Research Publications/Outputs

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A digital twin framework to support vehicle interaction risk management in the mining industry
(2023-08) Verster, Jacobus J; Roux, Pieter W; Magweregwede, Fleckson; De Ronde, Willis; Crafford, Gerrie; Mashaba, Mathews M; Turundu, Safiya L; Mpofu, Mvikel; Prinsloo, Jacobus V; Ferreira, Pieta; Brodner, Hartmut D
In recent years, transport-related accidents, notably those involving trackless mobile machinery (TMM), have consistently ranked among the top three causes of fatalities and injuries in the South African mining industry (SAMI) [1]. These accidents arise from a combination of mechanical and technical malfunctions, environmental factors, and human or machine operator errors. Remarkably, these incidents persist despite the existence of specific regulations, standards, and codes of practice for transportation and machinery. This paper introduces a digital twin framework for TMM, which employs a systems engineering approach combined with software tools and computational analysis. This framework aims to enhance the current regulations by offering a continuous, quantitative risk assessment. By modelling and detecting non-conformance and adverse vehicle interaction events, the framework provides a quantitative risk analysis that complements the prevailing qualitative methods reliant on historical data and operational experience. A case study conducted at the CSIR main campus in Pretoria showcases the potential of the TMM Digital Twin.
Acoustic device for recording and tracking rock hazards on the mining face
(2024-09) Greeff, Heinrich; Pienaar, M; Hanekom, Johan WL
To enhance personnel safety and operational efficiency in underground mining, this project introduces an innovative acoustic device for recording and tracking rock hazards on the mining face. This system combines advanced acoustic analysis with an ultra-wideband (UWB) location system to interpret sounds produced during rock mass sounding and scaling. The location system is georeferenced to the mine’s local coordinate system using available survey pegs. By integrating these technologies, each acoustic data point includes a spatial XYZ coordinate which facilitates tracking of loose rock locations throughout the mining excavation process. This dual-sensory approach advances previous methods by leveraging the innovation of acoustic technology and tailoring algorithms to specific rock types, enhanced by the tracking function so that rock hazards encountered underground can be mapped and communicated to the operational team. The collected data offers a systematic approach to hazard identification and enhances mine designs and operational strategies by providing insights into the dynamic response of the rock mass during excavation under different mining conditions. This project offers a new approach to proactive hazard management, potentially transforming how mines are operated and mine designs monitored to ensure safety and efficiency.
Assessment of modern training innovations for supervisors and trainers in the South African Mining Sector
(2025-06) Van Schoor, Abraham M; De Kock, N; Khan, Sumaya; Müller, R; Van Rensburg, R; Govindasamy, K; Botha, W; Maphalala, Busisiwe V; Mpofu, Mvikel; Pelders, Jodi L; Ramparsad, S
As the mining industry modernises, skills development needs to be a priority. The aim of this paper was to develop guidelines that consider the assessment of modern training solutions for supervisors and trainers in modern mining. A literature review was conducted on best-practice criteria for the evaluation of modern mining upskilling and reskilling solutions. A draft evaluation matrix was developed based on the literature review insights and incorporated 48 best-practice criteria for the assessment of training solutions. The assessment instrument was applied to training curriculums for supervisors and trainers of two participant entities. Data gathering included assessments of the training solutions, and an industry panel review process. Strengths, weaknesses, opportunities, threats, and gap analyses were undertaken. Key insights were revealed for the respective training solutions. Recommendations included continuous review and improvement of the curriculum for alignment to mining modernisation skills needs, including consideration of modern training methodologies and facilitation; revised content and assessments; skills and training required for modernisation; tracking of graduates and learner feedback; better alignment with modernisation objectives and industry skills needs, increased focus on safety and risk assessment and control; and more immersive learning experiences. While sample training innovations were selected for evaluation, the recommendations remain relevant for training entities looking to align to their curriculum to mining modernisation skills needs and industry skills demands for modernisation.
