure
environmental policies are observed and complied with. The safety officer is an activist whose
role is to make sure employees are safety conscious at all times.

UNDERGROUND DEPARTMENT
This department is responsible for blasting rock from ore body then transporting the
fragmented ore to a loading point which consists of a grizzly. Ore is classified and the oversize
is sent for further size reduction by crushing with an 18x 32jaw crusher. Undersize is
collected in a central loading bay at 25 levels and hoisted to the surface for metallurgical
processing. Besides driving the mining operations this department has a proto rescue team
which offers rescue services for mining related emergencies. The department is responsible
for the extraction of ore from underground. The department works hand in hand with the
geology and survey section. They also carry out the first stage of crushing reducing the mined
boulders to a transportable size. (150mm).

UNDERGROUND
MANAGER

MINE CAPTAIN

SHIFT BOSS

MINERS
ATTACHMENT PROGRAMME
ACTIVITY TASKS PERIOD DATES OFFICIALS
Survey Survey methods of 1 week 07/10/15 Senior
production plan To surveyor
Basic survey and 9/11/15
installation of pegs
Computers and surveying
Preparation of mining plan
Maintaining and updating
plans

Geology General geology of the 2 weeks 09/09/15 Senior

mine To geologist
Exploration and sampling 17/09/15
Grade control
Use of computers in
geology
Mine planning

Reduction Crushing 4 weeks 9/11/15 Asst met

Milling To manager
Benefaction 15/12/15
smelting

ACITIVITY; GEOLOGY
FROM; 09/09/15 - 17/09/15

This department explores the area to determine the ore body and then goes through grade
and development control as to end up with ores reserves estimates

SAMPLE- This is a small portion of ore taken from an ore body or rock mass to be analysed. It
is considered to be a representative of that part from which it has been taken
SAMPLING- it is a process whereby a small portion of rock taken and assayed\analysed to
calculate the value of that part sample

AIMS

To assist in the planning of mining operations

To calculate ore reserves
To affect an efficient control in the grade of the ore that is mined
To determine tenor in particular areas of the mine

GRAB SAMPLING

A sampling method used to sample broken rock from boxes, cars, draw points, and stock pile
at a face

Tools used;

Bucket, sampling shovel and a mixing pad

PROCEDURE

Ensure area of work is safe from bad hangings, dust etc

Ensure equipment is in good working condition
Ensure you have a correct list of active draw points
Sampling must be random and even and there must be taken from each corner of the
car and centre
The samples are collected into a bucket
At the end of the shift thoroughly mix the sample on a mixing pad before splitting
Conning and quartering should be done on a mixing pad to avoid contamination
Repeat the conning and quartering process until a measurable size sample is obtained
Ticket the sample
Sketch the pile and indicate positions of each sample(origin of sample)
Double check that the number of samples listed tallies with the number of samples
taken
Transport and log samples accordingly
Report any unsafe work to your supervisor
ACTIVITY; REDUCTION (PROCESSING PLANT)
FROM;09/11/15 - 15/12/15

CRUSHING CIRCUITS

Crushing circuits may be open or closed depending on product size. In open circuit crushing,
undersize material from the screen is combined with the crusher product and is then routed
to the next crushing operation (intermediate crushing stage). In closed circuit crushing, the
undersize from the screen is the finished product. The oversize material is re-circulated and
fed to a tertiary crusher, the crusher product is returned to the same screen. The screen
undersize is ready for milling.

CRUSHING CIRCUITS APPLICABLE AT HOW MINE

THE PRIMARY CRUSHING CIRCUIT

This is an open crushing circuit. Ore from the rough ore bin is fed to conveyor belt number 1
using either one of the three chutes via vibratory feeders. The belt discharges the ore onto a
vibrating grizzly screen of aperture size of 50mm. This allows the fines to bypass the jaw
crusher, thus reducing the load on the machine.

feed

14 x 24
(+)
jaw crusher
50mm grizzly
(-)
Conveyor belt number 2

THE SECONDARY CRUSHING CIRCUIT

This is an open circuit. The ore on conveyor belt number 2 is fed to a 50mm x 25mm vibrating
screen. The oversize material is fed to a 36 inch Gyratory Crusher. The undersize from the
screen meets up with the crusher product on conveyor belt number 3.

Feed end

shell

Crushing head

discharge
Eccentric sleeve

shaft

Feed conveyor 2
 36 gyratory crusher
(+)(+)

Vibrating screen
number 2

(-)
Conveyor number 3

THE TERTIARY CRUSHING CIRCUIT

This is operated in a closed circuit. The ore on conveyor belt number 4 is discharged onto
conveyor belt number 6. Conveyor 6 feeds the main vibrating screen ( 10mm x 10mm, 17mm
x 25mm, 20mm x 20mm) aperture sizes. The screen undersize is ready for milling and is
transported by belt number 7 to the fine ore bins for storage. The oversize is re-circulated on
conveyor number 5 to the Barmac crusher. The crusher product is again sent to the main
vibrating screen.
Conveyor number 4

Conveyor number 7

(-)
Conveyor number 6 Vibrating screen
number 3

(+)

Conveyor number 5
Barmac 9 600
Barmac 9 600
duopactor
Duopactor

SAFETY DEVICES FOUND IN THE CRUSHING PLANT

Sirens these are used for communication reasons. The crushing plant is noisy and rarely can
people communicate verbally with each other. Four long rings signify that the plant is about
to be started. Move away from machinery like the conveyors, vibrating screens and crushers.
One long ring signifies that either the operator on the gyratory crusher or barmac crusher is
facing a serious problem and needs help. Two long rings tell the jaw crusher operator to
resume operations. One long ring that stops conveyor number 1 signifies that a tramp metal
has been detected in the ore, the operator must remove it.

Guard rails these are there to protect the operators from accidentally falling from heights
and ladders. They also provide safe platforms to view the crushers from.

Trip switches these are installed on conveyor belts for emergence stops in cases that include
an operator being trapped by the conveyor belt, ore is falling from the conveyor belt, idlers
and rollers are falling off. The switch is also used to lock the conveyor when maintenance
work is in progress.
Panic/ emergence buttons these are buttons that override any controls in the crushing
plant when activated in cases of serious emergences like fires, potential life loss, equipment
damage and failure and loss of control on equipment.

Lightning conductors protection of equipment and operators during thunder storms.

Earthing of all equipment and structures this facilitates in welding and also protects the
operators from static electric shocks.

Guards/ covers these are placed on all moving parts especially on electric motors, crusher
and vibrating screen fly wheels, conveyor pulleys. The covers protect operators from
fatalities.

Fire extinguishers fires usually arise from the electric motors in the crushing plants. These
are put in place to manage fires at a tender stage.

Controlled entry into the plant the whole plant area is fenced this ensures that only
authorized people are allowed to work or visit the plant.

Danger signs these are put in place to alert operators of the hazards that they are prone to.

SAFETY HEALTH AND ENVIRONMENTAL ISSUES IN THE CRUSHING PLANT

The table below shows the risks and hazards associated with the crushing operation and how
these are managed and controlled.

