The lever, which activates the hydraulics for power and operation in the process of roof bolting, is mounted on the hydraulic manifold.

Because underground mining operates on a relatively low ceiling height, for practical reasons the lever is mounted on the manifold at leg level.

This always left the lever susceptible to accidental knocks and bumps by someone’s leg, which would activate the hydraulic valve and pump energy through the conduit.

In turn, this would cause a roof bolt to release. These can fall from the roof height and land on the finger, foot, or head of a worker, causing a severe crush injury, or even amputation.

Leussink engineered a completely new design that added a safety lever.

It is a spring-loaded safety lever that requires two different movements – one upward movement followed by a secondary, lateral movement, before it operates.

The moment the lever is released by the hand of the operator, it drops back safely into its “off” position.

And, because this resting position is at lock, from now on any time it is bumped by the leg of an operator or other worker it will not unexpectedly engage.

Leussink director Jason Leussink said the problem involved such a tiny component in an industry where giant-sized equipment is everywhere, the entire safety scenario around this relatively tiny piece was being overlooked.

“It all centred around the susceptibilities of a small lever that activates hydraulic power in the process needed to fix roof bolts, yet the traditional position of the control lever made it a potential trigger for accidents,” Leussink said.

“What we did was look at the nature of the problem and devise the simplest solution to keep the lever where it normally is but to better ensure the safety of workers was heightened.”