K3

 40, 41 & 42 Level Development Ends (3 Oct - 12 Nov 2011)
KDC East Hlalanathi (3 Shaft)
 40/21, 41/21 & 42/21 RAW

2
General Information and Scope
Information and background
 Shaft structure and travelling to work places
 Travelling to workplaces amounts to 80-120min on average in all levels due
to going down two or three shaft systems.
 Morning shift crews (40/41 level) use man carriages to travel to 3D sub
shaft but walk when coming back.
 42 Level crews use man carriages when they arrive on the 42 level.
 40/21 FWD (HPE RIG 3)
 Travelling to waiting place 88 min afternoon shift and 108 min morning shift.
 Hoppers and loaders derailed during loading and shunting (19min) (03/10)
 15-16 hoppers per shift are loaded and 47-54 face holes are drilled during
morning shift
 Temperature 35°C (Wet bulb) (07/10)
 Fixing drill rig before drilling also resulted in delay for marking and rig
preparation.
 9hoppers per span, 5min loading and 4 min shunting
 41/21 (HPE RIG 2)
 Travelling to waiting place 101min afternoon shift and 93min morning shift.
 Lost blast due to loco not arriving to move the drill rig to the face (04/10)
 Loco availability during morning shift was identified to be a common
problem (The afternoon shift leaves loco at fitter workshop due to a
breakdown)
 Damaged jump sets affects shunting and loading time (03/10)
 9 hoppers per span, 5min loading and 4min shunting
 18-22 hoppers per afternoon shift and 47-52 holes are drilled during the
morning shift
 42/21 RAW (HPE RIG 1 )
 Travelling to waiting place104 min afternoon shift and 106 min morning shift
 14- 18 hoppers loaded per afternoon shift and 56 face holes drilled during
morning shift.
 Previous shift hoppers not tipped (132 min) (delay).
 9-10 hoppers per span, 5min loading and 5 min shunting
 Loading mainly affected by worn loader shovel, low compressed air
pressure and changing full and empty hoppers when shunting
 Shortage of workers on morning shift.

4
46
Kloof 1 & 3# Layout
View looking North
Belt
Collar (BD)
4# Bottom
-3723.4 m
48
KEA# Bottom
-3849.4 m
Travelling to work places
Total average maximum time traveling to:
40/21 = 119 min back = 129 min
41/31 = 120 min back = 134 min
42/Raw= 127 min back = 87 min
Time on or travelling on the level
39 Level
23 Level
3#
1Sub# 2Sub# 4Sub#
3Sub#
7Sub#
14
16
18
19
20
21
22 22
21
15
17
12
18
19
20
17
22
21
40
35
37
(-3190 m) 39
33
(-2630 m) 31
32
31 Level
43 (-3444.4 m)
41
39
3A#
3D#
3B#
31
33
35
33
34
35
36
37
38
24
25
26
27
28
29
5A#
5B#
30
29
28
27
26
25
24
23(-2090 m) 23
45
40
42
1A#
3030
44
32
34
1 Shaft
Volkswagen
40
38
37
32
34
36
Belt41
Belt
Belt
Belt
-98.5 m
Belt
20
3# Bottom
- m
2 Sub # Bottom
-3306.17 m
3# Bottom
-3564.108 m
39 Level
+/- 40 m
to holing
41/42 Level +/-
2500t
waste to reef
Hot spots
25 Level +/- 2000t
waste to reef
44
45
46
47
Hot spot
25min/71min
11min
14min
1#
26 min
23 min 65 min
5 min
7 min
21-39 min
32-37 min
65-75 min
Cage time travelling down
Lay out edited from waste tramming layout
for 1 and 3#

