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The Use of Polymeric Chemicals in
Queensland Coal Mines
2010
The State of Queensland, Department of Employment, Economic Development and Innova

Except as permitted by the Copyright Act 1968, no part of the work may in any form or by
mechanical, photocopying, recording, or any other means be reproduced, stored in a re
broadcast or transmitted without the prior written permission of the Department of
Development and Innovation. The information contained herein is subject to change withou
copyright owner shall not be liable for t
tion, 2010.
any electronic,
trieval system or be
Employment, Economic
t notice. The
echnical or other errors or omissions contained herein. The
onsequences resulting
tion.

Enquiries about reproduction, including downloading or printing the web version, should be directed to
ipcu@dpi.qld.gov.au or telephone +61 7 3225 1398.


reader/user accepts all risks and responsibility for losses, damages, costs and other c
directly or indirectly from using this informa


Contents
1
1.0 Introduction 1
1
cals 3
3
3
s 4
ldehyde Resins (Phenolic Resins) 5
2.2.1 Health effects from exposure to Phenolic resin ingredients 5
6
6
6
Coal Mines? 6
4.0 Legislative Requirements 7
2001 7
quirements 9
5.0 Control Measures 9
10
ment (RPE) 11
g 12
8.0 Health Surveillance and Biological Monitoring 12
8.1 Health Surveillance for PUR and sodium silicates products 13
8.2 Health Surveillance for Phenolic Resins 13
9.0 Conclusions 14
Appendix 1 15
Contents
1.1 What are Polymeric Chemicals?
2.0 Types of Polymeric Chemi
2.1 Polyurethane Resins (PUR)
2.1.1 Health effects from exposure to PUR
2.1.3 Exposure Standard
2.2 Phenol Forma
2.2.2 Safety and fire hazards
2.2.3 Exposure Standards
2.3 Urea Silicate Resins
3.0 How much is used in Queensland
4.1 Queensland Coal Mining Safety and Health Regulation
4.2 NSW Coal Mining Legislative Re
6.0 Personal Protective Equipment
6.1 Respiratory Protective Equip
7.0 Personal Exposure Monitorin
The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010


1.0 Introduction
In February 2010 a survey was sent to the Site Senior Executives (SSE) of all Que
underground coal mines in orde
ensland
r to obtain information about the extent of use and the control
measures in place for the use of polymeric injection chemicals during the period of 2009. A copy of
provided one
survey that covered both Grasstree and Bundoora mines. Cook Colliery indicated that they had not
009 and hence do not contribute to the
nstruction
ealing. The
applications in metaliferous mines.
neral as PURs. The term PUR actually
e more commonly used polymeric injection
ategories;
Polyurethane resins (PUR) (eg. Bevedan, Marithan, silent seal, micon seal)
Phenolic resins (eg. Fenoflex, Rocsil, Carbofill, Carbomine)
367)
mmon uses of polymeric chemicals in underground
plug seals (including rapid sealing of mine roadways)
evices
Sealing cable bolt holes prior to grouting
Pumpable resins for roof and cable bolting application (self drilling bolts)

In addition polymeric chemicals are used for the flat-proofing of tyres. Typically a polyurethane
foam is pumped into the tyre cavity to form a solid core in order to make it resistant to puncturing.
This process is carried out in tyre fitting work shops offsite.

Figure 1: Flat proofed tyre with PUR fill.










this survey is included as Appendix 1.

Eleven (11) responses were received accounting for a 100% return rate. Capcoal
used any polymeric chemicals during the period of 2
quantities provided in this report.

This report summarises the responses provided by all mines.
1.1 What are Polymeric Chemicals?
Polymeric chemicals refer to a group of products used throughout the mining and co
(tunnelling) industries for various applications including strata stabilization and s
majority of use in mining occurs in underground coal mines although there have been recent

Polymeric products are often incorrectly referred to in ge
refers to just one type of polymeric chemical. Th
chemicals in the mining industry fall into three (3) c

Urea silica based resins (eg. Geoflex, Meyco

Common application and use in underground coal mines
The following list represents the most co
mining;

Strata binding of fractured or unstable roof.
Void or cavity filling (usually following LW roof collapse)
Formation of temporary
Sealing around ventilation d
The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 1


The use of these tyres was subject to an industry wide directive issued in 2005.
http://www.dme.qld.gov.au/zone_files/inspectorate_pdf/directive_1.pdf The purp
directive was to ensure that mines identify hazards associated with the heating o
ose of this
f these products,
the risks are assessed and that controls are implemented to ensure an acceptable level of risk is
ll current.
high pressure
migrates through the cracks and fissures in the strata
a silicate and
so be used for this application.