Risk/ Hazard Control Notes

Dust -open water sprays enough -exposure to dust damages
to suppress dust the lungs and results in
-wear respirators respiratory diseases like
-use water for cleaning floors pneumoconiosis and TB
Noise -wear respirators -damages ear plugs and
-avoid close range with noisy results in loss of hearing.
equipment where possible
Moving conveyors -never work under or near -being trapped by a moving
moving conveyors conveyor results in body parts
-lock the conveyor belt using loss
the trip switch when working -one can be trapped to death
near conveyors
Heights and ladders -guard rails -falling from heights results in
-never skip ladder steps body parts loss and death
-always walk in the plant, -falling on sharp objects also
running does not speed up results in body parts loss and
production. death
Falling objects -avoid working under -falling objects can result in
machinery, beware of falling severe damage to the head
ore and falling idlers and may result in fatalities
 -always put on the hard hat
Flying stones from the -do not use naked eyes to -small sharp stones may
crushers peep through the crusher, result in eye damage
put on goggles -bigger stones may cause
-do not throw stones into the severe body parts damage
crusher whilst it is working
Pipes and metal objects on -always put on safety shoes -can result in severe damage
the ground with a steel cap to the feet
-wear gumboots
Over head crane -always be alert and check if -can result in severe damage
the crane is in use. and even death
It is mandatory that each and every shift should hold a safety talk before work
commences. The hazards associated with the activities, their consequences and
controls are discussed during the meeting.
All operators should report any unsafe areas and machinery they would have
identified to the supervisor on duty.
Above all the employee should always take an act of safety
A fine is charged on anyone found doing unsafe practices in the plant.

CRUSHING PLANT TROUBLESHOOTING GUIDE

Problem/ Sign Likely cause Corrective Measure

Less than normal ore on -ore depletion in rough ore -inform and enquire from
conveyor number 1 bin North shaft on ext 777
-vibrating feeder is not -remove stones wedged
working or has been wedged between vibrating feeder
by ore stones and the belt skirt
-iron bars on the feeder -adjust the iron bars to allow
outlet are too tight more ore to pass
Conveyor number one -ore from underground is too -adjust the iron bars to
overload fine reduce the feed.
-iron bars on the vibrating
feeder are too loose
Chocking of chute number 1 -oversize material from -watch out and remove
underground these big boulders from the
-metal bar passed the belt before the ore reaches
detector undetected the chute.
Chocking of the jaw crusher -over feeding -feed the crusher in batches
-ore has caused bridging, the -stop conveyor 1 and remove
transverse length of the ore oversized ore from the belt
is bigger than the jaw before the crusher
crusher feed end -replace v-belts and remove
-breaking of jaw crusher v- all the chocking ore from the
belts crusher physically
Stand-by jaw crusher does not -ore escaping through some -tightly close the divider or
start openings on the jaw crusher install a fitting one
feed divider plate wedges -remove the stones between
the jaws of the stationery the jaws using a crow bar
 crusher
Jaw crusher crushing sound -overloading of jaw crusher -remove blinding from
slightly reduce and becomes -the crusher is about to vibrating screen 1-too much
slow and at the same time trip down fine material was being fed
fading out to the crusher
-reduce feed rate

Production of oversized -worn out jaws -replace jaws or turn them

material by jaw crusher -jaw setting is not properly upside down
adjusted -proper adjustment of the
gap
Gyrator crusher -overloading -remove blinding from
chocking -oversized material vibrating screen number 2 to
-ore is too damp allow the fines to bypass the
crusher and thereby
reducing the load on the
crusher.
-reduce feed rate
-adjust jaw crusher setting
-gyratory gap is too small
adjust it
Production of oversize -setting is too big or large -adjust crusher setting
material by the gyratory
crusher
Sudden reduction of crushing -crusher is chocking -reduce feed
sound by the gyratory crusher -v-belts are broken -replace v-belts
Vibrating of the barmac -damaged tips -replace tips
crusher
Whistling of the barmac -chocking Reduce feed
crusher

HOUSEKEEPING

This is one of the most strenuous activities on the plant. The cleaning up of the plant is called
housekeeping. Housekeeping is done mainly during maintenance time, when ore is depleted
from the rough ore bin or when deemed necessary. Shovels, scrappers, wheelbarrows and
hose pipe water are the major tools that are used for housekeeping. A lot of litter (wood,
plastics, PPE, wires, tramp metals, etc) is found in association with the ore from underground.
These are removed and are classified or segregated for the ease of disposal. Metals caught up
on magnets are also removed and thrown into the metal litter bay.

MOVEMENT OF ORE FROM UNDERGROUND TO THE ROUGH ORE BIN AND

TO THE FINE ORE BINS
MILLING
Milling is the final stage in the process of commination. The feed from the silo bin is
deposited onto the jump conveyer belt to the common conveyer belt taking it to the trouser
chute which divides the 8 * 16 mill feed and the transfer conveyer feeding mill 1 and mill
2.The feed is introduced into the mill through a feed hopper. The charge in the mill
experiences abrasion and cascading medium. The mill discharge does through the trammel
screen. The overflow of the screen, that is, rejected materials goes back to the ball mill for
further grinding. The underflow is pumped to the hydro cyclone by the 8/6 war man
pump.Overfeeding the mill may result in poor grinds, lowering of pulp density, chocking of
pumps and less production. On the other hand underfeeding the mill may result in wastage of
electricity, increased mill liner wear and less production.Lime is added to all three mils at a
rate of 75kg/hr. along the common conveyer belt. Lime is used to maintain the pH at alkaline
conditions of pH 8 - 9.5.Lime helps to prevent cyanide from decomposing .At a pH below 8
cyanide decomposes to form a very toxic substance called hydro cynic acid. The pH has to be
maintained always in order for cyanide to dissolves the gold.

THICKENING

Thickening is a dewatering process whereby the dilute pulp is separated into two components
one being partially free of liquid and one being completely free of solids. Convectional
thickening is the method used with the aid of a flocculent. The purpose of thickening is to
increase the pulp density from 8 10% solids to 43 45% solids by mass. This reduces the
size of the leaching plant required as well as reducing the amount of reagents used. The pulp
from the mills is pumped to the thickener and discharged into the thickener via the feed well.
The feed well is a means of introducing the pulp at an appropriate depth in the thickener as
well as dissipating energy movement in the feed stream.