Change impact evaluation dashboard for the adoption of modern mining technologies
(2024-10) Botha, W; Muller, R; De Kock, M; De Kock, M; Pelders, Jodi L; Ramparsad, S
Change management is imperative for the adoption of new technologies, and the impact of changes needs to be understood and measured. This paper is based on a project funded by the Successful Application of Technologies Centered Around People (SATCAP) programme. The aim of this project was to verify a Change Management Blueprint for gold, zinc and platinum group metals (PGms) and interlink it to Change Impact Evaluation (IE) dashboard.
Communications and engagement tool for local suppliers and small, medium enterprises
(2023-06) Naidoo, P; Khan, Sumaya; Swettenham, T; Ramparsad, S
With mining modernisation, the awareness of communities' social and economic needs is important for a sustainable socio-economic environment. Meaningful engagement and communication with communities is critical. This project entailed the development of a communications and engagement tool for local suppliers and small, medium and micro enterprises to support localisation at mine communities and improve local procurement for local economic development. The tool development was informed by a literature review, data gathering, pilot studies and validation sessions. The tool is a web-based digital application that includes five features: checklists, frequently asked questions, notice board, resource library and query submission. The tool, a user-guideline and video were developed for potential use by South African gold and platinum group metal mines. The tool is not meant to replace current systems or processes at mines but rather to complement them. The tool is customisable, may enable decision-making and aimed at improving local procurement processes.
Community social-needs assessment tool
(2023-06) Likaku, Y; Pelders, Jodi L; Bull, S; Swettenham, T; Ramparsad, S
Mining, mining modernisation, and eventual mine closure have impacts on mine communities, and an understanding of community socio-economic needs is necessary. This understanding is further important for the conceptualisation of communities that are self-sustainable beyond the closure of mines. The aim of the project was to develop a community social-needs assessment tool for potential use by gold and platinum group metal mines. The project was informed by desktop research, literature review and stakeholder engagement, and the tool was developed for use and piloted with industry partners. The assessment tool that was developed comprises of questionnaires for small, medium, and micro enterprises, community members, community-based organisations and non-governmental organisations, a notice board, and a resource library of useful information. Implementation of the tool is expected to generate an improved understanding of community socio-economic needs towards shared value creation to support environmental, social and governance agendas.
Community social-needs assessment tool
(2023-06) Likaku, Y; Pelders, Jodi L; Bull, S; Swettenham, T; Ramparsad, S
Mining, mining modernisation, and eventual mine closure have impacts on mine communities, and an understanding of community socio-economic needs is necessary. This understanding is further important for the conceptualisation of communities that are self-sustainable beyond the closure of mines. The aim of the project was to develop a community social-needs assessment tool for potential use by gold and platinum group metal mines. The project was informed by desktop research, literature review and stakeholder engagement, and the tool was developed for use and piloted with industry partners. The assessment tool that was developed comprises of questionnaires for small, medium, and micro enterprises, community members, community-based organisations and non-governmental organisations, a notice board, and a resource library of useful information. Implementation of the tool is expected to generate an improved understanding of community socio-economic needs towards shared value creation to support environmental, social and governance agendas.
Competency-based training for mine emergency response
(2025-06) Lange, Pieter; Bergh, Adriaan V; Pelders, Jodi L; Khan, Sumaya
Mine workers are exposed to hazards that can cause injuries or fatalities, including fires, underground explosions, irrespirable, falls of ground and mobile machinery. Emergency preparedness is important for improved safety outcomes and includes the deployment of self-contained self-rescuer (SCSR devices, effective escape routes, and adequately located refuge bays. The need has been identified for improved training solutions or mine worker escape situations, which should provide some exposure to the stressors that would be experienced. The CSIR mining Cluster has developed innovative multimodal competency-based training modules to improve the emergency response of mine employess. The modules include interactive e-learning, virtual reality training, SCSR donning and breathing simulation, and competency-based assessments. A pilot study was successfully completed with participation from a major coal mining operation. The competency-based approach improves the overall efficiency of the training and is especially well-suited to training for high-consequence, low-frequency scenarios.
