Rim‑UnLock™ is a frontline‑led safety innovation developed to eliminate one of the most critical fatal risks in surface mining: exposure to the crush zone during large earthmoving equipment tyre and rim removal. While previous innovations such as Rim‑Lock successfully reduced risk exposure during tyre fitment, a significant hazard remained during tyre removal when personnel were required to enter the crush zone to remove the final wheel nuts. This task has historically been managed through administrative controls alone, leaving outcomes vulnerable to human error and inconsistent conditions. Rim‑UnLock™ represents a decisive shift away from reliance on administrative controls toward a fit‑for‑purpose engineering solution that removes people from the line of fire altogether.
The problem was identified directly by tyre fitters during frontline safety interactions. They raised concerns that, despite procedures, exclusion zones, and experience, the removal of large tyre and rim assemblies continued to expose workers to a known fatal crush hazard. Personnel were required to position themselves between the tyre and rim assembly and the tyre handler while removing the final retaining nuts. The consequences of failure in this space are irreversible, and the presence of multiple interacting hazards meant that administrative controls could never fully account for variation in equipment condition, environment, or human performance. The frontline team explicitly challenged why an engineering control did not exist to eliminate this risk, given the industry’s long history of serious incidents and fatalities associated with tyre and rim work.
Rim‑UnLock™ was developed as the answer to that challenge. The solution consists of a series of remotely operated, dual‑action retainers that physically secure the tyre and rim assembly prior to the removal of the final wheel nuts. Once installed and engaged, Rim‑UnLock™ holds the assembly in place, preventing uncontrolled movement until the operator deliberately releases the system from a safe position outside the crush zone. This removes the need for any person to enter the hazard zone during the task. The concept was generated through BOS‑led problem solving and developed in collaboration with a local engineering partner, drawing on lessons learned from the existing Rim‑Lock system. The frontline team worked closely with our offsite partner to ensure a solution was achieved that completely removed personnel from the most hazardous part of the task, without adding unnecessary complexity.
Rim‑UnLock™ has progressed beyond concept and trial and is now a proven safety solution. Load testing achieved a capacity of 15 tonnes with no damage or movement detected. On‑site trials have been successfully completed across a range of operating scenarios on the Komatsu 930 fleet, demonstrating that the system performs reliably in real operating conditions. These trials confirmed that Rim‑UnLock™ not only restrains the assembly as intended but also integrates effectively into existing work practices without introducing new risks.
The primary benefit of Rim‑UnLock™ is the elimination of fatal crush zone exposure through engineering control. By physically restraining the tyre and rim assembly, the innovation removes reliance on behavioural compliance and procedural discipline to manage a catastrophic risk. The system eliminates the human error factor from a high‑energy task and advances the control measure up the hierarchy of control in a meaningful and tangible way. Secondary benefits include improved task ergonomics, as personnel can use engineered platforms and no longer need to reach into confined spaces while a handler is present. Operators report increased confidence in performing the task, with reduced cognitive load and stress knowing the assembly is positively retained.
Equally important is the cultural impact of the innovation. Rim‑UnLock™ is fundamentally a frontline‑driven solution. The idea originated with tyre fitters who refused to accept that exposure to known fatal risk was unavoidable. Their persistence in challenging the status quo, willingness to explore alternatives, and openness to iterative problem solving were central to the outcome. Leadership enabled this process by actively listening to frontline concerns, supporting engagement with external expertise, and maintaining focus on long‑term elimination of risk rather than short‑term procedural compliance. The innovation has since been shared through on‑site demonstrations and showcase events, reinforcing a culture where learning is shared openly and safety leadership is visible.
Rim‑UnLock™ demonstrates that long‑standing, industry‑wide fatal risks can be eliminated when organisations genuinely listen to their workforce and invest in practical engineering solutions. It challenges the assumption that administrative controls are sufficient for high‑energy tasks and sets a new benchmark for tyre and rim handling safety. This is not an idea on paper or a theoretical control; it is a tested, demonstrated, and transferable solution with clear applicability across fleets and operations. Most importantly, Rim‑UnLock™ reinforces a clear principle that underpins strong safety culture: no task is acceptable if it exposes people to an avoidable fatal risk.