6
Afternoon shift
Cleaning cycle
Time before loading span 1
-Travelling time to work place is 88min and
delays were only observed on 41 level
-Man carriages are used when travelling to
work places and are effective.
Time loading span 1 and 2
-Hopper derailed on switches during shunting
(03/10) span 2 (19min)
-Waste tip hanging up from 26/10 till 03/11,
-Special instruction to tip waste to reef issued
-03/11)
-Loading span 1 hopper derailed while loading
-Struggled to load first hopper due to vent columns
close to the face
-Time travelling to station tip span 1 affected by
reef tip grizzly blocked by big waste rocks (03/11)
-Loading time 5min, Shunting 4min
-16-17hoppers per shift
Time crew knocks off
-Crew use man carriages and go with
hoppers to the tip station,
-Time in 6:17-50pm to 03:10-04:20am
15 9 12
11 11 11
13
11 12
21 27 24
3 4 4
39 36 38
11 10 11
11 21 16
79
96 88
83
115
99
81
42
62
32
19 26
21 24 23
37 34 36
76
106 91
0
100
200
300
400
500
600
3/10/2011 3/11/2011 Average
Time(min)
Date
40/21 FWD 22 Time from station to surface
21 Time crew knocks off at workplace
and travel to station
20 Time end is barred solid and
cleaned.
19 Time Jump sets are extended
14 Time loco goes and come back from
tip station- span 2
13 Time started to load with loader span
2
12 Time loco goes and come back from
tip station- span 1
11 Time started to load with loader span
1
10 Time barring and face preparation
begins
9 Time travel to workplace
8 Time spent at waiting place (Meeting)
7 Time travel to waiting place
6 Time into cage- 3D sub shaft
5 Time travel to 3D sub shaft
4 Time into cage- 3 sub shaft
3 Time spent at 3 sub shaft
2 Time into cage- main shaft
502 min (Shift duration)

7
Morning shift
Drilling and blasting cycle
15 24 205 3 47 8 8
33 26 30
5 4 5
28 24 26
15 15 15
2 10 6
42
6
24
12
20
16
33
10
22
0
16
8
82
47
65
117
222
170
52
52
51
51
51
40
28
34
118
64
91
0
100
200
300
400
500
600
700
800
06/10/11 07/10/11 Average
Time(min)
Date
40/21 FWD
22 Time on surface
23 Time crew travel back to the
station
22 Time crew knocks off at
workplace
21 Time charging up the face begins
20 Time crew started to install
support
19 Time the drill rig was removed
from the face
18 Time the rig started drilling face
holes
17 Time the drill rig started drilling
support holes
16 Time drilling pilot holes begins
15 Time to prepare the drill rig
(machine set up)
14 Time the drill rig arrives at face
13 Time spent for marking the face
begins
12 Time testing for ventilation and
gas begins
11 Time treating of sockets begins
10 Time washing the face begins
8 Time spent at waiting place
(Meeting)
6 Time into cage 3D sub shaft
502 min(Shift duration)
-There was a problem with blasting cable when
connecting (06/10)
-Time in 05:00am to 15:36pm
Time drilling and charging up
-Drilling support holes (9-12 holes at 4:53min/hole)
-Drilling face holes (47-54 holes at 4:02min/hole)
-3m jumper was used to drill support holes 06/10
-While installing support , pump was blocked by
cement and crew had to fix pump 19min (06/10)
-Crew installed support while drilling the face (07/10)
-Machine clamps broke and caused a delay (45min)
(7/10)
Time before drilling support holes start
-Travelling to work place 108min
-Crew took 18 min cleaning foot wall during treating
of sockets (06/10)
-Drill rig had to be fixed before drilling (06/10)
-Man carriages are used
-35°C wet bulb (07/10)