Cost-effective in-mine seismic experiments to image platinum deposits and associated geological structures at Maseve platinum mine, South Africa
(2022-05) Rapetsoa, MK; Manzi, MSD; Westgate; Sihoyiya, M; James, I; Onyebueke, E; Kubeka, P; Durrheim, RJ; Kgarume, Thabang E
The detection of mineral deposits and their related geological structures is of great importance to the mining industry as structures (such as dykes and faults) can affect the safety, cost and efficiency of mining. With the goal of testing cost-effective seismic methods for mineral exploration and mining, active and passive seismic experiments were conducted at Maseve platinum mine in the Bushveld Complex (South Africa) in 2020. The experiments involved surface-passive (using 5 Hz wireless nodes; single vertical component) and in-mine active reflection seismic surveys (using 4.5 Hzland streamer and 5 kg sledgehammer) to image geological structures and delineate economic platinum-group elements bearing Merensky and Upper Group-2 chromitite layers (known as reefs). This paper presents only the results from the in-mine active seismic experiments. The in-mine seismic surveys consisted of seven 2D reflection seismic profiles in the development tunnels, which were located ~550 m below groundsurface and a few tens of metres above known mineralizations: the Upper Group-2 and Merensky Reef. The data were carefully processed to enhance the reflections and suppress noise generated by mine infrastructure (e.g., equipment and ventilation). We successfully imaged the Merensky Reef and Upper Group-2 orebodies approximately 55 m and 124 m below the tunnel floor, respectively, and delineated faults and dykes that crosscut them. Furthermore, the seismic data reveal relatively strong amplitude and faulted reflections below the Upper Group-2 that may represent deeper chromitite-enriched orebodies. However, the economic value of these horizons canonly be confirmed through drilling. The processed seismic data were combined with borehole data, synthetic modelling and geological models to constrain the interpretation. This study encourages the use of in-mine seismics for future mineral exploration, mine development and planning.
CSIR Dynamometer testing facility: Woven, brake liner, tests
(2024-09) Teleka, Ruth
The mining industry uses winder drums to hoist people and material in and out of shafts. Previously accidents have led to fatalities due to uncontrolled movement of such winders. Safety devices such as brakes are installed on the winders, and brake liners must be replaced periodically to assure safety. Quality testing and verification are also undertaken on brake liner samples.
Deep-level Gold and Platinum Mining - The Application of Geophysics in South Africa
(Springer, 2022-08) Van Schoor, Michael; Nkosi, Nomqhele Z; Magweregwede, Fleckson; Kgarume, Thabang E
This book provides the basic know-how and guidance to effectively exploit non-destructive geophysical technologies and apply them in the underground mining environment to optimise mineral extraction and to contribute to safer mining. The effective application of these technologies can enable a better understanding of the unseen orebody and the surrounding rock mass ahead of the mining face; the potential benefits of applying in-mine geophysics is demonstrated through a selection of case studies conducted in deep-level hard rock mines in South Africa. This book also offers valuable insight and training material for students in a variety of relevant mining disciplines like geology, rock engineering, mining engineering, mine planning and mineral resource management.
Development of Best Practice Guideline for the management of hot holes in surface coal mines
(2024) Mpofu, Mvikel; Maphalala, M; Kgarume, Thabang E; Magweregwede, Fleckson T; Stenzel, G
Surface coal operations in which mining activities are conducted above old underground workings experience hot holes after drilling. In a coal mine, hot holes are defined as shot holes, which after being drilled have an in-hole ambient temperature of 40°C or above or show a temperature increase of 3°C or more during monitoring. Hot holes and other cavities, such as cracks, pose health and safety risks to workers, such as exposure to hot air and high concentrations of noxious gases released from these holes. In addition, workers may be exposed to premature detonation of explosives caused by in-hole temperature increases and chemical reactions. To this end, Coaltech Research Association commissioned a project to develop a Best Practice Guideline for the management of hot holes. This paper is a compilation of the activities conducted in the development of the Best Practice Guideline between 2021 and 2022. The activities included a review of standard operating procedures and hot-hole temperature-measuring and -monitoring devices, and the assessment of current hot-hole procedures at selected mines. The results indicated that management of hot holes requires a focus on pre-emptive risk assessment of mining blocks, identification of hot holes using the correct temperature-measuring devices, and continuous monitoring of hot holes from the time of drilling until just before blasting. Hot-hole management accessories, such as polyvinyl chloride sleeves, were found to be effective in insulating the hot-hole emulsion from the rock mass temperature, thus preventing the potential for premature detonation.
