One of the biggest risks in mining is worker fatigue, which poses a physical threat to individuals and their coworkers.
Despite efforts, unlike with physical hazards fatigue remains particularly dangerous and difficult to identify as it is a “comparatively ‘invisible’, under-recognised and underestimated risk”, Dr Tim Bauerle PhD, a behavioural scientist at the US National Institute for Occupational Safety and Health’s Spokane Mining Research Division, tells Mining Technology.
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He explains there are several factors that contribute to our underestimation of worker fatigue. They include: “Our inability to accurately judge how our own fatigue negatively affects our performance; pressures to produce, prove oneself or not letting down the team; a lack of tools and resources to measure and address fatigue; perpetuating myths that miners can, or should, just ‘work through it’; or that the responsibility of managing fatigue falls exclusively on workers.”
Holding these beliefs and continuing to downplay the importance of fatigue can result in real-world impacts. A study by Caterpillar Global Mining found that fatigue may be responsible for 65% of accidents involving haul trucks, for example.
Josh Savit, principal advisor, safety at Hexagon, says noise, distraction, poor visibility and fatigue are daily hazards for mining equipment operators. “So too are long hours, repetitive tasks and heavy machinery that operate amid significant blind spots. Tackling these hazards is not just important, it is essential for ensuring safety and productivity. A safe mine, after all, is a profitable mine,” he adds.
Which mining environment presents the greatest fatigue risk?
Although both above and below ground mining settings are dangerous, subsurface mining is widely accepted to present more risks due to its unique environment.
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By GlobalDataHaving said that, the two mining disciplines are not often compared in any systematic way, according to Bauerle.
“There is very little quantitative scientific evidence that I am aware of that directly compares the work-related fatigue risk between underground and surface mining using the same measures.” However, he acknowledges the “unique combinations of fatigue risk factors” compounding worker fatigue mentally and physically in both environments.
Although there are likely very few differences between fatigue tolerance or the performance impact it may have on those working in either setting, surface mining primarily exposes workers to cognitive fatigue through repetitive and monotonous haul truck routes, continuous whole-body vibration that increases physical and mental stress, and environmental or weather elements – sometimes extreme – that bring with them additional demands.
Underground, fatigue is often caused by physically demanding and repetitive manual material handling, unusual postural positions, significantly darker conditions that disrupt circadian rhythms, the vagaries of ventilation leading to hot and humid conditions and communication isolation impacting social support and stimulation.
“Given the complexities of mining underground, it is certainly plausible that the risks posed by fatigue and distraction are even greater,” says Savit. Echoing Bauerle on concerns over the isolation workers may face, he adds there is a need for better communication and collaboration, particularly as mines push deeper beneath the surface. A significant innovation in recent times has been advances in networking and communications in these environments, in part facilitated by the application of 5G technology.
The impact of advances in 5G
In brief comments to Mining Technology, Shao Qi, general manager of the Open-pit Mine of Oil, Gas and Mining Business Unit at Huawei explains how 5G is helping overcome many traditional network challenges. “With 5G base stations, underground mines can access comprehensive, highly-reliable connectivity that supports real-time HD video and sensor data transmission. In addition, 5G networks can extend signals to areas that traditional networks like Wi-Fi and 4G cannot reach.”
He adds that 5G is also playing a crucial role in fatigue management, albeit less directly. As well as making communication faster and easier, when combined with the latest technologies 5G networks are increasing mineworker efficiency and reducing the manual effort needed. One example Shao gives is the “one-tap connection” function on some of the company’s devices, meaning underground equipment can be operated remotely, even from above ground.
“This allows for remote fault diagnosis, reducing the time workers need to spend underground […improving] worker efficiency by minimising manual labour. For example, real-time pump status monitoring and online management has helped mineworkers spend 75% less time on inspections, reducing their workloads,” he says.
Separately, Savit draws attention to the fact that the “myth” that some technologies are only suitable for above ground operations had been dispelled, thanks to the evolution in below-ground connectivity.
“The same systems can be used in both surface and underground,” Savit says. “This also allows mining companies to access data from all operations for a more unified community of practice on fatigue, distraction and safety overall,” he adds.