9
Afternoon Shift
Cleaning cycle
11 5 8
14
71
437
10
9
26
30
28
5
7
641
33
3718
8
13
7
4
6
80
56
68
54
64
59
159
71
115
24
24
14
140
14
14
5
12
9
30
25
28
95
95
95
0
100
200
300
400
500
600
700
3/10/2011 6/10/2011 Average
Time(min)
Date
41/21
22 Time from station to surface
21 Time crew knocks off at workplace
and travel to station
cleaned.
16 Time loco goes and come back
from tip station- span 3
15 Time started to load with loader
span 3
span 2
span 1
10 Time barring and face preparation
begins
(Meeting)
6 Time into cage- 3D sub shaft
-Man carriages are used when knocking off
-Time in 18:44pm to 03:52 am
Time loading span 1 & 2
-Loading span 1 affected by 50mm hose broken and
had to be fixed (03/10)
-Loading span 2 jump sets damaged (12min loading)
Shunting affected by waiting for loco from another
cross cut (38min) (03/10)
-Full hopper derailed (19 min) ( 03/10)
-Loading 5:19min, Shunting 4:30min
-22 hoppers loaded (03/10)
-10 hoppers loaded (06/10)
-Travelling to waiting place 131min
-Time spent at 3 sub shaft was a delay due to cage
off loading material
-Hopper derailed while travelling to the working
place (03/10)
10 hoppers
were loaded

Drilling and blasting crew
Morning shift
20 6 11 12
6
15 10 10
8 9 7 8
17 23 19 20
7 5 8 7
28 36 30 31
106
19
6
44
11
7
4
7
5
6
34
13
7
10
7
4
6
30
127
79
63
74
69
155
141
148
28
29 29
60
29 45
15
10
13
141
50
40
77
59
80
78
72
0
100
200
300
400
500
600
700
800
4/10/2011 5/10/2011 2/11/2011 Average
Time(min)
Date
41/21 22 Time on surface
station
workplace
support
from the face
holes
support holes
(machine set up)
begins
gas begins
(Meeting)
6 Time into cage 3D sub shaft
Drilling not
done (rig
could not
be moved
to face)
Time before drilling starts
-Travelling to waiting place 92 min
-Time spent at waiting place is increased by waiting
for loco to come back from the fitter shop (04/10)
-Time spent marking the face is also affected by loco
not available to move the drill rig(2/11)
-Loco was still leaking oil from fitter shop after being
serviced (02/11)
-Drilling is affected by power pack setting when drilling
support holes right boom (7min/hole) 02
-Breakdowns and operational delays (18min) (05/10)
-Drilling support holes (4:58min) (15 -16 holes)
-Drilling face holes (03:55min) (47 -52 holes)
-5 people charging up the face making use of the rig
booms (02/11) when drilling starts late
-Derailed hopper caused a delay when knocking off
(02/11)
-Crews use man carriages to go to the station
-40-50 min is spent travelling back to sub shaft
-Time in 05:17 am to 15:33 pm

Afternoon shift
12
Cleaning cycle
-Crew first tip previous shift hoppers before loading
span one (132min)
-Short of man carriages to travel to work place 3
crews (2 man carriages)
-Travelling to waiting place delayed by loco , still at
fitter work shop (75 min) (03/10)
-Work place was flooded with water and drainage
system not working
Time loading span 1 and 2
--Loading time 5:37min, but 6:18 min once reef crews start
using compressed air. Shunting time 5:07min (10/11)
-Shunting affected by changing full and empty hoppers when
shunting (short space to shunt)
-Time loco goes and come back from the station tip(131 min)
caused by tramming congestion when coming back from
station tip and derailing of guard car (10/11)
-Span 2 affected extending jump sets and installing sliding
rails (10/11) (4 hoppers loaded for 64min)
-Loader shovel worn (reported)
-Man carriages used only on 42 level and crew
have to walk on 43 level to the station
-Shift had to wait 35 min on 23 level due to
explosives being put down to levels.(10/11)
-Time in 18:54 pm – 06:32am
25 7 16
5
13 9
15
8 12
75
59
67
10
2
6
116
148
132
114 114 114
123 138 131
75 64 70
36 36
7 7
40
63 5235
87
61
0
100
200
300
400
500
600
700
800
3/10/2011 10/11/2011 Average
Time(min)
Date
42/21 RAW 22 Time from station to surface
workplace and travel to station
cleaned.
span 4
span 3
span 2
span 1
10 Time barring and face
preparation begins
(Meeting)