Figure 2: Strata binding via injected PUR through drilled holes in the fractured strata. (Image sourced
from Wilsons Mining Services)









Cavity Filling involves the pumping of a phenolic resin into a large void or cavity. When mixed with
a catalyst the resin undergoes rapid expansion to form a dense foam that plugs the cavity,
stabilizes debris and prevents gas accumulation in the void.

Figure 3: Cavity filling via pumping of phenolic resins into void over the longwall face. (Image sourced
from Wilsons Mining Services)










Seal Construction. On occasions phenolic resins may be used to form temporary seals in a
roadway by pumping foam between two stands of mesh or boarding. This can be performed
relatively quickly prior to the construction of a more robust seal. In a similar fashion polyurethane
resins are sometimes used to construct seals of a more permanent capability.





achieved when using these products. The requirements of this directive are sti

Strata binding involves the injection of a polyurethane resin and catalyst under
through drilled holes in the strata. The resin
to form strong and flexible bonds that stabilize the surrounding ground. Some ure
phenolic resins may al








The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 2


Figure 4: Construction of a plug seal in a controlled environment (shipping container) during a trial
exercise.










Health Management System must provide ways
sks and controlling the hazards that each of these products may present.
Part A - the resin and,
for most PUR products and 1:4 for most of the phenolic resins.
the ratios are strictly followed so that all of the catalyst is
orkers from a
as PURs. These resins are formed by mixing a
lecular weight
nufacture of polyurethane
ate (TDI)
lower vapour
ns at room
still contain TDI.
these are well
documented. Isocyanates are irritating to the eyes, skin and the respiratory system.

The most significant health effect associated with exposure to isocyanates is occupational asthma.
This is an allergic reaction of the respiratory system that is caused by exposure to respiratory
sensitisers or asthmagens. Isocyanates are known respiratory sensitisers. Not everyone who gets
exposed to a sensitiser becomes sensitised and goes on to get asthma. But once the lungs
become hypersensitive, further exposure to the substance, even at quite low levels, may trigger an
attack. This can happen to you even if you have worked without any problems for many years. A
sensitised individual may suffer chest tightness, coughing, wheezing and shortness of breath for

2.0 Types of Polymeric Chemicals
Each type of polymeric product has a different chemical make up and hence the hazards will vary
for each during application. A mines Safety and
for assessing the ri

Essentially each polymeric product used will consist of a two component system. These
components are generally referred to as;

Part B - the catalyst.

Mixing ratios will vary between 1:1
Care must be taken to ensure that
exhausted during the reaction.

It is generally the catalyst (Part B) that represents the greater risk to coal mine w
health perspective.
2.1 Polyurethane Resins (PUR)
Polyurethane resins are often referred to
diisocyanate and a polyol in the presence of a catalyst. Isocyanates are low mo
compounds which are highly reactive. The diisocyanate used in the ma
resins is typically methylene diphenyl diisocyanate (MDI). Previously toluene diisocyan
was used in Europe but this has since been substituted with MDI which has a much
pressure and is relatively easy to handle. MDI will not produce vapour concentratio
temperature. However isocyanates used for flat proofing of tyres sometimes
2.1.1 Health effects from exposure to PUR
There are considerable health hazards associated with the use isocyanates and
The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 3


several hours after the exposure ceases. It is worth noting that occupational asthma is the most
Skin contact with unreacted catalyst can cause rashes, blistering and reddening of the skin.
cause irritation, conjunctivitis and eye tissue damage.
lies that during the
nding on the mixing ratio and the
presence of any contaminants, the temperature reached during the setting can vary between
pplied to all
ignificant fires in underground mines in which PUR was a causal
sulted in the production of copious quantities of toxic smoke and
the burning of these
s to Life and
hly toxic gas
liberated in such fires. The report into the Kinross Gold Mine fire states
e died from exposure to noxious gases.
of these
In
s in Germany
sure Stand
The most hazardous ingredient in PUR with respect to health is the diisocyanate contained in the
is is methylene enyl diisocyanat I) and is l PUR products
land coal mines. The occupational exposure limits (OEL) specified by Safework Australia
tes. These limits should protect most workers from adverse health effects.
R) and urea
common occupational lung disease in developed countries (ASCC 2005).

Contact with the eyes may

2.1.2 Safety and fire hazards

The chemical reaction that creates polyurethane foam is exothermic. This imp
reaction process heat is released to the surroundings. Depe
100
o
C and 198
o
C. A current upper action limit reaction temperature of 150
o
C is a
polymeric injection chemicals used in underground coal mines in NSW.