1. The Problem
Anglo American’s Aquila Mine is a high productivity coking coal longwall operation, producing about 6.5MT PA ROM from a uniquely low height seam (1.6m–1.8m). This constraint makes traditional Rapid Face Bolting (RFB) equipment unsuitable for longwall face recovery activities, resulting in workers potentially handling bolting tools weighing 80–120kg above shoulder height in confined conditions (four to six times the site's 20kg manual handling guideline).
The geological constraints of Aquila Mine created an operational challenge in which traditional rapid face bolting equipment could not physically operate within the low-height seam. As a result, longwall recovery and bolt up activities relied heavily on manual bolting, requiring workers to install 1.8m bolts and 6–8m cable bolts in confined, ergonomically demanding conditions.
A review of the most recent longwall relocation identified bolt up activities accounted for about 25% of all injuries recorded at the mine over 12 months, with 86% of those injuries linked to manual handling or slip, trip and fall events.
The need for this safety innovation was identified through:
• Formal incident trend analysis
• Workplace risk assessments
• Direct workforce consultation
This data highlighted the need for a purpose-built bolting solution that would operate safely and effectively in a low seam environment while significantly reducing exposure to injury.
Aquila Mine set out to fundamentally reduce worker injury exposure during longwall recovery by engineering out manual bolting tasks in ultra-low seam conditions.

2. The Solution
Aquila Mine developed the Mini Face Bolter (MFB), a purpose-built mechanised bolt-up platform that transforms a historically high-risk, labour-intensive manual task into a safer and more controlled process.

The Mini Face Bolter design integrates:
• Zero-gravity bolting arms removing manual support loads
• Hydraulic cable-bolt installation technology
• Powered haulage allowing controlled movement across the longwall face
• Modular lightweight components optimised for underground assembly with minimal manual handling
This transformed bolt installation from a physically demanding manual process into a controlled, mechanised system.

Internal and external resources
The project was delivered through collaboration between:
• Aquila Mine workforce (operators, supervisors and engineers)
• Mackay-based Jet Group (design and manufacturing partner)
Extensive workforce engagement ensured the system addressed real operational and ergonomic challenges experienced during bolt-up activities.

Trialling and testing
The innovation was delivered through a structured, risk-led methodology:
• Workforce engagement to define design requirements
• Multiple design iterations informed by operational feedback
• Factory Acceptance Testing (FAT) to validate prototypes
• Continuous refinement to address hazards and operational constraints

Challenges addressed included:
• Weight optimisation of components
• Interaction with existing equipment
• Development of haulage drive systems
• Hydraulic power integration

Implementation Process
The system was designed as a modular platform that could be:
• Assembled underground efficiently
• Integrated with existing longwall recovery processes
• Operated within 1.6-1.8m seams where conventional equipment cannot function
At the time of submission, the MFB has been deployed on one of Aquila’s longwalls, mechanising the bolt-up task during recovery.

Applying the hierarchy of control
The project prioritised higher-order controls:
• Elimination: Removed the need for manual bolt handling in confined conditions
• Substitution: Replaced manual installation methods with powered, controlled equipment
• Engineering controls: Introduced mechanised bolting, zero-gravity arms and hydraulic systems
• Administrative controls: Supported implementation through procedures and training
• PPE: Retained as a final control layer
This represents a fundamental shift from manual exposure to engineered control.

3. Benefits / Effects
The Mini Face Bolter is delivering significant safety, operational and productivity benefits by directly addressing the highest risk component of longwall recovery.

Outcomes include:
• Mechanisation of a task previously responsible for ~25% of site injuries
• Significant reduction in manual handling exposure
• Reduction in slip, trip and fall risks
• Improved ergonomics through elimination of above-shoulder heavy lifting
• Increased control and consistency in bolt installation
• Improved working conditions in confined low seam environments
At the time of writing, performance monitoring is under way to quantify reductions in injury exposure and productivity impacts.
The system is actively reducing exposure to high-risk manual tasks rather than relying on behavioural controls, delivering a permanent improvement in how the task is performed.