CARBON IN PULP

Leaching is a process of extracting gold of low grade ore by dissolution with sodium cyanide,
in the presence of oxygen. Leaching takes place in a series of two leach tanks with agitators.
Agitation leaching is a mechanical process where the blades in the leach tanks rotate and for
proper mixing of reagents in the pulp, to create or allow homogeneity in the entire leach tank.
Leaching of gold is conveniently represented by the Elsner equation: -
4Au + 8NaCN + O2 + 2H2O 4NaAu (CN)2 + 4NaOH

THE LEACH TANKS

Feed of 43 45 % solids is pumped into the leach tanks 1 and 2. the pulp enters the first leach
tank 1 through a feed box. Compressed air is added in tank 1 as source of oxygen to speed up
the reaction and achieve maximum dissolution. The pulp then flows to another 450cm3
capacity tank 2 where all the gold is expected to have been dissolved and is ready for
adsorption. The pulp then flows to 6 carbon tanks. These tanks are in series to each other. Due
to gravitational forces the pulp succeedingly flows from the first tank to the last tank via
launders. As the pulp moves down from one carbon tank to the next carbon tank the carbon is
retained in its tank by interstage screens. These screens only allow pulp to move down stream
and thus prevent carbon migration downstream. If carbon migrates downstream loaded carbon
will return into the process resulting in low recovery. Blow pipes are placed next to the screens
to prevent blinding of the apertures by carbon and aid the pulp in moving to the next tank
hence preventing overflowing of the tank. Air lancers are used to suspend carbon that has
settled. Once the pulp has passed through all six tanks.
ACTIVITY; SURVEY
FROM; 07/10/15 - 15/10/15

The survey department falls under the technical services department

It deals with;

Calculation of tonnage and volume of ore mined

Drawing of plans, records figures\tables
Drawing of lay outs
Measurement of rainfall
Determination of elevations and distances

SURVEY PLANS

Plans are drawn on different sizes of paper depending on the size of ore being represented and
the scale used

On the plan ,ANG line parallel to the north is the y-axis(this is how the y and x axis\grids are
determined)

WHEN DRAWING A PLAN

Cut the paper size

Draw the border line
Know the source of the ore body
Grids must be 25m apart
Survey system employed at how mine is Lo 29degrees zero south
A scale rule is used for drawing border lines
Light table is used for tracing

In underground survey the following activities are carried out; grade installation, survey
transfers, traversing, development updates, and survey control

SETTING OUT; MARKING OF CENTRE LINES UNDERGROUND

Tools used; Bob tape, 50m tape, 30m tape, paint, clinorule

This was to mark\give direction to be followed to get to the ore body. After locating the
pegs\points needed, the horizontal distance between the 2 pegs is measured and another tape
cutting across the required distance is placed on top of the other tape. The angle required is
then measured and then removed from where the 2 tapes meet. The tapes are shifted until they
form the required angle. The tape from peg 1 to another is removed leaving the one cutting
across.A stone is then dropped at the centre and where it falls a light is placed facing up .all
lights are switched off except the one put under the tape .the shadow of the tape will be seen on
the wall enabling a line to be drawn using paint on the walls with the shadow as a guide.
MINING ATTACHMENT PROGRAMME
ACTIVITY TASKS PERIOD DATES OFFICIALS
Lashing Development lashing 5 weeks 21/01/15 O/ miner
Stope lashing To
11/02/15
Production Loader lashing 3 weeks 11/02/15 o/ miner
Loco tramming To shift boss
Grizzly operation 06/03/15
Ore handling and hoisting
Secondary blasting

Shaft Shaft exam and 3 week 09/03/15 Timber

construction maintenance To man
Transportation of heavy 13/04/15 Shift boss
materials
Construction work and
waste disposal

P.T.V Installation of pipes and 1 week 05/08/15 o/ miner

tracks To
Installation of barricades 12/08/15
Raise rigging

Drilling and Development 6 weeks 24/04/15 o/ miner

blasting Lateral development To shift boss
Raises 05/06/15
Face marking
Drilling and charging
Stoping
Long hole drilling 08/06/15
Ring charging and blasting 5 weeks To
13/07/15
Explosives Distribution 1 week 27/07/15 o/ miner
Storage To m/ captain
Handling 1/08/15

Rock drill Machinery maintenance 2 weeks 14/07/15 o/ miner

shop and repairs To m/ captain
25/07/15
Supervision Lashing 12 weeks 23/09/15 o/ miner
Production To m/ captain
PTV 14/12/15 shift boss
Development
Stoping
ACTIVITY; LASHING
FROM;21/01/15 - 11/02/15

It is the transfer of ore\waste from a blasted end to a tipping point.

Lashing procedure

Firstly safety talks are carried out before work progresses

The muck pile is then watered down to suppress dust and dilute mine gases, enough
water is indicated by clear water flowing from the muck pile
When watering down, you bar down bad hangings using a pinch bar to a distance of
8m from the muck pile
After the working place has been made safe, lashing can then commence
In manual lashing ,ore\waste is lashed using a shovel into a wheelbarrow which then
tips into an ore\waste pass
For purposes of safety, at a stope or within 2m of an ore\waste pass, a safety chain
anchored to a lifeline must be used
A tipping barricade should also be placed
Do not undercut the muck pile to avoid collapse of the muck pile which might cause
accidents
11 shovels = 1 wheel barrow on average
22 wheelbarrows=2t coco pan

Purpose of lashing

To measure tonnage from previous blast

To check for over breakage which might be caused by undercharging or drilling
shorter holes than required
To expose lifters and misfires
DATE WORKPLACE WORKDONE

21/01/15 to 11/02/15 Sublevel 26 level 10 metres Did hand lashing using a shovel, lashed 143
wheelbarrows into an ore pass

06//02/15 to 11/02/15 Sublevel 26 level 20 metres Manual lashing into an ore pass.190
wheelbarrows lashed by a lashing crew of 6

06/02/15 to 02/02/15 Sublevel 26/20 to 26/10 Manual lashing,102 wheelbarrows were

levels lashed into the ore pass

PROBLEMS OR CHALLENGES FACED

Insufficient number of equipment such as shovels, wheelbarrows

Old and worn out tools that need replacement

Shortage of labour

RECOMMENDATIONS

Purchasing of new equipment to replace the old, dilapidated ones

Employing more lashers

ACTIVITY; PRODUCTION (TRAMMING)
FROM;12/02/15 - 06/03/15

Tramming is the transportation of ore through a track work system to the designated
tipping point or using a LHD or conveyor in a trackless system. The main production
levels are 24l and 26l. Ore is trammed in haulages from the draw points where an air
loader-locomotive combination is used and then tipped at grizzley by the locomotives.
Ore is mined from above levels; it can be either from open Stope sublevels or from
coning levels. Ore that is drilled and blasted goes through ore-passes and is collected in
the cones and goes through the ore passes to the draw points.

TYPE OF MACHINERY USED FOR TRAMMING FROM DRAW POINTS TO

THEGRIZZLEYS

Air loader with a 1 tonne capacity bucket.

Battery powered locomotive which pulls Granbys with a 5 tonne capacity each

In the case of large boulders choking the cones or at the draw points, secondary
blasting is carried out to further fragment these large boulders

SIGNALS

The following whistle signals should be used:

1 blast - stop when loco is in motion

1 blast - move forward when loco is stationary
2 blasts - reverse
2-2- reverse slowly
1 long blast- move to grizzly