There have been a number of s
factor or where its combustion re
gases. These include the following:

Michael Colliery Scotland 1968
Westcliff Colliery Australia 1986
Perisher Bullocks Flat tunnel Australia 1987
Kinross Gold Mine South Africa 1988
Daw Mill Colliery England 2006

Of particular concern is the liberation of hydrogen cyanide (HCN) gas during
products. HCN is extremely toxic and has been assigned an Immediately Dangerou
Health (IDLH) level of 50ppm. Copious quantities of carbon monoxide (CO), a hig
(IDLH 1200ppm), are also
that the majority of peopl

To minimise the potential for fire, fire retardants are added during the manufacture
products and restrictions have been placed on the quantity of PUR that can be injected per hole.
addition, extensive testing is required during the approval process of these product
and then in New South Wales.
2.1.3 Expo ards
catalyst. Th diph e (MD currently used in al
in Queens
apply to all the isocyana

Table 1: Exposure Standards for isocyanates contained in polyurethane (PU
silicate resins
Substance
TWA* (8 hour) STEL^
Additional
mg/m
3
mg/m
3

Isocyanates all
(as - NCO)
0.02 0.07
Respiratory and skin
sensitiser
* Time Weighted Average
^Short Term Exposure Limit
#
NCO - Chemical chains found in isocyanates
Note: Exposure limits specified are based on a standard 40 hour working week. Adjustment may
be required for extended shift rosters.
The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 4


2.2 Phenol Formaldehyde Resins (Phenolic Resins)
There are two distinct types of phenolic resins used in underground mines.
classified as cavity filling
They are either
or strata injection resins. Both of these resins are two component
id catalyst.
filling. The
henol and formaldehyde. The acid catalyst generally comprises of
sulphuric, phosphoric and phenolsulphonic acid and has a low pH of approximately 1 (strong acid).
gerous Good
olic resin and an ester
tassium hydroxide or
line). These resins also contain
al formaldehyde and phenol. The resin is classified as a hazardous substance and a
hazardous.
systems.

Cavity Filling Resins (Carbofill, Rocsil)
These systems are dual component resins that consist of phenolic resin and an ac
They are mixed in a ratio of 4:1 by volume and foam up to 30 times for mass cavity
phenolic resin contains p
Both components are classified as hazardous substances and the acid is also a Dan
class 8 (corrosive substance).

Injection Resins (Carbomine, Fenoflex)
These systems are dual component resins that consist of an alkaline phen
for curing of the resin. The alkaline phenolic resins may contain either po
sodium hydroxide giving the resin a high pH of 13 (strong alka
residu
Dangerous Good class 8 (corrosive substance). The ester is not classified as

2.2.1 Health effects from exposure to Phenolic resin ingredients

Phenol
Phenol is a highly corrosive and toxic substance that may enter the body through
ingestion and skin absorption as a vapor, liquid, or solid. The absorption effici
is approximately equal to that by inhalation. Therefore absorption through the ski
significant source of exposure.

inhalation,
ency through the skin
n may be a
phenol may result in acute irritant effects and systemic toxic effects. Locally, phenol
emic toxic
and kidney
n with known kidney or
Exposure to
exposures may result in irritation of the nose, throat and eyes and skin burns. Syst
effects due to high exposure include central nervous system impairment and liver
damage that may lead to death. It has been recommended that no perso
liver damage be exposed to phenol at any concentration. Phenol has not been classified as a
human carcinogen.

Formaldehyde
Formaldehyde is toxic by inhalation, skin contact and by ingestion. Formaldehyde solutions readily
itching
g.
Skin contact with formaldehyde solution can cause skin rashes and allergic skin reactions. For
individuals allergic to formaldehyde, even very low levels of formaldehyde are likely to cause skin
reactions. Splashes into the eyes can cause irritation, corrosion of the cornea, and possibly
blindness. Formaldehyde has been classified as a suspected human carcinogen.

Acids
give off formaldehyde gas, which has a pungent odour. Breathing formaldehyde vapour can result
in irritation of nerves in the eyes and nose, which may cause burning, stinging or
sensations, a sore throat, watery eyes, blocked sinuses, runny nose, and sneezin

The use of strong acids to make the polymer is also a significant hazard. These acids are highly
irritating to the skin, eyes, mucous membranes and respiratory system. In addition, sulphuric acid
is classified as a suspected human carcinogen, when contained in strong inorganic acid mists.

The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 5


2.2.2 Safety and fire hazards
In the cured state phenol formaldehyde polymers are of low toxicity and are d
burn they may give off a
ifficult to ignite. If they
number of toxic and irritant gases including sulphur dioxide, carbon
xide.
rds
tances found in phenolic
re are li
2: Exposure Stand for hazardo bstances f s
monoxide and carbon dio
2.2.3 Exposure Standa
The current national posure rd for hazardous subs occupational ex
sted below.
standa
sins systems
Table a s rd us u s ound in phenolic resin
Substance
TWA (8 Hour)* STEL^
ppm ppm
Additional
Phenol 1 - Skin absorption significant
Formaldehyde 1 2 Respiratory sensitiser
Sulphuric acid 0.2 0.7 -
Phosphoric acid 0.2 0.7 -
Acetic Acid 10 15 -
* Time Weighted Average
^Short Term Exposure Limit
Note: Exposure limits specified are based on a standard 40 hour working week. A
required for extended shift rosters.
djustment is
th a diisocyanate in the
cyanate MDI in
e products are
spiratory system and skin.
es?
sked to provide detail e of polymeric chemic and the total volume of
d during the p 2009. A total of four hundred and ninety five (495)
ns were reported across all underground coal mines. Phenolic resins accounted
2.3 Urea Silicate Resins
Urea silicates are a two part system combining a sodium silicate mixed wi
presence of a catalyst. Like polyurethane resins the urea silicates contain the diiso
Part B.