Key accomplishments:
• Delivered the first mechanised bolt up solution designed specifically for ultra low seam longwall operations, replacing a high-risk manual task.
• Engineered out manual bolt-up activities that had accounted for ~25% of the site’s recordable injuries, significantly reducing exposure to manual handling and slip-trip-fall risk.
• Combined multiple technologies into a compact, modular system suited to 1.6–1.8m seams.
• Established a new benchmark for low seam mechanisation, demonstrating historically accepted manual handling risk can be engineered out through purpose-built mechanisation, with a design that can be adapted across the industry.
• Enabled strong ‘from-the-floor’ workforce engagement ensuring the solution was practical, effective and directly addressed a real workplace hazard.

4. Transferability
The Mini Face Bolter establishes a new benchmark for low seam mechanisation and demonstrates manual handling risks previously considered unavoidable can be engineered out.
The system provides a replicable foundation for:
• Other underground coal mines operating in low seam conditions
• Longwall recovery processes across the resources industry
• Adaptation to different seam heights and operational configurations
The modular design enables:
• Scalability to other operations
• Modification for varying geological and operational conditions
• Integration with existing mining systems
The project demonstrates how purpose-built mechanisation can overcome constraints that have historically limited innovation in underground operations.

5. Innovation
The Mini Face Bolter represents a genuine mining innovation because it resolves a long-standing industry limitation that had previously been accepted as unavoidable in ultra-low seam longwall environments.

Industry first and originality
Conventional rapid face bolting systems are designed for seam heights well above those at Aquila Mine and cannot physically operate within confined clearances of 1.6–1.8m. As a result, low seam operations across the industry have historically relied on manual bolting despite known safety, ergonomic and productivity impacts.
Before this project, no commercially available mechanised solution existed to perform both bolt installation and cable bolting within these constrained conditions.
The Mini Face Bolter delivers the first mechanised bolt-up solution designed specifically for ultra-low seam longwall operations, combining multiple technologies into a compact, functional system.

Integration of existing technologies in a new way
The innovation lies not only in the components, but in their integration into a system capable of operating in extreme constraints:
• Zero-gravity bolting arms eliminating manual load
• Hydraulic cable bolt installation in restricted headroom
• Powered haulage for controlled movement
• Modular construction for underground assembly
Individually, these technologies exist, but their integration into a functional low-profile system is unique.

Departure from conventional practice
Historically, the industry has accepted:
• Manual bolt installation in low seams
• High levels of manual handling
• Increased injury risk as an operational constraint
The Mini Face Bolter challenges this by:
• Mechanising a task previously considered unmechanisable
• Eliminating heavy manual handling above shoulder height
• Introducing precision and control into bolt installation
• Demonstrating low seam constraints do not require risk acceptance

Overcoming barriers to innovation
Delivering this solution required overcoming barriers that had prevented mechanisation in low seams, including:
• Strict weight limitations
• Spatial constraints
• Power and hydraulic system integration
• Interaction with existing longwall recovery equipment
These constraints made direct downsizing of conventional systems impractical, requiring a ground-up redesign.

Workforce-led design
A key differentiator of the bolter innovation was strong ‘from-the-floor’ workforce engagement, ensuring:
• Practical usability
• Alignment with real operational conditions
• High levels of acceptance and confidence
This ensured the system was not only technically viable but operationally effective.

Step change in industry capability
The Mini Face Bolter redefines what is possible in low seam longwall recovery by demonstrating:
• Mechanisation is achievable in environments previously considered unsuitable
• High-risk manual tasks can be engineered out
• Safety and productivity improvements can be delivered simultaneously
It establishes a new benchmark for how historically constrained mining activities can be redesigned through purpose-built innovation.