Experimental and in-situ physical properties measurements from a seismogenic zone in a deep South African mine
(2022-09) Nkosi, N; Manzi, M; Roberts, David P; Durrheim, R; Ogasawara, H; Ziegler, M; Liebenberg, B; Onstott, T
Since the 1990s, South Africa has experienced several sizeable earthquakes occurring in mining regions at depths ranging between 2 km and 4 km below the surface. These consist of the Welkom (ML 4.2) and Stilfontein (ML 5.3) earthquakes, which occurred in 1990 and 2005, respectively. The occurrence of these seismic events resulted in the destruction of mine infrastructure and some cases the death of miners. More recently, the 2014 ML 5.5 earthquake, which occurred in the Orkney mining district, in the Witwatersrand Basin, is the largest event to occur in a mining region in South Africa (Figure 1). Although mining-related seismic events are common in South Africa (ML<2), the large magnitude and shallow hypocentral depth (~5 km) of this earthquake raise concern for future large events occurring at active mining levels and their potential to negatively affect mining operations. Additionally, the physical properties of the rocks around the active rupture zone are not well understood because no boreholes had been drilled at depths in and around the aftershock zone. Therefore, no meaningful correlations of the lithological units with physical properties obtained from experimental and in-situ measurements have been done.
Improving spatial mine-to-plan compliance at an open pit mine through enhanced short-term mine planning
(2025-05) Otto, Theunis J; Mkhatshwa, T; Van Keerden, TJ; Cloete, CH
The value realised by an open pit mine depends on the quality and integrity of the mine planning process as well as the level of execution against these mine plans. When managing the execution against the mine plan, how well the mine plan is executed spatially, is of critical importance. The short-term mine plan is the plan that is physically executed on most open pit mines. At the same time, the spatial mine-to-plan compliance is typically reconciled against the annual business plan. Short-term mine planning, therefore, plays an important role in the effectiveness of the spatial mine-to-plan compliance reconciliation process by providing operational teams with detailed designs and schedules, while ensuring that mining execution is spatially aligned with the business plan. The Sishen open pit iron ore mine (Sishen) strives to continuously improve spatial compliance to the business plan. Sishen enhanced the role that short-term mine planning plays in enabling the forward-looking component of the spatial mine-to-plan compliance reconciliation process. The enhanced short-term mine planning process focuses on detailed tactical sequence designs per mining pushback, the health of value chain buffers, spatial plan-to-plan reconciliation, and the associated management routines. This led to improved spatial mine-to-plan compliance to the business plan from 71% to 94% over the four-year period from 2020 to 2023 inclusive. These results indicate that the application of short-term mine planning as part of an integrated spatial mine-to-plan compliance process at open pit mines can contribute positively to improving the level of spatial execution against the business plan. This paper presents the enhancements made to the short-term mine planning process, which other open pit mining operations can consider to improve spatial mine-to-plan compliance.
The influence of stemming practice on ground vibration and airblast
(2021-01) Mpofu, Mvikel; Ngobese, Sibusiso SG; Maphalala, B; Roberts, David P; Khan, Sumaya
This paper details an assessment of stemming practices at a South African opencast coal mine and their influence on ground vibration and air blast. Quantitative and qualitative analysis methods were used for the study. The parameters assessed for the quantitative analyses included stemming length, stemming material type, blast-hole depth, burden, and spacing. Pre-blast data from the mine was analysed to determine the deviation between actual and mine design stemming parameters. Mine design stemming length was also compared to the rule-of-thumb stemming lengths. Peak particle velocity (ground vibration) and air blast data from seismograph stations around the mine was analysed to determine the correlation between stemming length and excessive ground vibration and air blast. The qualitative analysis involved observations of blasting procedures at the mine to determine compliance with mine procedures. Some level of non-compliance of actual stemming parameters to design stemming parameters was found, which initially suggested that non-compliance may have contributed to excessive air blast. However, further analysis of the seismograph results indicated no direct correlation between stemming length and excessive air blast and ground vibration. Since stemming parameters are interrelated, it is crucial that all blasting procedures, including stemming, are executed in accordance with best practice, and recorded accurately. There is a need for digital systems for capturing on-bench blasting parameters, as the currently used manual data recording and reporting systems are inefficient and prone to error. Improvements to blast designs are possible through efficient and accurate data recording and reporting systems.