The hazards for these products would be very similar to the PURs. In addition thes
strong alkalines and are severely irritating to the eyes, re
3.0 uch is u eens How m sed in Qu land Coal Min
Mines were a s of the typ als
each type that was use eriod of
separate applicatio
for approximately 85% by volume of the polymeric chemicals used.

Table 3: Product type and total combined volume used during 2009
Product Type Volume used (L) Number of mines using
Phenolic Resins 1, 245 847 6
Polyurethane Resins (PUR) 200 895 9
Sodium Silicate Resins 4000 1

The majority of applications were for the purpose of strata stabilisation (68%).
accounts for significantly less number of tota
Although void filling
l applications in general the quantity of chemical
required per application is far greater.

In Queensland there are two (2) main companies who supply the polymeric injection chemicals
used in Queensland coal mines. In addition these companies employ contractors who undertake
the majority of void filling and strata stabilisation applications. These companies also operate in
New South Wales coal mines.

The use of single use systems such as silent seal are typically applied by coal mine workers
employed by the mine and not specialist contractors.
The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 6


495
90
336
69
100
200
300
400
500
600
N
u
m
b
e
r

o
f

a
p
p
l
i
c
a
t
i
o
n
s
Total ber of
applic ions
num
at
Void fill
Strat tabilisation a s
Seal
0
Type of appl i cati on
0
20000
40000
V
o
l
60000
80000
100000
120000
140000
160000
G H I J K
u
m
e

o
f

r
a
w

p
r
o
d
u
c
t

(
L
)
A B C D E F
Mi ne
PUR
Phelolic
Sodium Silicate
Figure 5: Type and number of applications














ccording to the
d the way in which e strata fails. Some mines
are fortunate to encounter minimal geotechnical issues in the coal seam and therefore are not
required to use these products regularly (if at all).

Figure 6: Type of product and volume used by each mine




















or longwall
al supervision
ontroller (60%).
4.0 Legislative Requirements
4.1 Queensland Coal Mining Safety and Health Regulation 2001
The use of polymeric chemicals in Queensland Coal mines is covered under s55 and s56 of the
Coal Mining Safety and Health Regulation 2001, Hazardous Substances. These regulations do
not set out specific requirements for the use of polymeric chemicals but they apply to all hazardous
substances generally. Under this legislation a hazardous substance is defined as follows.

The type of product used and the subsequent quantity used by each mine will vary a
geological conditions encountered during mining an th
The majority of mines have indicated that the mine geotechnical engineer (40%)
superintendant (30%) coordinate the use of these chemicals at the mine. The actu
during the application of these products is generally provided by the section ERZ c

The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 7



A ha
ntitled List of
SC:10005]; or
(b) meeting the criteria stated in NOHSCs document entitled Approved Criteria for
ed in Queensland coal mines for strata binding, void filling and
ified as Hazardous Substances and therefore s55 and s56 of the
(1) T ubstances used at
the
dous substance; and
n a location that is easily accessible by each coal mine worker at
Safety Data Sheets [NOHSC:2011].

56 Using hazardous substances
(1) A g hazardous substances at the
(a) purchasing, selecting, storing, using, moving, decanting and disposing of hazardous
us substance.

In addition section 29 an Coal Mining Safety and Health Act 1999 (CMSHA 1999)
be achieved.
level , the
(b) as low as reasonably achievable.
nd operating
ance is not
sk assessed
rarchy.
Acceptable limits with regard to hazardous substances are usually defined in terms of the
substances occupational exposure limit (OEL). Currently there are no exposure limits specified in
the Queensland Coal Mining Safety and Health Regulation 2001 for hazardous substances
contained in polymeric chemicals used in Queensland mines.

However, Safework Australia provides occupational exposure limits for a range of hazardous
substances that are designed to protect the health and prevent undue discomfort to nearly all
workers who are exposed. These limits may be in the form of Short Term Exposure Limits (STEL)
and/or Time Weighted Averages (TWA).

zardous substance is a substance
(a) listed as a designated hazardous substance in NOHSCs document e
Designated Hazardous Substances [NOH
Classifying Hazardous Substances [NOHSC:1008].