SECONDARY BLASTING

Secondary blasting is a result of poor fragmentation of primary blasting

Poor fragmentation is caused by poor stemming, poor timing, hole deviation
and poor burden and spacing
During secondary blasting of several large boulders, detonating fuse is used in
conjunction with 0.9m capped fuses, mega mite cartridges and ignitor cord
Detonating fuse is used as it results in all the boulders breaking up at the same
time hence reducing the chance of misfires occurring like when only capped
fuses and ignitor cords are used on separate rocks
During secondary blasting, first an alarm is rang thrice then after initiating the
ignitor cords, verbal warnings should be given by guards who also barricade
and prevent persons from coming to the area to be blasted
The re-entry period is 5minutes, so after 5 minutes the compressed air pipe is
closed as it would have been opened soon after blasting
 A locomotive pulls on average 4 or 5 Granbys and tips at the grizzly at the 24
level
From the grizzly the ore goes into an ore pass and then into the jaw crusher at
the 24.5 level ,the crusher reduces the size of the ore to about 150mm.the jaw
crusher is an impact crusher and has a swinging jaw and a fixed jaw. The
swing jaw hits ore against the fixed jaw.
from the crusher the ore moves via a conveyor belt to the 25.5l which is the
loading level where it is loaded into a trouser chute system which allows two
skips to be fed one at a time depending on which compartment is in use
the ore is then hoisted to the surface in two 5 tonne skips in the north shaft
these skips alternate and each takes about 3minutes 30seconds to reach the
surface from underground
the ore is taken to a rough ore bin above the plant by a 2 tonne coco pan being
pulled by a locomotive powered by 20 lead acid batteries of 2 volts each

LOCOMOTIVE DRIVER DUTIES

- Carry out pre-shift checks to ensure the loco is in good working condition

- When the locomotive is to be left for any period of time, it should be locked out

- Never remove the plug from the power supply if the locomotive is under load,
i.e. the lights or siren is on or the locomotive is in motion.

- Never carry passengers in the locomotive or in the cars

- Never allow an uncertified or unauthorised person to drive the locomotive

- Keep the drivers compartment clean and clear of any object which could move
when the locomotive is in motion. Ensure that every locomotive has a fire
extinguisher or carries a tin of sand

- Never attempt to stop a locomotive in motion by reversing the direction of

travel on the controller and applying power

- Never pull more than the authorised number of cars, see step 20

- Slow down at all bends, junctions, and switches and on approach to the grizzly
and sound the hooter.

- At the end of the shift, take the locomotive to the battery bay, transfer the
battery to the rack, remove the battery cover, put the battery on charge and
clean the locomotive.

DUTIES OF A LOCOMOTIVE ASSISTANT

Proceed in front of the train when the locomotive is at the rear, i.e. pushing the train,
and remain at a distance of 20-30m from the train

- Check all tracks and turnouts; remove rock, debris and other obstructions from
the tracks.

- Place the stop light on the end car and ensure that it is functioning.

- Make reports on any defective equipment including cars, loco jacks etc. Ensure
the overseer miner is informed immediately

- Ensure that no personnel climb between the locomotive and a car or between
cars

- Ensure that No Smoking signs are observed in the battery and service bays.
No smoking is permitted whilst driving or working near the locomotive

- Coupling of cocopans shall be done only with 10mm link chain and a 25mm
round bar pin

- No coupling shall be done whilst the cocopans or locomotive are in motion

- At the end of every shift, the batteries from a battery locomotive should be
transferred on to the rack in the battery bay and the battery put on charge. The
charging of a battery whilst still on the locomotive is not permitted

- At any time that cocopans are separated from the loco they must be spragged
with a suitable heavy duty chain.

Also carries out the functions of the box operator, as follows:

Keep the area around the box free of spillage.

Ensure that cars are positioned centrally before opening the box.

Check that all personnel are clear of the box and cars before opening the
box.

Use the pinch bar provided to relieve any hang ups.

Ensure that all cars are filled flush to the top of the bodywork.

EMPTYING COCOPANS

One lasher should unclip the locking pin on the base of the cocopan.

Two lashers should tip the cocopan over on its axis using the handles on the
long side of the cocopan in order that the contents fall into the rock pass.
 One lasher should assist the tipping by pushing one handle on the short side of
the cocopan upwards with the tipping device.

One lasher must ensure that the cocopan is held in place with a 1m restraining
pipe placed under the side flange.

Whilst in the fully tipped position, one lasher should ensure all material has
been removed from the cocopan using the 14lb hammer on the reinforced
sections of the unit.

When the cocopan is empty the restraining pipe should be removed. The
tipping device should then be removed so that the cocopan can return to the
chassis. The cocopan must then be locked onto the chassis.

Ensure the cocopan is secure on its base before signalling to the driver to move
the train forward.

After tipping cars at the grizzly, the cocopans should be cleaned thoroughly
with a shovel or pinch bar and then blown out with compressed air. Any
material or caked dirt should be removed by hammering on the reinforced
sections

NOTE THAT

. No smoking is permitted whilst driving or working near the locomotive.

. Never allow an uncertified or unauthorised person to drive the locomotive

PROBLEMS OR CHALLENGES FACED

Locomotives- derailments, flat batteries

draw points-choking of raises by large boulders, derailments of air loaders, misfires
when blasting
crusher-jamming of jaws when a rock lodges itself firmly between a fixed jaw and a
swinging jaw
Power cuts and low compressed air, insufficient to operate the air loaders

RECOMMENDATIONS

Improve drilling efficiency so as to reduce the extent of secondary blasting

regular servicing of locos and maintenance of tracks
improve compressed air supply
Ensure loco batteries are fully charged in-between shifts at loco bays and that extra
fully charged batteries are always available.
ACTIVITY; SHAFT EXAMINATION AND SERVICING
FROM;09/03/15 - 13/04/15

Duties of the shaft crew

Shaft examination and maintenance

Shaft equipping

General shaft house keeping

Shaft construction, includes barricading and pipe fitting

SHAFT EXAMINATION PROCEDURE

Log in the hoist drivers log book indicating time of commencement of exam and
official in charge before the exam starts
After logging in the book, communicate verbally with the hoist driver in regards to
carrying out the exam
Shaft examination of the main shaft is carried out on Tuesdays and Thursdays and that
of the north shaft is carried out everyday
6-6 bells are rang to indicate to the driver that shaft exam is to begin making use of the
key bell
Driver replies 6-6 bells acknowledging that the exam may begin
The cage is lowered using 2-2 bells so that a safety hood can be fastened on top of the
cage
1 short bell signals the driver to stop the conveyance
A platform is put once the cage is low enough such that the shaft crew can disembark
on top to fasten the hood , then the platform is removed
Safety chains must be used throughout this procedure
After the hood is fastened , the cage is raised slowly using 3-3 bells and stopped using
one short bell
The safety chains of the men are tied on the humble hook of the conveyance along
with the rest of the equipment they need which will be placed on top of the
conveyance such as cutting torch, hoses and the two gas cylinders, tool box
containing spanners, hammers, chisels, bolts and nuts, washers, tape measures,
pinch bars, T-pieces and gaskets
After the men are satisfactory secured they then proceed with the examination
 Movement of the conveyance is through the 2-2 and 3-3 bells
As the conveyance is descending slowly men will be knocking the runners with a
hammer to check for their rigidity and alignment as well as checking all the buntons
to make sure they are secure , all nuts that are loose should be tied and all bad
hangings should be brought down
All pipe leakages are sealed
The shaft is searched throughout its length and upon reaching the shaft bottom, it
returns to the surface where the hood is removed
Upon removal of the hood ,6-6-6 bells are rang to release the conveyance and to
mark the completion of the shaft examination
The official in charge then signs out in the hoist drivers log book

CHALLENGES OR PROBLEMS FACED

Pipe leakages in shaft especially water pipes

Rust forming or accumulating on the runners and buntons

Misalignment of runners hence leading to bumps when conveyance is in motion

RECOMMENDATIONS

Complete replacement of all old pipes

Applying grease or any other lubricant on the runners to prevent the formation of rust

