Training matters when it comes to mill relining safety

Mill relining safety has improved since RUSSELL MINERAL EQUIPMENT (RME) introduced mechanised mill relining in 1985. While incident rates have trended steeply downwards, this necessary task remains one of mining’s most hazardous maintenance activities. Incidents, when they occur, can risk serious consequences: equipment damage, unplanned downtime, costly shutdown delays and, worst of all, devastating injuries, and fatalities. 

The role of training in reducing fatal risk 

The 2020 Brady Review into fatal accidents in Queensland (Australia) mines and quarries from 2000 to 2019 highlighted a sobering reality: more than 50 per cent of these accidents involved either inadequate or non-existent task-specific training and competencies. An even greater portion of these accidents involved absent or insufficient supervision for the task (1). 

Training matters on the ground

The mining industry's resource shortage and reliance on contractors for highly specialised, yet infrequent maintenance operations, like mill relining, also creates unique safety challenges. Diverse workforces can have varying experience levels, so safety practices can be inconsistent, while high turnover can hinder training continuity. Contractor reluctance to report safety concerns also further complicates matters. Professor Michael Quinlan spoke generally to this point in a 2023 article when he said there can be a complex chain of command and fear of job loss for contractors as key obstacles to raising safety concerns. This calls for greater collaboration between miners, contractors, equipment manufacturers, and regulators. Developing accredited and shared training standards, and addressing cultural barriers to reporting safety incidents, are crucial steps towards a more unified safety culture. 

The intersection of safety and Environmental, Social, and Governance (ESG)

RME’s 40 years in the comminution industry means it has had a front-row seat to these challenges in mill relining. Our filmed safety studies consistently reveal significant opportunities for site safety improvement, from mitigating hazards with engineered solutions to addressing crucial competency and training gaps. Compliance is just the starting point. Ensuring RUSSELL Mill Relining Machine (MRM) operators are highly skilled, practice safe behaviours, are familiar with the latest technology and methods is paramount.

Key aspects of MRM operator and supervisory training 

Prioritising training for MRM operators and supervisors offers numerous benefits, including: 

• Safe practices and skills: Equipping personnel with knowledge and skills to avoid unsafe practices and poor maintenance that can lead to incidents. 
• Familiarisation with complex machinery: Ensuring operators are aware of their MRM’s specific configuration, systems, controls, recommended safe operating practices, and load capacity limits. 
• Competent handling: Instilling competence in safe handling, placement, and release of liners, sway minimisation, and correct grapple attachment selection for various tasks. 
• Enforced SOPs: Enforcing Standard Operating Procedures (SOPs) regarding crew activity around the MRM during operation or when holding stored energy. 
• Adaptability and technology: Keeping operators proficient in changes in processes and new automation technologies to enhance reline speed and safety. 

On choosing the right training provider...

Why accreditation matters 

Training certification plays a crucial role in improving mill relining safety for several reasons: 

• Compliance: Courses ensure compliance with industry standards and regulations, creating a baseline of knowledge essential for safe mill relining practices. 
• Risk mitigation: They address specific hazards and challenges, reducing the likelihood of incidents. 
• Task-specific skills: They promote awareness of, and reduce risky operator behaviours, and instill task-specific competencies to prepare reline crew for the unique challenges of their role, and their role within the reline team. 
• Assurance: Mine sites can be assured that they have taken all practicable steps to create a safe, secure and productive mill relining work environment.

Invest in safety excellence with RME Certified Training  

RME’s Certified Training is developed in consultation with industry and user feedback. Courses are also certified with TAFE Queensland RTO No. 0275 and endorsed by the Australian Government’s Australian Skills Quality Authority (ASQA), guaranteeing quality content, regular audits, and continuous improvement. RME also offers ongoing support with refresher courses available for previously trained personnel. Courses are delivered by RME Certified Trainers in multiple languages. To date our training has empowered over 2100 personnel across 36 countries and all continents world-wide with safer more efficient mill relining practices. 

A collaborative journey towards safer mill relining 

Continually improving safety standards in mill relining requires a concerted effort to prioritise high quality training for MRM operators and supervisors. Partnering with accredited training providers empowers mine sites to build and develop site-specific expertise, boost reline efficiency, safeguard asset integrity, and minimise downtime.

This topic, however, raises an equally important point, and that is the role of mentorship. Mill relining technology is changing rapidly. The ‘RME Advanced Technology Mill Relining System’ means that commercial solutions ‘now exist’ to enable ‘safer relining from outside of the mill’. While these solutions leverage established and proven technologies, they still entail process shifts, which in turn demands a corresponding cultural transition. 

Beyond equipment mastery, this also cultivates a safety-centric culture. Mentorship programs impart hands-on guidance and expertise, fostering a safety-first mentality and adherence to optimal practices. This knowledge exchange is indispensable for optimising the benefits of both existing and new technologies. Additionally, the program serves as a conduit between suppliers and mine sites, facilitating open dialogue, problem-solving, and continuous improvement. RME, as the mentor, leverages these real-world site insights to ensure all users of the RME Mill Relining System globally benefits from enhanced safety practices. Ultimately, empowering reline crews through mentorship will significantly improve safety across the sector. 

Together, we can make mill relining safer, one skilled operator at a time. 

Click here to learn more about RME Certified Training for your operators and mill relining crews. And reach out to your nearest regional sales and support centre for more information on the RME Mill Relining Optimisation Program which has a mentorship program at its core. 

1. Brady Review | Brady Heywood. Review of all fatal accidents in Queensland mines and quarries from 2000 to 2019 | By Sean Brady for the Queensland Government Department of Natural Resources, Mines and Energy | December 2019 [online] https://www.bradyheywood.com.au/brady-review/ . Available at: https://documents.parliament.qld.gov.au/tableOffice/TabledPapers/2020/5620T197.pdf