All polymeric chemicals currently us
sealing applications are class
Regulation applies. The Regulations state:

55 Hazardous substance register
he site senior executive must ensure the mine has a register of hazardous s
mine.
(2) The register must
(a) contain the material safety data sheet for each hazar
(b) be kept at the mine i
the mine.
(3) The material safety data sheet must comply with NOHSCs document entitled National Code of
Practice for the Preparation of Material
coal mine must have a standard operating procedure for usin
mine.
(2) The procedure must include provision for
substances; and
(b) appropriate first aid for a person affected by a hazardo
d 30 of the
defines what constitutes an acceptable level of risk and describes how this may

29.(1) For risk to a person from coal mining operations to be at an acceptable
operations must be carried out so that the level of risk from the operations is
(a) within acceptable limits; and

30.(1) To achieve an acceptable level of risk, this Act requires that management a
systems must be put in place for each coal mine.

Achieving an acceptable level of risk with regards to exposure to a hazardous subst
unlike any other hazard on a coal mine. The hazard must be clearly identified, the ri
and control measures implemented and reviewed in accordance with the control hie

The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 8


These exposure limits are listed in the document tilted Exposure Standards f
Contaminants in the Occupational Environment [NOHSC: 1003(1995)] or are avai
or Atmospheric
lable on line at
http://hsis.ascc.gov.au/SearchES.aspx. Information relating to the interpretation
standards can be found in th
of exposures
e Guidance Note [NOHSC: 3008 (1995)]. In addition the Material
Safety Data Sheet (MSDS) for a hazardous substance must specify the exposure limits for each of
The New South Wales Department of Industry and Investment define Polymeric Chemicals as
udes polyester
Chief Inspector of Coal
in this approval the
, Thornton
exothermic
d oxygen index.
German Authority
ts demonstrating suitability for use in underground coal mines. These
fire and flame propagation properties.
re a polymeric chemical is used in an underground coal mine in NSW the supplier
ust provide the Chief Inspector with a risk assessment that addresses:
Application method
Storage
nt that all entities carrying out injection of
underground coal be licensed.
easures
presents the control measures employed by each of the mines during the application of
Trained operators
Exclusions zones
PPE

All mines using these products have indicated that these products are approved for use according
to the mines Standard Operating Procedure for Hazardous Substances. In addition specific risk
assessments for the use of each product have been conducted and standard operating procedures
for each product developed. It was not clear from the survey responses if risk assessments have
been conducted for the use of single use systems such as silent seal.



the ingredients that are hazardous.
4.2 NSW Coal Mining Legislative Requirements
any material (including its constituents) that is polymerised underground, but excl
resin capsules for strata support .

In New South Wales (NSW) polymeric chemicals must be approved by the
Mines prior to them being able to be used in underground mines. To obta
material must pass tests that are carried out at the Mine Safety Technology Centre
Laboratory. This includes the Mine Safety Test Method 98/1070 for maximum
temperature, fire resistance, flame propagation, flashpoint an

The NSW Mines Inspectorate also requires that all polymeric materials meet the
(LOBA) test requiremen
requirements relate to

In addition befo
of the product m
Equipment used
Transport
Handling
Clean up

Under recently introduced legislation there is a requireme
polymeric chemicals in NSW

5.0 Control M
Figure 7 re
polymeric chemicals. All mines report that control measures include:
General mine ventilation
Bunded storage
Use of approved chemicals (LOBA and NSW- Mine Safety Test Centre)
Material Safety Data Sheets
The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 9


Control Meausre
0%
10%
100%
20%
70%
100%
60%
90%
100%
100%
100%
100%
40%
70%
Health surveillance
Personal exposure moniotring
Spill kits
Exclusion zones
MSDS
Training provided on Haz Subs
Training provided in SOP
LOBA approved chemicals
Bunded storage
Flow meters
LEV
Mine ventilation
Substitution 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Percent
Elimination
Figure 7: Percentage of coal mines using control measure listed
ance with the hierarchy of controls after
conducting us substances.

Elimination of the hazard
less hazardous process
rom the hazard

Where a hazard cannot be eliminated or substituted than the use of engineering controls such as
uld be considered.
duction methods
rative / procedural controls and personal protective equipment will be required.
ersonal Protective Equipment (PPE) must always be
gh appropriate training, supervision and leadership.
equired when using

Respiratory Protective Equipment (RPE)
Coveralls
Gloves
Eyewear

The type of glove, coverall and eye protection was not stipulated. When handling hazardous
substances it is imperative that the material that the glove or protective clothing is made of is
appropriate for the substance being handled. This is based on the permeation and degradation

Control measures should always be implemented in accord
is no different for the use of hazardo a risk assessment. This

Substitution with

/substance
Separation of persons f
Engineering controls

Administrative controls

Personal Protective Equipment

Least des
me
irable
thod
local exhaust ventilation and enclosed systems sho

Where the risk cannot be reduced to acceptable limits the use of lower level risk re
such as administ
The use of administrative controls and P
reinforced throu

6.0 Personal Protective Equipment
All mines (100%) indicated that the following personal protective equipment is r
polymeric chemicals.
The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 10


rating. The Material Safety Data Sheet (MSDS) should specify the type of glove material required
e obtained from the AS/NZS 2162.1:
O use and maintenance or by consulting selection guides
p
http://www.allsafetyproducts.biz/page/74172
(eg. neoprene, PVC, natural rubber, viton etc).