Secure tightening of all nuts on the buntons to prevent misalignments

ACTIVITY; PIPES, TRACKS AND VENTILATION (P.T.V)
FROM;05/08/15 - 13/08/15

-The duties of the P.T.V crew are;

track laying
pipe fitting and repairing
installation of water blasts at development ends
installation of force and exhaust fans
construction of ventilation doors
placing of barricades and lifelines

Tools and equipment used

Spanners(sizes 24 and 48), size 48 ranch spanner, hacksaw, chisels, 4 pound hammer, bends,
T-pieces, clamps, blockers, nipples, spots, couplings, valves, reducers, gaskets, bolts and nuts,
Frenchs

INSALLATION OF A WATERBLAST,

A water blast was installed at every development end being blasted

A water blast unit is a device that uses compressed air to produce a fine spray of
water that is used to suppress dust and fumes at all development ends
A water blast should discharge at a distance of between 8m and 15m and should be
opened for a period of not less than 15 minutes
 It has 2 inlets , one for water and the other for compressed air and outlet for the
discharge pipe

Track laying at 26 level main haulage drive

The top of both tracks shall be 1m below the grade line and shall be horizontal. The
spirit level should be used to check this. At bends the outer rail should be 12mm
above the elevation of the inner rail

The top of the drain shall be at the same height as the bottom of the slippers in order
to allow the tracks to drain freely.

Track layout

0,61
mmm Rail
Cotch screw
45lb

Wooden
slipper

Drain apex

Salvaging of old slippers and cotch screws in old working areas which were to be used at 070
cross cut. Safety should be considered when working in old working areas since gases like
hydrogen sulphide are likely to be present.

Bending of rails using Jim crow

Procedure

Lay the rail in a convenient position, and secure one end.

Lay out the curve on the footwall of the haulage or drive using chalk or paint.
Alternatively, use a curved rail as a guide, or use the line of holes in the sleeper.
 Mark the crown of the rail every 0,3m. These will be the positions where the shoe of
the Jim Crow will bear. Do not bend up to the fish plate holes, except for particularly
sharp curves that will not be used for normal tramming.

Place the Jim Crow, with the claws gripping over the crown of the rail. Screw the shoe
hand down tightly.

Raise the arch of the Jim Crow to a horizontal position, and hold it in place by sliding a
pinch bar over the rail and under the arch.

Place a raise pin or piece of round bar into the hole in the screw head, and turn until
light strain is produced in the rail. The same amount of strain should be used for each
bending operation. Actual bending is measured by counting the number of turns of
the screw beyond this point.

Give the screw one complete turn. Release the screw and repeat at every chalk mark.

After completing a length of bend, check the track. Repeat the above steps if further
bending is required.

Supply of compressed air should be in such a manner that it is pure air without water hence
water traps should be incorporated in the main compressed air line. According to SI 72 of
1989 section 62 the air valves in case of raises should be placed at the foot of the raise.

MENDING OF LEAKS

Clamps are used for sealing all leakages on pipes,

BARRICADING

Safety barricades are put at all open stopes, ore passes, pits or anywhere else where there is
a risk of someone falling in

Barricades are removed prior to blasting operations and then re-constructed after are-entry
procedure

VENTILATION

Ventilation is carried out by force fans and exhaust fans

Ventilation doors are also constructed near each shaft main station, so that fresh air from
surface which will be downcast in the shaft can reach the bottom of the shaft before it is
diverted into haulages in various levels. The ventilation door shall be kept closed at all times.

PROBLEMS OR CHALLENGES FACED

Pipe bursts and plenty of leakages due to old pipes

Shortages of safety chains

RECOMMENDATIONS

Change old piping and fit new pipes

JACKHAMMER DEVELOPMENT DRILLING

FROM;24/04/15 - 05/06/15

In the month of May to June the trainee was attached in the development drilling and
blasting section. This report is therefore a summary of the activities carried out concepts
learnt and practiced by the trainee during this period as shown in the table below

DEVELOPMENT DRILLING AND BLASTING

Development drilling at how mine is done using jack hammers. Development blasting at how
mine is done using mega mite explosives size 29 capped safety fuse, igniter cord and an
electric shur starter.

Introduction to development drilling and blasting

This is the drilling that is carried out at all development ends, whether to create raises, drives,
tunnels, cross-cuts, haulages or by-passes.Development drilling and blasting are the life blood
operations of how mine. Development drilling and blasting is mainly meant for development
operations which include

a) sub level drive development

b) haulage development
c) raise development
d) cone/draw point development

Jack hammer

A jack hammers is an electro mechanism tool that combines a hammer directly with a chisel
hence it is used for rock drilling. Jack hammer which are used at how mine are powered by
compressed air .jack hammers efficiency is dependent on the amount of force applied to it
and in in this case the amount of compressed air is a major factor.

Types of jack hammer used in development

 s215

Drill bits used development drilling

The jack hammers in development drilling use button bits with dimensions of:

Drill steel dimensions of jack hammers in the development section

Air leg

In development drilling jack hammers are supported by hydraulic air legs which drilling which
include:

a) Retractable air leg

b) Non retractable air leg
c) Telescopic air leg

Six 6 burn cut

In development drilling the surface area of drilling ends is moderate to small and less
competent in terms of the rock strength hence six burn cut is recommended this is shown
below:

Four (4) holes are charged on a six burn cut and 2 holes in the middle are used as breathers.

Nine (9) burn cut

When drilling in a haulage drive the surface area to be drilled is large and the rock strength is
competent so a nine burn cut is used as shown below:

Nine burn cut will have 5 holes charged and the other 4holes will remain uncharged and act
as breathers which are used as the free face when blasting.

Drilling operation

Before any drilling operation a competent person clears all the sockets and marks the
face to be drilled.
Watering down and barring down of bad hangings
Connection of water connection of water and compressed air pipes to the jack
hammers
Testing of the jack hammers
Lubrication of the machine
The amount of water supply to the jack hammers should be enough to cool down the
friction and flushing away the sludge when drilling
The starter is said to start the drilling operation and the finishes the drilling
The drilling holes must be away from socket with at least 15cm
The machine operator must strictly drill on marked position
Charging operation

In development blasting charging is done using mega mite explosives size 29.charging is done
to enable blasting hence fragmenting the rock in to small granules hence advance in haulages
and sub levels and tonnage targets are achieved. Charging is carried out by a competent
person who is an MBL mine blasting license holder. The charging procedure in development
blacking is show below in sequence from the drilled hole

Explosives Safety fuse Igniter code

(megaa

Blasting cables Electric shur

starter

a) Blasting cables

There are two electric cables one position and one negative which supply power to the
blasting end .the two cables are tested by a continuity tester before connecting to the electric
starter.

b) The electric starter

An electric starter igniter cord the electric starter receives electric power from the positive
and negative cables

c) Igniter cord

Igniter cord is used to initiate capped safety fuses in various blasting operation. Igniter cords
perform post connection timing for detonation to be effectively carried out.

d) Capped safety fuse

A green safety fuse has delaying or burning speed of 1cm /sec the safety fuse is a tube with
a gun powder coated surround by a water proof varnished jute /rope

e) Explosives

Mega mite size 29explosives are used at how mine .mega mite explosion are packed in
cartridges
Face marking

a) Sub level drive face marking (3x3 cut design).