6. Approximate Cost
The approximate cost of the project was $900,000.

1. Summary of the Innovation
The HNA Strut Handling Tool represents a breakthrough in safe, efficient heavy equipment maintenance. Designed for use with Caterpillar haul truck front strut assemblies, it replaces high-risk overhead lifting and manual handling with a fully self-contained, remote-controlled, electrohydraulic system. By integrating a 16-tonne forklift interface, 4-way motion control, and solar-charging transport system, the innovation eliminates crane use, reduces suspended load exposure, and enhances operator control — dramatically improving safety, productivity, and compliance with RS23 and Australian Standards.
2. Background / Problem Statement
Historically, replacing front strut assemblies on large Caterpillar trucks (777–793) required overhead cranes, complex lift plans, and multiple personnel working under suspended loads. Key risks included: struck-by and crush injuries during alignment and pinning, manual handling of heavy components (up to 8 tonnes combined load), exposure to suspended loads and pinch points, and maintenance delays caused by crane unavailability. These legacy processes presented significant risk even for experienced technicians, driving the need for a purpose-built, engineered solution that reduces hazard exposure while improving task efficiency and repeatability.
3. Description of Innovation
Developed by HNA Group in Mackay, QLD, the Strut Handling Tool combines advanced hydraulic engineering, intuitive controls, and solar-integrated transport to set a new benchmark for maintenance safety in mining.

Key Technical Innovations:
- Remote-Controlled Electrohydraulic System: Battery-powered 24 VDC electric-over-hydraulic drive with dual joystick remote for precise lift, rotation, and tilt control.
- Four-Way Hydraulic Movement: Allows full rotation, elevation, and alignment without manual intervention.
- Solar-Charging Transport Frame: Includes fold-out solar panels, isolator lockouts, and Anderson plug connections for sustainable charging.
- Multi-Model Adapter System: Fits multiple Caterpillar truck models (777, 785, 789, 793).
- Built-In Safety Redundancies: Emergency hydraulic release points, personal lockout isolators, and pinch-point guards meet AS4100, AS3990, and RS23.
- Two-Person Operation: Removes the need for crane operators and rigging teams, reducing human exposure.
4. Implementation and Results
The Strut Handling Tool has been successfully deployed across multiple mine sites, achieving measurable reductions in both risk and downtime.

Performance Outcomes:
- Reduced strut replacement time by up to 60%.
- Eliminated overhead suspended load risk.
- Reduced manual handling exposure by 80%.
- Improved HME availability via shorter maintenance duration.
- Enhanced operator confidence and safety compliance through consistent procedure and built-in isolation points.
5. Safety, Health & Environment Impact
Zero-Exposure Design: Operators remain outside drop zones and suspended loads.
Psychological Safety: Remote operation reduces stress and cognitive overload.
Environmental Benefit: Solar-charging frame reduces carbon footprint.
Health Outcomes: Reduced vibration, strain, and physical exertion.

The innovation aligns with RS23 and other standards, addressing fatal risk categories of energy release, vehicle interaction, and suspended loads.
6. Transferability and Industry Benefit
The modular, self-contained design allows easy replication across fleets and sites. Adaptable to hydraulic cylinder removal on other HME, OEM maintenance systems, and underground or civil operations. The balance of safety, efficiency, and environmental responsibility makes it scalable across the industry.

The problem

Mobile equipment wheel and tyre assemblies are a persistent, high consequence risk domain in surface mining and quarrying operations. Key exposure pathways include:

• Loss of control and stability events driven by variable terrain, load shift, and wheel ground interaction.

• High-energy maintenance hazards associated with wheel/tire change out tasks, including tooling, manual handling, stored energy, and in field interventions.

• Whole body vibration and shock transmission to operators from haul road inputs and machine dynamics, contributing to fatigue, reduced situational awareness, and longer term health impacts.

At multiple sites, the improvement opportunity was identified through a combination of: (i) incident and near miss learning related to wheel/tyre maintenance and handling; (ii) operator feedback regarding vibration/shock and control on degraded haul roads; and (iii) reliability and downtime reviews showing wheel-end related stoppages as a material contributor to exposure hours in the line of fire.

The safety and health consequences targeted by this innovation are therefore both acute (loss of control, line of fire maintenance tasks) and chronic (vibration/shock exposure contributing to fatigue and musculoskeletal risk).

The solution

Air Suspension Wheel (ASW) is a wheel-end innovation that introduces a suspension function at the wheel assembly to reduce shock transmission, improve wheel ground compliance, and reduce operational instability inputs at the machine. The solution was developed as a practical, field deployable engineering control for large mobile equipment operating on variable haul road and pit conditions.

Strategies and initiatives used

1. Risk-focused design process
o Hazard identification workshops with maintainers and operators to map exposure points across the wheel lifecycle: operation, inspection, service, and change out.
o Failure modes and effects considerations to prioritise controls that reduce high energy, line of fire tasks and reduce conditions that drive loss of control.