More information on the selection of gloves can b
ccupational protective gloves Selection,
rovided by the suppliers of protective equipment such as:

eGuide.pdf http://www.ansellpro.com/download/Ansell_7thEditionChemicalResistanc
100%
80%
40%
10%
0%
0%
10%
20%
30%
100%
40%
50%
60%
70%
80%
90%
RPE Worn
Disposable half face piece (Particulate)
Cartirdge half face (organic vapour)
Cartridge full face (organic Vapour)
Powered air purifying

level of eye protection should be determined through risk assessment and consultation with
nces being handled are corrosive or irritating to
may be splashed or sprayed, goggles must be
the application of
piratory protection that is used varied between each
ticulate P1 or P2)
st mechanically
hey are not
1715:2009
1716: 2003
n required, it is important to
know the concentration of airborne contaminants that will be generated during the work activity.
g should cover
all tasks performed. It is suggested that if the mean exposure can not be reduced to below 50% of
the Occupational Exposure Limit (OEL) by other means then the requirement for RPE should be
seriously considered. This is in line with Section 29 (1)(a) of the CMSHA 1999 which requires that
operations be carried out so that the level of risk is as low as reasonably achievable.

Figure 8: Type of respiratory protection worn during use of polymeric chemicals.
It is important that the use of RPE is supported by a program that addresses the selection, use and
maintenance of these devices. The program should include individual fit testing, donning and
doffing procedures and a clean shaven policy if the program incorporates negative pressure
respirators. As a minimum this program should meet the requirements of AS/NZS 1715:2009
Selection, Use and Maintenance of Respiratory Protective Equipment.


The
the Material Safety Data Sheet. Where the substa
the eyes and there is likelihood that the substance
worn.
6.1 Respiratory Protective Equipment (RPE)
All mines have indicated that Respiratory Protective Equipment is worn during
polymeric chemicals. The type and level of res
mine. A number of mines (80%) indicated that disposable half face piece (par
respirators are worn. These respirators are designed to provide protection again
generated particulate such as dust (P1) or thermally generated particulates (P2). T
designed to provide protection against organic vapours.

Respiratory protective equipment should be selected in accordance with AS/NZS
Selection, Use and Maintenance of Respiratory Protective Equipment and AS/NZS
Respiratory Protective Devices. When considering the level of protectio
This can only be achieved through personal exposure monitoring and this monitorin
The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 11


The purpose of fit testing is to ensure the coal mine worker is provided with a respir
their facial features and will provide adequate protection. Fit testing should be per
respirator selection process or whenever there is a change in respirator supply. Fit testing may be
ator that fits to
formed during the
quantitative and/or qualitative. Some qualitative and all quantitative methods require the use of
train those required to use it on
or fit testing.

OSHA provide a freely downloadable training tool that demonstrates respirator donning procedure
specialist equipment and trained operators.

Once respiratory protection has been selected it is important to
how to correctly fit (don) and how to check for leaks. Leak tests do not substitute f
They should however be performed each time after donning the respirator.
and leak check. This is available at the following link:
http://www.osha.gov/SLTC/respiratoryprotection/index.html#trainingvideos

The presence of facial hair does not allow for a perfect seal and will provide a pathway for
pirator. For this reason all personnel required to

tmosphere that a
ent and is
t, sampling media and analytical
d to determine
rm monitoring for
filling applications.
osure monitoring
orted that grab
tor tubes. These methods
are useful in determining the presence of a contaminant in the atmospheric environment but are
which polymeric
ittle personal exposure
simulated applications
ab samples).
ing
Figure 7 indicates that seventy per cent (70%) of mines using polymeric chemicals indicated that
contractors applying these chemicals underwent additional health surveillance. Responses
indicated that this was restricted to biological monitoring for those using phenolic resins.

Health surveillance involves the medical monitoring of a person who may be exposed to a
hazardous substance. The purpose of health surveillance is to ensure controls measures are
effective and to identify workers who have an increased risk of developing an occupational disease
from exposure to a hazardous substance. Health surveillance may involve biological monitoring
and/or medical assessment to evaluate the effects of exposure to a hazardous substance.

contaminants to enter around the edges of the res
wear negative pressure respiratory protection should be clean shaven.