b) Haulage drive face marking

Back hole

Burn Cut

Side Hole

1.8m

Big easer

Lifter

Drain Hole

1.6m

Activity 1

Drilling operation at 26 level haulages and 26/20 sub level

Responsibilities

Drilling miner Makombe

Objectives

1) To enable the charging procedure

2) To enable blasting
3) To breakdown or fragment the rock
 4) To meet advance and tonnage target

Tool or equipment used

Key spanner
Jack hammers lubricating
Drill steels
Red and yellow paint
PPE
Jack hammers
Retractable air leg
Water and compressed air hose
Pinch bars
Socket

Procedure

a) Safety talk
b) Barring down of bad
c) Watering down of wall
d) Blowing of misfires and socket
e) Installing socket plug in socket
f) Marking of the face and maintaining a distance of15cm from the socket
g) Drilling operation commences
h) A competent person checks if all holes are drilled according to markings
i) Washing/clearing of sludge from the drilled holes using water
j) Drying of the drilled holes by using a blow pipe and compressed air
k) Housekeeping of machinery and hose pipe

Problems encountered

Faulty air leg which was not retracting consistently

Recommendations

Repairing the air leg at the rock drill shop at 16 level

Activity 2

Charging a drilled round at 26 level haulage drive and 26/20 300n sub level drive

Responsibilities

Mine blasting license MBL holder

Objectives

1) To fragment the drilled ends

2) To meet daily tonnage targets
3) To enable production operation of tramming
4) To facilitate blasting

Tools or equipment used

Blowing pipe
Aluminum charging stick
Mega mite explosives size 29
Electric cables
Chain barricades
Water blast
Capped safety fuse
Igniter cord
Tamping /stemming material
Sign post
Electric starter

Procedure

a) Clearing of sludge from drilled holes using water

b) Clearing of drilled holes using compressed air
c) Transportation of explosives from the magazine
d) Priming of explosives
e) Charging of the primed explosives into the drilled holes
f) Charging of explosives into the drilled hole amounting to effective fragmentation
g) Using a charge stick which is non-ferrous
h) Stemming of charged holes to improve fragmentation
i) Tying of long safety fuse cables
j) Timing of charged holes using an igniter cord
k) Connection of the electric starter
l) Testing of the electric cables using a continuity tester
m) Connection of the electric cables to the electric shur starter
n) Securing the connection with insulation tape
o) Installing a chain barricade to the charged end
p) Checking if the water blast is working properly

Problems encountered

Charging was difficult due to large diameter deviations in the bits used as starter and
finisher in the drilling procedure.

Recommendations
 The diameters of the starter and the finisher used in drilling the holes must not have
large deviations.
The diameter of the finisher must not be smaller than the diameter of the mega mite
cartridge size 29.

Activity 3

Installation of blasting cables from 24 levels to 26 levels respectively using grout cement

Responsibilities

Development drilling and blasting supervisor

Objectives

1) To facilitate movement of electricity for blasting operations

2) To enable the blasting procedure
3) To secure the cables from damage
4) To meet the OHSAS requirements of employee safety at the work place

Tools and equipment used

Grout mixing pot

PPE
Grout cement
Electric cables
Cable clippers
Continuity tester
Insulation tape
10cm cable separators

Procedure

a) Lining of cable at about 1.5m from the foot wall

b) Testing of cables after every 10m interval using a continuity tester
c) Connection and insulation of joints on the electric cables
d) Mixing of grout cement and water using the grout mixing pot to secure the cable
clippers to the sidewalls
e) Securing the electric cables
f) Warning persons not to disturb the cables

Problems encountered

Damage of electric cables in the production levels

Recommendations
 Checking all cables after the production shift to enable primary blasting

Problems encountered in development drilling and blasting at how mine

1) Low pressure of compressed air about 520 kPa (11/07/13)

2) Shortage of 1.8m drill steels out of stock at the rock drill shop
3) Breakage of 2m drill steels
4) Breakage and stacking of 4 drill bits in the drilled holes (16/07/13)
5) No drilling platform rigged for haulage drive drilling at 26 levels especially when
drilling back holes
6) Long sockets of about 10- 15cm
7) One machine drilling in the haulage drive instead of two machines
8) Faulty air legs
9) Damage of blasting cables
10) Delays in drilling operations due to pipe installation

Recommendations

1) Ensuring that there is proper planning of drilling operations to avoid compressed air
congestion
2) Ordering of drill steels in time to avoid production delays
3) Acquiring high quality drill steels in time to avoid production delays
4) Proper and durable button bits
5) Setting and rigging of a platform for high drilling in the haulage drive
6) Proper charging and use of explosives to avoid sockets
7) According to regulations the 3x3 haulage drive is drilled using two jack hammer
machines
8) Repairs of all faulty air legs at the rock drill shop at 16 level
9) Checking and repairing of all blasting cables after each and every shift before blasting
10) Proper planning of pipe installation to avoid production delays
ACTIVITY; LONGHOLE DRILLING
FROM: 09/06/15 - 10/07/15

PURPOSE

To mine out the ore fully from the stopes, the ore is accessed in sublevels hence the mining
method employed is sublevel open stopping.

DRILLING EQUIPMENT USED

Drifters (Konkolla S36)

Air hose and water hose
Oil
1m extension drill rods
Drill bits(cross)

Production drilling and blasting/ stoping (long hole drilling)

In the month of June to July the trainee was attach was attached in the stoping drilling and
blasting section. Hence forth this chapter is a summary of activities carried out and concepts
learnt and practiced by the trainee during this period as shown in the table below.

Introduction

Stoping is mainly done for the purpose of extracting ore. Stoping at how mine is done by long
hole drilling machines called konkolaseco 36 machines. Stope drilling requires a stratified ore
body shape and drilling patterns and plans are designed by the mines survey department. The
drilling layouts give guide lines of the ore body to avoid drilling in waste ore since it is costly.
Blasting in the production at how mine is done using mega mite cartridges size 38, shock
tubes and also rioflex emulsion with gasoline as a booster.

Importance of production drilling plan and layouts

Specifies how blasting holes are to be collared

Specifies length to be charged per fan hole drilled
Specifies depth of holes to be drilled
Specifies location of the hole
Specifies angles of fan holes to be drilled
Enables calculations of advance and tonnage
Enables future mine planning
Enables drilling guidelines in order to avoid drilling in waste
 Application of stopes drilling and blasting

a) Steeply dipping ore body the foot wall inclination must exceed the angle of repose
b) Competent rock/stable hanging and foot wall
c) Regular ore body/deposit

WORKDONE

RE-ENTRY PROCEDURE

Take a water hose and water down thoroughly

Get a pinch bar/barring stick and bring down all bad hangings

DATE WORK PLACE WORKDONE

08/06/15 24 level 11 north pillar Face preparation was down

i.e. barining all bad hangings
using a pinch bar and
watering down using a hose
to allay dust and to expose
cracks.3*10m slipping holes
were drilled.

09/06/15 24 level 11 north pillar Face preparation was carried

out then 3*7m down holes
were drilled.