2. Hierarchy of Control applied (demonstrated)
o Engineering controls (primary): Introduce wheel-end suspension to reduce shock/vibration transfer and improve contact stability; design features intended to lower the need for reactive field interventions by improving ride compliance and reducing shock loading on wheel-end components.
o Administrative controls (supporting): Standardised inspection points, defined acceptance criteria, and change management procedures for any deployment.
o PPE (last line): Remains unchanged; the objective is to reduce reliance on PPE by controlling hazards at the source. (PPE is not claimed as the innovation.)

3. Internal/external resources used
o Internal: Site maintenance leadership, reliability engineering, operator representatives, and HSE teams to define functional requirements and risk controls.
o External: Specialist engineering/manufacturing capability for component development, verification testing, and safe introduction planning (e.g., design verification, service tooling review, and maintainability considerations).

4. Implementation approach
o A controlled deployment model: prototype → limited field trial → staged scale up, with formal risk assessment at each gate, and clear “stop” criteria if performance or safety thresholds are not met.
o Training packages for operators and maintainers focused on what changes and what does not change in daily pre start, inspections, and planned maintenance tasks.

Benefits/Effects

The ASW is intended to deliver measurable safety and occupational health benefits via reduced shock transmission, improved stability inputs, and reduced exposure hours to high risk tyre/rim interventions.

Safety and health benefits achieved / targeted

• Reduced shock and vibration transmission to operators
Early trial measurement indicates reductions in peak shock events and/or vibration dose values on representative routes when compared to baseline wheel assemblies.
• Operator feedback and machine telemetry indicate improved directional control and reduced harshness over corrugations/potholes, supporting reduced fatigue and improved hazard perception.
• Reduced maintenance exposure hours in the line of fire
Where shock loads are reduced, downstream wheel-end and related component stressors are reduced, supporting fewer reactive interventions and less time spent in high-exposure positions.
• The innovation has been deployed to both Haul Truck and Wheel Loaders across sites in Australia, North America & China for across 13 Wheeled assets over a significant amount of testing & evaluation since 2015, including Haul Trucks [CAT740GC (R29), CAT777/KOM730 (R49), CAT793F (R57)], and Wheel Loaders [CAT980 (R25), CAT994H (R57)] under an approved change management and risk control plan.

Transferability

ASW is designed to be transferable across the resources industry to all Rubber Tyre’d Assets because the core risk drivers it addresses "shock/vibration exposure, stability inputs, and wheel-end maintenance line of fire exposure are common across surface & underground mining, quarries, and related heavy industries.

Transferability can be achieved through:

1. A standardised “safe introduction” package that includes: risk assessment templates, inspection standards, training modules, maintenance procedures, and verification checks.
2. A staged trial protocol usable by other sites: baseline measurement → controlled pilot → monitored scale up, including defined performance and safety KPIs.
3. Compatibility mapping across common machine classes and duty cycles, allowing sites to assess suitability based on operating hours, haul profiles, and road condition severity.
4. Shared learnings via industry forums and conference publication to enable adaptation to varying site conditions.
This innovation is not dependent on unique site infrastructure and can be adapted to different operations by adjusting verification metrics, inspection intervals, and duty cycle parameters.

Approximate cost

Approximate cost is dependent on machine class, deployment scale, and the level of supporting trial instrumentation. As a guide:

• Per machine (wheel assemblies and installation):

The Life-Of Wheel cost is equal or less than the current cost of the current Tyre/Rim across all rubber tyred assets.

• Trial verification costs (instrumentation, analysis, training, change management):

There is no change is current verification systems to that is already in use for the mining operation.