7.0 Personal Exposure Monitoring
Personal exposure monitoring generally refers to measuring contaminants in the a
worker breathes. Personal monitoring generally involves using specialised equipm
undertaken by personnel with specialist skills. The equipmen
methods used will be dependant on what substance is being measured.

Personal monitoring is an important part of the risk assessment process that is use
the level of control required to protect the worker. Methods are available to perfo
all the substances used in strata stabilisation and void

Only ten per cent (10%) of mines indicated that they have conducted personal exp
during the application of polymeric chemicals. Forty per cent (40%) of mines rep
samples are taken during application of phenolic resins using stain indica
not a reliable indicator of personal exposure (Refer to Figure 7).

Due to the specialised nature of the equipment required and the adhoc nature at
chemicals are used in underground coal mines, historically there has been l
monitoring conducted. The majority of monitoring has been undertaken in
on the surface or by using less conclusive methods such as stain tubes (gr

8.0 Health Surveillance and Biological Monitor
The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 12


Biological monitoring involves sampling and analysing body tissues or fluids to p
exposure to a toxic substance or metabolite
10%
90%
40%
70%
30%
0% 20% 40% 60% 80% 100%
no health surveillance conducted
health surveillance conducted
grab sampling
no personal monitoring
personal moniotring conducted
rovide an index of
. Biological monitoring may be particularly useful for
for strata
e workers have
here are a number
es that are available to assess a workers exposure and/or to
ques used will depend on the type of
chemical contained in each product.

Figure 9: Personal exposure monitoring and health surveillance.
During the application of PUR products, the diisocyanate may enter the body through inhalation of
ory function tests,
respiratory system. It is
l monitoring has been pursued to identify workers
e able to assist
hese
techniques are currently not available in Australia but may be in the near future.

Guidelines on health surveillance for isocyanates can be found at the following website.
http://www.deir.qld.gov.au/workplace/resources/pdfs/ddp-isocyanateguide.pdf
substances that may be absorbed through the skin.

There are contracting companies that specialise in the use of polymeric chemicals
binding and void filling applications in underground coal mines. These coal min
potential for significant and ongoing occupational exposure to these products. T
of health surveillance techniqu
confirm the absorbed dose from the exposure. The techni

8.1 Health Surveillance for PUR and sodium silicates products
vapours or absorption through direct contact with the skin.

Traditional health surveillance techniques for isocyanates include respirat
respiratory questionnaire and physical examination of the skin and
recognised that these techniques are generally looking for lag indicators after the exposure has
occurred.

More recently urinary isocyanate biologica
potentially at risk and to assess the effectiveness of controls. This technique may b
in early intervention and prevent the onset of sensitisation or respiratory disease. T

8.2 Health Surveillance for Phenolic Resins
Dermal absorption of phenol may also contribute significantly to exposure. A worker's exposure to
phenol can be determined by analysing a urine sample taken at the end of the shift for total phenol.

The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 13


9.0 Conclusions
The health and potential safety implications associated with the chemical ingredients contained in
these products are well documented, however to date there is limited health data available to
ialised contractors
th and safety information.
mines and the potential
products and the limited personal exposure data, it is
recommended that the use of these products be tightly monitored and controlled.

To a

1. Only products that have undergone the LOBA and the NSW approval process be allowed to
efer to:
i.nsw.gov.au/__data/assets/pdf_file/0010/249760/Review-Process-Polymeric-
suggest that the risks are or are not being controlled.

The use of these products in Queensland coal mines is only performed by spec
who appear to have good systems in place and provide appropriate heal
However, based on the extent of use of these products in Queensland
health and safety effects of these
chieve this it is recommended that:
be used in Queensland underground coal mines. For more information r
http://www.dp
Chemicals-_and_-Systems.pdf

2. Applicators of these products are licensed as per the requirements under the NSW coal
the use
ate and monitor personal exposure levels
generated during application of PUR, phenolic and sodium silicate resins.
orn by
matched to the hazard (eg. organic vapour). The level of protection requirement should be
determined through assessment of personal exposure.

6. All mines ensure that the use of single use systems such as silent seal are subject to a
risk assessment with a cross section of the workforce and ensure controls are implemented
and all personnel applying these products are adequately trained.
mining legislation.