10/06/15 24 level 11 north pillar Very low compressed air, no

drilling operations were
carried out.

11/06/15 24 level 11 north pillar and Face preparation was carried

26 level out ,3*7m hole were drilled,
there was a shortage of
extension drill steels used,
only 7 were available

19/06/15 Sublevel 26 /10 metres No water due to burst water

pipes, no drilling operations
were carried out
06/09/13 26/20 level 180 drive north 2*7m holes were drilled,
blunt drill bits, there was a
shortage of water hence the
drill bits were not sharpened.

07/09/13 26/10 400 drive north Face preparation was carried

out then 4*10m down holes
were drilled.

CHARGING PROCEDURE

A detonator is placed into a megamite(38*580)mm cartridge, a hole is put into the centre of
the cartridge about 3 deep using a sharp wooden spike, the detonator is then pushed into
the hole until it is fully inserted, the resultant product is known as a primer. The primer is put
in the hole and cartridges then follow until up to two-thirds of the hole is charged, the
explosives are then pushed home firmly using a copper or aluminium charging rod that is cut
square at the end. The hole is then tamped with mud until the collar of the charged hole is
closed off.

Power cables from surface are connected to an electric starter which is then linked to the
fuse by a length of ignitor cord. The fuse is then connected to the Handidates(shock tubes)
Handidates from each hole are then connected to the breaking point. Barricade the area and
put up a NO-ENTRY, CHARGE END sign and vacate the area in awaitance of blasting at
1500hrs.

Slipping-The purpose of the slipping holes was to create space or pave way for the long
holemachine.

-meant to break ground for exploitation.

DRILLING EQUIPMENT

SECO S215 ROCK DRILL

Air leg
Drill steels(0.6m;1.0m;1.3m;1.5m;1.8m;2.0m;2.3m)
Air and water hoses
Lubrication oil

RE-ENTRY PROCEDURE

Take a water hose and water down thoroughly.

Get a pinch bar\barring stick and bring down all bad hangings.

Expose the lifters from the previous blast and look for sockets
Gang leader who is a holder of a blasting license looks for any misfired holes and if any are
found he pumps out the misfires using a copper, brass or aluminium 2-way blow pipe, making
sure that the water tap is opened first before the compressed air pipe, as heat and pressure
of compressed air might initiate the misfires to blast.

After pumping out the misfires, wooden socket plugs are then inserted into all sockets. Lifters
are exposed to 2m.after the area has been made safe ,the round is then marked using chalk
or paint, taking care to maintain the spacing and also to mark a hole not less than 150mm
away from a socket. Direction lines are also drawn on the hanging wall in order to guide the
machine operator as he drills so as to maintain centre and direction

During drilling

Do not hammer a jammed drill steel. It must be extracted using a drill steel extractor

Do not dry collar a hole .this leads to overheating and pre-mature failure of the steel and it is
also a health hazard.

Do not allow the drill steel to bend. An air leg provides vertical and horizontal thrust as the
hole deepens the horizontal thrust increases and air leg pressure must be progressively
increased during drilling to provide the vertical thrust necessary to keep the drill steel
straight.

If an insert breaks in a hole do not try to deepen the hole as any particles of insert left in the
hole will damage the new drill steel. a new hole must be started.

Slipping holes were drilled to a depth of 1,5m.the holes are collared using the 1,0m drill
steel then after it has drilled its whole length it is removed and the 1,8m steel is then inserted
and drills until only the shank is protruding from the hole, hence making the hole 1,5m in
length. The drill steel tungsten on the 1.8m steel has a smaller diameter compared to that on
the 1.0m steel hence on average the 1.8m steel drills fully in 2 minutes whilst the 1.0m steel
drills fully in 3 minutes.

CHALLENGES OR PROBLEMS FACED

Inadequate supply of compressed air

Shortage of water
Shortage of drilling equipment such as drill bits., drill steels, couplings
Labour shortages
Power cuts

RECOMMENDATIONS

Purchasing of more equipment and spare parts

Training more drilling personnel
Change old water and compressed air pipes, and mend all leaks in order to minimise
pipe bursts which cause shortages of water and compressed air.
ACTIVITY; TRANSPORTATION, HANDLING AND STORAGE OF
EXPLOSIVES
FROM; 09/09/13 - 14/09/13

How Mine has a main magazine situated 500m from the main shaft

The initial capacity of the magazine is 15 tonnes (600 cases *25kg of fractures) but it has been
increased to 29 tonnes (772 cases *25kg of fractures)

Explosives were ordered from the main magazine 3 times a week where they are conveyed by
a vehicle to the main shaft for transportation down to the 16level underground magazine
which has a capacity of 30 cases(750kg fractures) and 4 cartons of accessories

The vehicle carrying the explosives had the following provisions, an earth chain being dragged
on the ground from the chassis of the vehicle, a lining of wood or robber where the
explosives will be placed so as not to expose them to any iron or steel

DOCUMENTS STORED IN THE MAIN MAGAZINE

MAGAZINE REGISTER- It shows the amount of explosives in the magazine and the quantities
being taken in or out. The first in first out policy (FIFO) is used in the issuing of explosives
from the magazine

LIGHTNING RECORD BOOK- A lightning conductor for the main magazine is tested at least
once every 12 months. Either in the months of July, august or September by a competent
person

TEMPERATURE RECORD BOOK-daily temperature readings are recorded in this book,

temperatures in a magazine should not exceed a maximum of 35 degrees Celsius and a
minimum of 2 degrees Celsius. The average temperature of the month of October 2009 for
the underground magazine was 25 degrees Celsius.

LETTER OF APPOINTMENT OF MAGAZINE MASTER-It should be posted on the door and

should have the names of the appointer and the appointee

TRANSPORTATION OF EXPLOSIVES

During transportation of explosives underground by the cage 5-5 bells are rang to
inform the hoist driver that explosives are about to be placed in conveyance
The hoist driver also rings 5-5 bells to acknowledge that explosives are about to be
conveyed
Explosives are not to be placed directly on the floor but should be placed on wooden
trays or boards
 Detonators or capped fuses may only be stored or carried together with other types
of explosives if they dont exceed 2000 in number or if the other types of explosives
dont exceed 500kg in total mass or if there is a distance of more than 75cm between
them
No person shall load, unload or convey explosives between the hours of sunset and
sunrise in a vehicle
Explosives should never be left unattended during their conveyance, they should also
be under the care of a competent person, whether a magazine attendant or master
who is a holder of a blasting license
No smoking or naked lights should be within the vicinity of explosives(20m) and signs
written NO SMOKING should be placed at all shafts stations during the conveyance
From the cage the explosives are placed in an explosives box or trolley which is lined
with wood internally and painted red , and clearly labelled EXPLOSIVES in white, the
explosives are then conveyed to the underground magazine where they will be
placed and registered in the register
After unloading the explosives 5-5-5 bells are rang to inform the hoist driver that all
explosives have been removed from the conveyance

STORAGE OF EXPLOSIVE

If the magazine carries more than 250kg of explosives, its height should be more than 2m

Production and machine gang leaders determine the amount of explosives and accessories
they require by either checking the ore in the draw points and the number of drilled holes to
be charged respectively.