• Ongoing costs:

The ASW eliminates the key safety issues with Off-The-Road (OTR) tyres in mining are primarily related to sudden tyre failures (like blowouts and explosions),improper maintenance, extreme operational demands (heavy loads and harsh terrain), and the physical hazards associated with handling enormous, heavy tyres.(Operational Hazards, Maintenance & Handling Hazards, Environmental Factors, and a significant reduction in Key Mitigation Measures)

ASW Key Points / Additional Benefits:

• No stored pressure energy management required
• The ASW is a flexible coupler; reducing stress & strain on axel, transmission and engine
• Reduced non-suspended weight
• No tyre management
• No compressed air or other gases (e.g. nitrogen)
• No heat or fire or risks associated with lightening strikes etc..
• No chemicals
• No TPMS
• No Tyre Storage
• No Tyre Scrapping
• No Tyre Rotation
• No Offsite Tyre Repairs
• No Tyre Logistics and associated COR responsibilities
• Improved circuit times + increased truck availability
• Fuel Savings / Increased Battery Life

Executive Summary

Installation of mechanical and electrical services in mining and mineral processing plants traditionally requires welding or cutting to attach supports to structural steel. These hot work activities introduce ignition sources, fire risk and additional permitting controls, particularly within operating plants and shutdown environments.

In addition, poorly installed or non-compliant welded pipe supports and brackets have contributed to dropped object incidents across the resources industry, creating potential hazards for personnel working below.

To address these challenges, Skopit developed a structural steel beam clamp installation system that allows pipe supports, cable trays and service brackets to be installed without welding or drilling into structural steel.

The system provides engineered clamping connections that eliminate hot works while improving the consistency and compliance of service support installations.

By removing ignition sources and improving support integrity, the approach reduces fire risk, reduces dropped object hazards and simplifies installation practices in mining and industrial facilities.

This innovation provides a practical and transferable solution that can improve installation safety across the resources sector.

Introduction

Mining and mineral processing facilities rely heavily on structural steel frameworks to support plant infrastructure and services. Mechanical and electrical systems such as pipework, cable trays, instrumentation and equipment supports are commonly attached to these structures during plant construction, shutdown modifications or operational upgrades.

Historically, the most common installation method has been the welding of brackets or plates directly to structural steel beams. While widely used, welding and cutting activities introduce hazards that must be carefully managed within operational mining environments.

Hot works generate sparks, molten metal and heat that can ignite combustible materials within plant structures, creating fire hazards in operating facilities where dust, insulation or hydrocarbons may be present.

To manage these risks, operations typically rely on administrative controls such as hot work permits, fire watch personnel and additional supervision.

While these controls reduce risk, they do not remove the hazard itself.

At the same time, the resources industry has experienced incidents where poorly fabricated or inadequately installed pipe supports and welded brackets have failed, resulting in dropped objects or falling components within plant areas.

Dropped objects represent a serious hazard for workers operating beneath elevated infrastructure.

Ensuring that pipe supports and service mounting systems are robust, compliant and consistently installed is therefore critical to maintaining safe plant operations.

Recognising these challenges, Skopit developed an alternative installation method designed to eliminate hot works while improving the reliability and compliance of service support systems.

The Safety Challenge

Installation and modification projects within mining operations frequently involve the addition of pipework systems, cable tray infrastructure, instrumentation supports and mechanical service brackets.

These installations often occur within structural steel frameworks such as processing plants, conveyor galleries and maintenance facilities.

Traditional welded supports require workers to perform welding or cutting activities, often while working at height or within congested plant environments.

Hot works create ignition sources in the form of sparks, heat and molten metal. In facilities where combustible dusts or materials may be present, this creates a potential fire hazard.

Administrative controls such as permits and fire watch systems are necessary but increase complexity and worker exposure during installation.

Another significant risk relates to the integrity of welded supports themselves.

Across the resources sector, incidents have occurred where pipe supports or welded brackets have failed due to poor fabrication, inadequate weld quality or insufficient design consideration.

When supports fail, pipes, cable trays or structural components can fall from height, creating serious dropped object hazards.

The challenge therefore was to identify a method of installing services onto structural steel without introducing ignition sources while ensuring the supports themselves remain robust and compliant.

Development of the Innovation

Through practical field experience working in mining and industrial environments, it became apparent that many service supports did not necessarily require welded connections.

In many situations, supports simply needed a reliable mounting point on existing structural beams capable of carrying the load of the supported services.

This observation led to the development of a mechanical clamping system that could provide these mounting points without welding or drilling into structural steel.

The design objective was to develop an installation method that would eliminate hot works, avoid modification of structural steel, provide a strong and reliable support connection and remain practical for installation crews to deploy using standard tools.