Integration of in-mine seismic and GPR surveys to gain advanced knowledge of Bushveld Complex orebodies
(2023-08) Onyebueke, EO; Manzi, MSD; Rapetsoa, MK; Kgarume, Thabang E; Westgate, M; Durrheim, RJ; Pienaar, M; Sihoyiya, M; Mpofu, Mvikel; Van Schoor, Michael
Improving the exploration of deep-seated mineral deposits and assessing the stability of the mine pillars require that geophysical techniques are deployed in a fast and cost-effective manner with minimal environmental impact. This research presents results from in-mine reflection seismic experiments and a ground penetrating radar (GPR) survey conducted at the Maseve platinum mine, South Africa. The research aims to develop and implement methods to image platinum group metal (PGM) deposits and geological structures near mine tunnels and assess the stability of pillars. The seismic experiments were conducted using a sledgehammer source (10 lb), conventional cabled geophones (14 Hz), and a landstreamer with 4.5 Hz vertical component geophones. The GPR survey was conducted using a Noggin 500 GPR system with 500 MHz centre frequency. An image of the underlying orebody and geological structures down to 100 m from the mine tunnel floor (~500 m below ground surface) was produced. We correlated the coherent reflections beneath the tunnel floor with a known Upper Group (UG2) PGM orebody. The final seismic section shows that the UG2 mineralisation is dissected by near-vertical dykes, faults and fractures. These structures, faults in particular, are interpreted to have been active post-mineralisation, implying that they may have contributed to the current complex geometry of the deposit. Four GPR profiles were collected around a stability pillar adjacent to the seismic lines. The radargram sections were processed to improve the signal-to-noise ratio (S/N). The results show different patterns of fracturing and stress-induced structures. These fractures were shown to be sub-vertical and, possibly, constitute complex micro-structures within the pillar, which could compromise the pillar stability and integrity. The study demonstrates that in-mine seismic and GPR surveys can be cost-effective and valuable for mineral exploration.
Light detection and ranging-based georeferencing of underground mining ground-penetrating radar data
(2025-07) Kgarume, Thabang E; Van Schoor, Abraham M; Mpofu, Mvikel; Grobler, H
The South African mining industry has committed to achieving a state of zero harm for its workforce, with a strong emphasis on worker health and safety. Among the major safety concerns are falls of ground, a leading cause of injuries and fatalities. Ground-penetrating radar, a non-destructive geophysical method, is recognised for its ability to image structures, fractures, and geological features within the rock mass. However, ground penetrating radar data is often acquired in local coordinates, posing challenges for visualisation in mine computer-aided design or three-dimensional visualisation software. This study explores the pivotal role of light detection and ranging data in transforming ground penetrating radar data from local survey coordinates to absolute mine coordinates. A comprehensive georeferencing methodology is presented, providing the stepwise progression from the initial georeferencing of ground penetrating radar data to the ultimate integration of ground penetrating radar and light detection and ranging datasets, resulting in the creation of a ground penetrating radar-light detection and ranging three-dimensional model. The proposed approach not only facilitates the integration of but also offers a practical means of visualising the integrated datasets within commonly used computer-aided design or three-dimensional visualisation software. An essential aspect of this integration is the adoption of non-proprietary data formats, specifically American Standard Code for Information Interchange text files, ensuring broader accessibility and compatibility. The potential for integrating diverse datasets to construct insightful models of the underground mining environment is illustrated. Integration of different datasets has the potential to offer a holistic understanding of the mining environment, providing essential information to decision-makers.