Explosives should be stored in an approved bult under the inspectors approval structure
called a magazine according to the rules and regulations that governs the mining industry.
Below are the requirements under which the explosives should be kept in a magazine and
also after being used in an old explosive box. Conditions in a magazine;

To be stored in regular layers of 2m high

To be readily inspectable

To be stored on wooden pallets

When packed the explosives should be 300mm from the magazine sides and

150mm from the ceiling

Temperatures controls required

i. Use reliable maxmin thermometer

ii. Max temperature 350C

 iii. Min temperature 20C

TYPICAL APPROVED PLAN OF AN IMMOVABLE MAGAZINE

Contraband
box

DOCUMENTS FOUND IN A MAGAZINE

Magazine license to store explosives stating quantity of explosives, class, expiry date
and name of license.

Magazine log book (Issuing and receiving).

Letter of appointment of magazine master.

Temperature record book.

Explosives which remains after a primary or secondary blasting and misfires are kept in a
designed container called Old Explosive box explained below.

OLD EXPLOSIVE BOX

An old explosive box must be of robust construction of non-ferrous material.

Provided with adequate locking arrangement and lock.

Painted red and clearly marked with words OLD EXPLOSIVES.

Indicate the type of explosive that may be placed therein. It must be kept locked at all
times except when removing explosives for destruction.

Must be kept in a dry safe place not less than 15m from other box containing explosives.
CONVEYANCE OF EXPLOSIVES

Conditions of the vehicle

Should run on 4 wheels.

Be in serviceable condition.

Provided with efficient brakes.

All metal portions should be covered with wood or rubber.

The vehicle to have earth leakage chain on the chassis.

Explosive should be securely fastened in the vehicle so that they form part and parcel of
the vehicle.

The mass of explosive should not exceed the gross vehicle mass of the vehicle.

Provision of a fire extinguisher

Explosives to be covered with tarpaulin.

Traveling in built up areas like towns

1. When transporting explosives only gazette routes shall be used.

2. The vehicle should avoid towns and villages as far as is practicable.

3. Conveyance should be done only between sunrise and sunset.

4. Mechanically propelled vehicles shall not exceed a speed of 50km/hr

5. An animal drawn vehicle must not proceed at a faster speed than walking pace.

When underground in track equipped mines explosives are conveyed by trolleys which are
rubberized inside and should be painted red outside and labeled Danger Explosives only to
be transported by valid blasting license holders.

DESTRUCTION OF EXPLOSIVES

Explosives are not to be buried in hope that they are going to decompose or naturally
breakdown for they can be an ever present hazard.

Reasons for destroying explosives

Deterioration

When explosives are no longer needed

Unexploded products after blast

 Mine closure

PROBLEMS FACED

Delay of transportation of explosives from the main magazine to the shaft due to the
unavailability of a vehicle

RECOMMENDATION

Allocating a vehicle especially and only for the sole purpose of transporting explosives such
that no delays are encountered
ACTIVITY; ROCK DRILL SHOP
FROM; 16/09/13 - 21/09/13

The rock drill shop is located at the 16 level

It comprises of two (one underground, one surface) workshops. Altogether, with a four-
member team (three rock drill fitters and one supervisor) Two operate from the surface
others from underground

WORKSHOP REQUIREMENTS

Permanent lighting ,water supply ,separate drainage from the main drainage system because
of oils, compressed air supply, discard bins, storage chambers and lock out system for
compressed air supply

ACTIVITIES THAT WE DO AT OUR ROCK DRILL SHOP

Issuing of drilling accessories to all drilling crews

Issuing of drilling equipment

Servicing of Jackhammers and air legs

Keeping records of all drilling equipment

Records of daily and monthly consumption of all drilling accessories(Taper rods,

button bits, rock drill oil)

Forge work (pinch bars of different sizes)

Discard analysis of button bits and taper rods.

Records of monthly consumption of jackhammer and air leg spare parts.

Educating machine operators and assistants the proper handling of machines.

Other activities not in operation presently involves

Grinding of integral drill steel.

JACKHAMMERS
There are three types of jack hammers at the mine;

Seco 25 with a weight of 29kgs and compressed air consumption of 186,67cfm at

500kp. This is the common jackhammer at the mine because of its high performance.
These are used in development at Renco.

Seco 23 is almost of the same size as the seco25 but differs in piston size and valve
box since less powerful than the Seco 25. No longer in operation at Renco because of
short supply of spare parts from the manufacturers.

Seco 215 .Its a smaller size and light-weight jackhammer found at the mine mainly
suitable for light duty operations such as support holes. Also used in stoping
operations. Its air consumption is 116.6cfm at 500kpa.

AIR LEGS

We have four types found at this mine but only two types are in use now due to shortages in
spares and lack of technical support from the suppliers. They all use compressed air and they
consume 60cfm@500kpa.

D-type there are two kinds, one is retractable and the other is non-retractable. Only
the retractable one is used in development drilling operations.

Telescopic It is used in stoping

Roof bolting a small size used when drilling support holes

LIFE OF DRILLING EQUIPMENT

Jack hammers perform effectively for a period of five years when fully utilised. However,
some can span for more than that depending on the type of service and usage.

When the internal lining of the cylinder wears out, then the machine is condemned.

Drill steels each drill steel should at least drill for total distance of 150m before
replacement. Those, which fail prematurely, are also replaced but in exchange with the
failure as a control measure. They are then recorded on a discard analysis sheet.

COMMON FAILURES OF DRILL STEELS

- Mushroom face, shank failure, collar slip, broken taper (which is the highest
percentage) and broken rod, stuck-in and blasted bent

Each machine is allocated with two x1, 3m drill steels and two 1, 5m/1, 8m/2,3m drill steels
every week.

Button bits -have a life span of 75 metres each. This implies that a machine should be
allocated with two 36mm and two 38mm button bits every week.
Cross bits and expansion rods

FUNCTIONS OF THE ROCK DRILL SHOP

1) Storage and maintenance of drill steels, drill bits and drill rods
2) The following drill steels for the SECO S215 Jackhammer kept at the shop; 0.6m(used
mainly for collaring in raises and cross-cuts) It is also used for pins, 1.0m ;1.3m ;1.5m
;1.8m ;2.0m ;and the 2.3m
3) Drilling machine assistants collect the drill steels at the start of each drilling shift, 4
drill steels are allocated per jackhammer and are to be returned at the end of the
shift for storage and re-sharpening
4) Long hole assistants also collect six cross bits of different sizes at the start of each
shift
5) The shop also issues lubrication oil for both jackhammer and long hole
6) Drill steel bits are re-sharpened after each day, a mark is punched on the shank after
each sharpening until the steel breaks or is no longer in use, that way it can be known
how many times a steel has been re-sharpened or used
7) The diameters of the tungsten tip bit for steels are 34mm ;36mm ;and38mm ,a drill
steel gauge is used to measure the diameter
8) Servicing and maintenance of the SECO S215 Jackhammer and the Long hole S36
Konkolla is carried out by fitters stationed at the rock drill shop, if there is a
breakdown , fitters at the shop are notified and they go to the working place where
the breakdown is and fix the machine or if it needs close attention ,it is transported
to the shop for repairing, in the meanwhile will be given another machine from the
store room to temporarily use until his machine has been fixed