Morning shift
13
Drilling and blasting crew
10 10 10
10 5 8
15 30 23
95
35
65
20
20
5
10
8
25
20
23
25
25
25
10
10
15
15
20
20
50
85
68
180
162
171
55
38
47
95
45
70
10
10
10
20
25
23
30
25
28
0
100
200
300
400
500
600
700
800
6/10/2011 7/10/2011 Average
Time(min)
Date
42/21 (RAW) 22 Time on surface
station
workplace
support
from the face
holes
support holes
(machine set up)
14 Time the drill rig arrives at face
begins
gas begins
(Meeting)
Time before drilling support holes
-Crew did not use a loco to travel to work place,1 loco for
2 workplaces (06/10)
-2 people are preparing the face before drilling and
delays drilling start time.
-Work place flooded with water, drainage system not
operating well
-Temperature 33°C (06/10)
-Drilling time 5min/ hole
-3 people install support and charge up the face (6/10)
-Left boom had a breakdown (06/10) while drilling the
face (25min)
-10-11 support holes drilled . 56 face holes drilled
-5 people at face, charging up and installing support
was faster(07/10)
-From the station to surface crew travel faster than any
other level (61min)

14
Key focus
Key issues summarised per level for both morning and afternoon shift
Morning and afternoon shift main areas of concern per level
Morning shift
-Installation of rails and condition of switches
-Drilling, blasting and charging up(waste tip
hanging up (26/10- 03/11)
-Fragmentation (Big rocks)
-Temperatures (35°C) (07/10)
-Machine breakdowns during drilling .
40 level (HPE 3)
Afternoon shift
-Hoppers are derailed on switches and on jump sets
when loading and shunting
-Waste tip hanging up (26/10-03/11)
-Installation of jump sets, some are without fish plates.
41 Level (HPE 2)
Morning Shift
-Work elements before drilling starts are increased
by loco availability. Marking (127min)(02/11), lost
blast (04/10)
-Drilling is affected by power pack settings,
pressure, one boom quicker than the other
-Loco breakdowns, one loco used, questionable
maintenance, Loco leaking oil during operation
Afternoon shift
-Work elements before loading span 1 starts are
commonly increased by derailed hopper while
travelling from station
-Hoppers derail during loading and shunting (19min)
-Damaged jump sets affects loading time(12min /
hopper (03/10)
42 Level (HPE 1)
Morning shift
-Work elements before drilling starts are
increased by travelling arrangements on the level
-Shortage of workers in the crew affects time
installing support and charging up.
-Temperature 33°C (06/10)
Afternoon shift
-Man carriage shortage.
-Tipping previous shift full hoppers before loading
span1, is a common delay.

15
Conclusions
 Mining parameters such as installation of jump sets, rails, switches, drilling and charging up would have to be further
investigated on the levels so as to avoid operational delays during the afternoon shift.
 Availability of locos and man carriages compromises the time to start with the main elements per shift and even can
result in a lost blast. Management will have to pay attention to having equipment available for operation at all times
(41/21).
 Failure to organize crews to the correct size per workplace in different situations compromises the time to complete the
work cycles in time (42/21 morning shift) (lower management must ensure consistency)
 Crews must tip second span hoppers when they knock off as it delays the next afternoon shift before loading span one
(42/21). Arrange with morning shift to always tip full hoppers during their shift and leave loco and man carriages at the
station tip. (Communication, lower management)
 Compressed air pressure, conditions of equipment, breakdowns and maintenance on locos will have to be addressed by
management.
Further investigation would then have to be carried out for more findings and clear conclusions to be finalised.
Based on the observations

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