Mitigating the rock fall and rockburst risk in South African gold and platinum mines through advanced knowledge of the ore body
(2023-10) Pienaar, M; Durrheim, RJ; Manzi, MSD; Nwaila, GT; Grobler, HCI; Kgarume, Thabang E; Pretorius, Dean D; Van Schoor, Michael; Oberholster, AJ
The Mandela Mining Precinct was launched in 2018 with the goal of modernizing the South African mining industry. It comprises three major initiatives that seek to improve efficiency, health and safety in current mining operations; develop fully mechanized systems to mine narrow tabular ore bodies in hard rock; and develop non-explosive rock-breaking systems. The crosscutting Advanced Orebody Knowledge (AOK) program seeks to develop technologies to characterize the rock mass ahead of mining and identify potentially hazardous geological features. Mining methods, layouts and rock support systems will be adjusted accordingly to mitigate the risk of rock falls and bursts. Technologies include rock drilling, light detection and ranging (LiDAR), ground penetrating radar (GPR), electrical resistance tomography (ERT), and various acoustic, thermographic and seismic techniques. Machine learning methods are being implemented to improve data processing and interpretation. This paper describes the status of the research program at 31 May 2023.
Optimization of shift cycles in the South African mining sector
(2021-08) Pelders, Jodi L; Magweregwede, Fleckson; Rupprecht, SM
Increased depths of conventional gold and platinum mines, longer travelling times as working places move further from the shaft, and ancillary activities taking place in the mining cycle reduce the useable time spent at the workface. Current shift lengths of 8 hours 20 minutes may no longer be adequate to complete required mining activities. The impact of mineworker commuting times on shift work is also not well understood. The aim of this research was to draft a framework to optimize shift cycles in order to maximize productivity, health, safety, and wellness in the South African mining sector. The framework was informed by a review of the literature, case studies at a local gold mine and platinum mine, and a workshop with industry experts. The findings indicate potential advantages of extended shift lengths and continuous operations, such as improved productivity, asset utilization, and employee morale. However, concerns included fatigue and the associated safety hazards, particularly when working longer shifts, night shifts, and numerous consecutive shifts. Job demands, personal factors, and commuting times are further considerations when scheduling shifts. The ideal shift system for the mining sector should holistically consider and balance operational requirements, health and safety, and employees’ and their families’ requirements, and suit the unique needs of each operation. Changes in shift cycles will require a structured change management process, which involves all stakeholders, and could help to enhance the viability of the South African mining sector.
Physical property studies to elucidate the source of seismic reflectivity within the ICDP DSeis seismogenic zone: Klerksdorp goldfield, South Africa
(2022-07) Nkosi, Nomqhele Z; Manzi, MSD; Westgate, M; Roberts, Dave; Durrheim, RJ; Ogasawara, H; Ziegler, M; Rickenbacher, M; Liebenberg, B; Onstott, TC
Petrophysical properties of cylindrical core specimens from three boreholes from the International Continental Scientific Drilling Program, the DSeis project, measured at ambient pressure and room temperature conditions in various laboratories are presented and compared with downhole petrophysical data (sonic and density). The measured properties are from sixty-six rock specimens constituting metasediments, metabasalts and intrusives. Seismic velocities were measured using 0.5 MHz P- and S-wave transducers. To investigate the source of seismic reflectivity observed on the 2D legacy seismic data, we computed synthetic seismograms for adjacent rock units using downhole petrophysical data and compared them with seismic reflections from the reflection seismic profile. The experimental measurements show that the metasediments exhibit lower bulk densities and seismic velocities than the metabasalts and intrusive specimens. The porosity was found to be less than 2% for all the samples. No clear trends emerge when the Poisson's ratio is plotted against the P-wave velocities and porosities of the samples. A positive relationship is observed between the bulk modulus and P-wave velocities of the rock samples. The highest calculated reflection coefficients (RC) are associated with the metasediment-intrusive interfaces in all three boreholes. The intrusive-metabasalt and the metasediment-metabasalt interfaces exhibit low RC. Synthetic seismograms reveal strong reflections that coincide with high RC calculated using the bulk density and velocity data. The synthetic seismograms also revealed additional strong reflections that were not identified using the reflection coefficients calculated from the rock specimens, due to core loss in some lithological units. Successful correlations are carried out between the synthetic seismic data and the real seismic data, enabling us to correlate the stratigraphic sequence drilled in the boreholes to the seismic reflections observed on the legacy 2D reflection seismic data.

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