3. Applicators of these products be required to undergo routine health surveillance for
of these products

4. The Queensland Mines Inspectorate investig

5. All mines review the requirement for and the type of respiratory protection w
operators during the application of polymeric chemicals. Respiratory protection must be
The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 14


The U












se of Pol ymeric Chemicals in Queensland Coal Mines 2010 15
Appendix 1
Polymeric Chemical Survey



























Mine Name: Date survey completed :
Person Completing Questionnair Position: mber: e: Contact Nu
Site Senior Executive:
Question Response: (Tick box where appropriate and / or type response)
1. What type of polymeric chemic
do you use at this mine (for str
stabilization and sealing
applications) and what was t
total quantity used in 2009
each product?
als

ata
he
for
sed
es of
eric
ctively as
e
po l into
th

pur
Carbofil
eyco)



Polymeric chemicals refer to a group of products u
throughout the coal mining industry for various typ
strata stabilization and sealing applications. Polym
products are often incorrectly referred to colle
PURs. The term PUR actually refers to just one typ
polymeric chemica
of
l. The more commonly used
lymeric chemicals in the coal mining industry fa
ree (3) categories;
l

M
Polyurethane based resins (PUR) (eg. Wir ,
arithan, Silent seal)
Phenolic resins (eg. Fenoflex, Rocsil,
Sodium silicate resins (eg. Geoflex, M
l)
No polymeric chemicals are used at this mine.
Polymeric chemicals are used at this mine but not aware what type as it is done by a
contractor.

Phenolic resins:
Carbofill quantity _________(L)
Rocsil foam quantity _________(L)
Fenoflex quantity _

________(L)
Polyurethane resins (PURs):
Bevedol / Bevedan quantity _________(L)
Marithan quantity _________(L)
Silent seal quantity _________(L)
Micon seal quantity _________(L)

Sodium Silicate resins:
Geoflex quantity _________(L)
Meyco 364 Flex quantity _________(L)
Meyco 367 Foam quantity _______

__(L)
___(L)
____(L)
Others:
Specify _____________ quantity ______
Specify _____________ quantity _____
2. How many times were these
products used in 2009?

Void filling ___________number of uses______
Strata support _________number of uses______
Seals ________________number of uses _____

3. Who applies these products at
your mine?

Product supplier (specify name) ________________
Contractor other than the supplier (specify name) ______________
The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 1


Mine employees

4. Who has responsibility for,
(a) Controlling /coordinatin
and,
g
_______
_______

(b) Supervising,
the use of these products
this mine
at
?

Please specify:

(a) ______________________________
(b) ______________________________
5. How are these products approv
for use at this mine?
ed
Please specify________________________

________
________
____________________________________________
____________________________________
____________________________________________

6 s are in
the use of these
products?
. What controls measure
place for

Elimination
Substitution

Engineering
Mine Ventilation
Local Exhaust Ventilation (auxiliary fans)
Flow meters, indicators and pressure gauges
Self bunded storage pods for transport
Other (specify) ___________________
Other (specify) ___________________

ive Administrat
Chemical approved for use by LOBA
Trained operators assessed as competent and authorised by UMM
Training ( SOP )
Training (Hazardous Substances)
Material Safety Data Sheets (MSDS)
Exclusion zones
Spill kits and emergency procedures
Personal exposure monitoring
The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 2


Health surveillance
Other (specify) ___________________
Other (specify) ___________________

Personal Protective equipment
Respiratory protection (specify type)
Disposable half-face
Half-face cartridge respirators
Full face cartridge respirators
Powered Air Purifying Respirator
Other ___________________
Coveralls
Protective eye wear
Gloves (specify type) _______________
Other (specify) ____________________
7
tio
mine?
. Has personal exposure
monitoring of operators been
conducted during the applica n
of these products at your

Yes (Please specify detai

ls) _____________________
No personal exposure monitoring

8 ucts

. Do users of these prod
undergo additional health
surveillance?
(eg. Phenolic resins - Total phenol in
urine)

Yes (Please specify) ________________

No additional health surveillance

9. What Safe Operating Procedur
se o
_________
_______
________
es
Please specify___________________________________
________________________________________________________
(SOP) are in place for the u
these products?
f
_________________________________________________
________________________________________________

10. How are these chemicals
stored onsite, and how is the
Please specify _____________________________________________
_________________________________________________________
_________________________________________________________
The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 3


issuing of these chemica
controlled / coordinate
ls
_________
_________

d?
________________________________________________
________________________________________________
_________________________________________________________
11. What procedures are
place for the transport
polymeric chemicals?
in
of
_________
_________
_________
_________
Please specify ____________________________________
________________________________________________
________________________________________________
________________________________________________
_________________________________________________________
12. What procedures are i
place for the disposal of wa
material, unused product an
empty container
n
ste
d
s of polymeric
__________
_________
_________
_________________________________________________________
chemicals?
Please specify ___________________________________
________________________________________________
________________________________________________
_________________________________________________________
Please provide any additional information or comments on the use of polymeric chemicals:
___________________________________________________________________________________________________________________
__________
__________
__________
___________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
___________________________________________________________________________________________________________________



The Use of Pol ymeric Chemicals in Queensland Coal Mines 2010 4