Diacon Australia has helped a major South Australian miner significantly improve the safety and efficiency of its conveyor operations.
With countless moving parts and multiple tonnes of rock or slurry moving at high speeds, conveyors have long been associated with safety challenges.
Workers are often in close proximity to conveyors while they carry out monitoring and maintenance duties, clear blockages, make adjustments and calibrations, and load and unload materials.
Miners who come close to conveyors can run the risk of incidents such as entanglement in parts of the conveyor, including the belt, rollers or gears, slipping due to spilled materials, oils or dust that has fallen from the belt, or being struck by falling material like hard rock.
In this environment, Diacon Australia’s conveyor guard system is one solution leading the way in conveyor safety.
Since its launch in 2010, Diacon Australia has continuously advanced safety solutions for the mining and resources sectors. The foundation of this ongoing development has been the introduction of its conveyor guard system, which has become known in the industry for improving safety and productivity while reducing maintenance costs.
Diacon has used this solution to help a major miner in South Australia take its operations to new levels of safety and efficiency.
Diacon managing director Brendan Refalo said the company established a relationship with the mine several years ago through a range of discussions with its engineering provider.
“The key challenges that the mine was facing was large-scale expansion necessitating large volumes of guarding,” Refalo told Safe to Work. “Diacon Australia offered an opportunity for the design, manufacture and supply of many thousands of guards, all of which are made to Australian standards, are simple to install and remove, lightweight and corrosion free.”
Steel mesh guards have historically been used to prevent workers from coming into contact with the moving components – but this approach has its limitations. Steel guards are heavy, prone to corrosion, and can be difficult to maintain, making them cumbersome to work with in high-demand mining environments.
Diacon’s high-density polyethylene (HDPE) plastic guard system provides an alternative to traditional heavy steel guards that have long been the standard for protecting workers around conveyor systems.
HDPE is up to four times lighter than steel, making installation, maintenance and handling easier. It is also resistant to corrosion, impact and UV damage.
“Diacon was compared to traditional guarding forms and it was seen that large volumes of steel guards on a new installation could potentially require on-site adjustments, which would then not be painted correctly, further reducing the life of guards,” Refalo said.
“Corrosion was also seen as a major challenge for this site due to the saline nature of its mining operations.
“Diacon guards provided a fully corrosion-free alternative to traditional guards.”
Refalo emphasised that the Diacon system was always intended for use in highly corrosive environments.
“This is the standout feature in transitioning from traditional steel guarding to high-density polyethylene guards reinforced by stainless steel hardware,” he said.
“This means that the product is well suited to harsh marine environments like that encountered at ports, on jetty conveyors and shiploaders alike.”
Another standout feature of the Diacon system is its ‘hook, hang and lock’ mechanism, which is designed to simplify installation and removal.
Guards are mounted on custom-made bosses attached to brackets and lock into place using a unique slide-lock system. This system ensures the guard remains secure while in use, complying with Australian safety standards and mitigating the risk of the guard becoming loose during operation.
When they need to be removed for maintenance, Diacon’s system allows workers to hang the guard on a nearby handrail. This eliminates the risk of the guard becoming a tripping hazard while not in use, something to which heavy steel units are often prone.
The hook, hang and lock feature can also make maintenance tasks significantly easier and quicker, as workers can remove and store the guards without struggling with heavy or bulky equipment.
This feature was just one of many benefits the South Australian mine said helped improve its conveyor safety and operations.
The mine also praised the Diacon system’s seamless installation, which required no modification, how easy it is to remove and replace, and how neatly the guards were designed to fit not only the conveyor but also the structural steel and adjacent concrete plinths that supported the conveyor.
“Most importantly, site personnel said the guards have stood the test of time since they were first installed in withstanding the harsh operating conditions at the site,” Refalo said.
Diacon has a proven track record of success in mining, with its commitment to quality and customer satisfaction earning the company a reputation as a trusted supplier of conveyor guards.
“As the mine has further developed, new conveyor systems are being installed with the Diacon guarding system to continue to meet the needs of the operators,” Refalo said.
“Back-up service and support throughout the life of our product is important to us at Diacon Australia, ensuring our clients can continue to operate their facilities for the life of mine.”
The company has continually refined its product offering to stay ahead of industry demands, working to ensure it remains a leader in safety innovation. Part of this evolution involves working closely with clients to ensure their Diacon guards are tailored to fit specific requirements.
By conducting 3D scans of existing conveyor systems, Diacon is able to design guards that fit precisely, ensuring maximum protection and efficiency. The company also offers a “clear view” option for sites requiring additional visibility or specific requirements.
“By being involved at the earliest of planning stages for the mine’s conveyor equipment, Diacon was able to specifically design guards that accurately fitted the conveyor structure, ensuring complete compliance to Australian standards for machine guarding was maintained,” Refalo said.
“Being involved in the design process so early allowed Diacon designers to influence the steel structure design, greatly reducing the bracketry required to later install the conveyor guarding solution.
“This component alone has the potential to save the client as much as 30 per cent of the overall cost of guarding the conveyor.”
Diacon has similar relationships with mines across Australia, which Refalo said will remain a priority as the company increases its capacity and supports the ever expanding needs of the resources industry.
“Every day we listen to the feedback from our clients and their operation staff, ensuring that the product continues to meet and exceeded their very specific on-site requirements,” he said.
“Rest assured, our team are equipped to go above and beyond to support them in their maintenance and expansion activities.”
With safety always at the forefront, Diacon Australia’s conveyor guard system is paving the way for safer, more efficient mining operations across Australia and beyond.
By offering a lightweight, corrosion-free and durable alternative to traditional steel guards, Diacon is helping mining companies protect their workers while simultaneously improving the overall efficiency of their operations.
“Diacon Australia has set an entirely new benchmark for the quality and design of conveyor guarding systems for use in Australian mining,” Refalo said.
“We are an Australian company here for the long haul, to service and support the needs of Australian miners for the years to come.”
This feature appeared in the May–June edition of Safe to Work.