Technology is reshaping fatigue
Aside from 5G, there have been other significant technological advances in fatigue management in recent years. Broadly speaking, they encompass fatigue detection technologies (FDTs), which are becoming increasingly common, including:
- in-cab cameras
- computerised impairment detection tests that assess psychomotor performance against personal baselines
- biomathematical models (BMMs) that predict fatigue levels based on sleep/wake history and work schedules
- fleet management systems that analyse driving performance
- vehicle automation
- wearable devices that monitor physiological signals.
Bauerle mentions other emerging analytics trends that complement FDTs, including cloud-based systems that integrate multiple data streams through Internet of Things technologies for more comprehensive monitoring and reporting; edge computing that processes data immediately at the source for instant alerts, without requiring internet connectivity; and AI solutions that analyse complex patterns across physiological, behavioural and operational data, making sophisticated fatigue risk predictions that improve over time.
Savit adds that these technologies are helping to coordinate and choreograph the movements of miners and machinery in above-ground settings, where blind spots, distraction, fatigue, inclement weather, noise and slope instability all pose significant hazards. Below ground, where darkness can amplify many of these risks, their ability to digitise processes and react to workflow changes in real-time becomes even more important. Newer tools, used in both environments but of particular benefit here, include fleet management systems and BMMs.
Based on human performance data, BMM algorithms are intended to predict how fatigue and alertness could modify over time for the average worker by reviewing sleep/wake history, work hours and time of day. More sophisticated models can incorporate rest breaks, sleep inertia and workload intensity.
Fleet management, or vehicle performance-based technologies, are using AI to analyse driving performance metrics to determine fatigue levels. Variables monitored include brake pressure analysis, drifting, lane position standard deviation, steering wheel angle variations (or jerking), reaction times, speed consistency and vehicle positioning/GPS.
Together, these FDTs are part of bigger picture around Fatigue Risk Management Systems – the “gold standard”, according to Dr Bauerle – that provide continuous monitoring and alert strategies. Through them it is possible to proactively identify scenarios which could cause a loss in operation productivity, even worker harm.
Being able to intervene means not only averting an incident but also engaging in “non-punitive decision-making” through “compassionate and meaningful” discussions with mineworkers. In doing so, immediate fatigue management solutions such as breaks, environmental adjustments, task rotation, or other countermeasures can be actioned, according to Bauerle, all while collecting usable large-scale data to develop broader approaches that better protect workers.
The irony of automation
Savit draws attention to another technology that can help cut mineworker risk – automation. “Technological advancements have focused on reducing operator fatigue by minimising direct exposure to high-risk or exhausting environments,” he says, suggesting the notion that prevention is better than cure is where the industry is headed.
“Autonomous equipment and remote operations are becoming more common. Autonomous haul trucks are helping to eliminate the need for human drivers in repetitive, fatigue-prone tasks,” Savit continues.
He adds that coupled with remote monitoring centres, where operators work in safer, more comfortable environments, fatigue-related risks associated with on-site work, particularly in remote or extreme conditions, are being reduced.
There are, though, hazards associated with this evolution, warns Bauerle. “As automation improves in accuracy and performance, it can place greater demands on the humans monitoring the system, whose role becomes more essential,” he says.
Adding that some refer to it as “the irony of automation”, Bauerle says this could result in degraded situational awareness, increasing fatigue through mental underload and disengagement, and worsening takeover performance.
He suggests it might be sensible to design systems and processes that promote dynamic, active monitoring rather than passive observation, supported by continuous training, fatigue assessment and scheduling practices that will help workers maintain situational awareness and ensure they are ready to intervene when needed.
Shaping the future of fatigue management
The differences between surface and underground mining are clear, with each presenting its own unique inherent dangers around mineworker fatigue.
“Worker fatigue is a substantial risk in both surface and underground mining because it can impair mental abilities that are essential for safe operations,” says Bauerle. However, with evolving technology now becoming domain-agnostic and the understanding of the causes and impacts of fatigue clearer than ever before, the industry is better equipped to counter it.
In years to come, the risks posed by fatigue in mining will be very different, shaped by the new roles mineworkers take, the evolving processes they follow and the innovative tools at their disposal. However, as Bauerle’s comments on automation illustrate, when you address one cause, another is sure to follow. Fatigue will be an ever-present concern for the mining industry; but it will also be a constant motivation to do things better – an endeavour no-one will surely tire of.