The result was a structural steel beam clamp system designed specifically for service installation applications.

The Beam Clamp Installation System

The beam clamp system consists of engineered clamps that attach securely to structural steel beams using mechanical clamping forces.

Once installed, the clamps provide connection points for common installation components such as threaded rods, pipe saddles, channel support systems and cable tray brackets.

Loads are transferred into the structural beam through the clamp assembly rather than through welded joints.

This allows services to be supported directly from existing plant steelwork without introducing ignition sources or modifying the structural member.

Key characteristics of the system include mechanical installation using standard tools, elimination of welding and cutting activities, no drilling or modification of structural steel, compatibility with common pipe hanger components and the ability to remove or adjust supports if plant modifications occur.

Because the system integrates with commonly used installation hardware, it can be adopted easily across the industry.

Application of the Hierarchy of Controls

The innovation aligns strongly with the principles of the Hierarchy of Controls, which prioritises eliminating hazards rather than relying solely on administrative measures.

Traditional installation methods rely heavily on administrative controls such as permits, supervision and fire watch personnel to manage the hazards associated with welding.

While these measures reduce risk, they do not eliminate the hazard.

The beam clamp installation method addresses the hazard at a higher level of the hierarchy.

By removing welding and cutting from the installation process, the system eliminates ignition sources associated with hot works.

This removes the fire hazard rather than simply managing it through administrative procedures.

The engineered clamp system also acts as an engineering control by providing a consistent and reliable structural support connection.

This reduces variability associated with site fabricated welded brackets and improves overall installation quality.

Safety Benefits

The introduction of beam clamp installation systems provides several safety improvements.

Elimination of hot works removes ignition sources and reduces fire risk within plant structures.

Workers are no longer exposed to hazards associated with welding such as fumes, radiant heat and sparks.

Mechanical installation methods also allow supports to be installed more quickly, reducing the time workers spend working at height.

The use of engineered support systems improves consistency in the installation of pipe supports and service brackets.

This reduces the likelihood of support failures that could result in dropped objects.

By improving both installation safety and the reliability of support systems, the approach addresses two recognised fatal risk categories within the resources sector: ignition sources and dropped objects.

Case Study Examples

Peak Downs Mine – Pipe Support Upgrade

At Peak Downs Mine, pipe hanger upgrades were required within the plant to improve support arrangements for process piping.

Traditionally, these installations would have required welded brackets attached to structural steel.

Using beam clamps and pipe hanger kits allowed the supports to be installed without welding. This eliminated the need for hot work permits and removed ignition sources from the installation process.

The installation method also provided a consistent and engineered support system for the pipework.

Goonyella Riverside Mine – Service Installations

At Goonyella Riverside Mine, beam clamps were used to support service infrastructure within plant structures.

By attaching service supports directly to structural steel beams using clamps, installation teams avoided welding within the plant.

The elimination of hot works meant atmospheric conditions within the work area did not change during installation activities, avoiding additional confined space requirements that welding may have triggered.

South32 Cannington Mine – Workshop Safety Improvements

At the South32 Cannington Mine mobile maintenance workshop, beam clamps were used to install davit arms onto the structural framework of the workshop.



Industry Transferability

Structural steel beams are widely used across mining and industrial facilities including processing plants, conveyor structures, workshops and infrastructure buildings.

Because the beam clamp system attaches directly to these structural members, the installation method can be applied across a wide range of operations including coal mining, metalliferous mining, mineral processing and heavy industrial construction.

The approach is particularly beneficial for brownfield installations where modifying structural steel through welding or drilling may be restricted.

Because the system integrates with standard pipe support and installation hardware, it can be readily adopted by maintenance teams and contractors across the resources industry.

Outcomes and Industry Impact

The development of structural steel clamping systems demonstrates how practical engineering innovation can improve safety outcomes.

By eliminating hot works and improving the reliability of service supports, the approach addresses two important safety risks in plant installations: ignition sources during installation and dropped object hazards from inadequate supports.

Importantly, the solution is simple, practical and scalable across the resources sector.

The innovation reflects the principle that improving everyday installation components such as pipe supports and mounting systems can significantly improve safety performance.