Company & Application

STRABAG UK’s tunnelling project, based in North Yorkshire, UK, is being constructing as the world’s longest conveyor tunnel, known as the Mineral Transport System, as part of the Woodsmith mine development. This project will see transportation of tens of millions of tonnes of Polyhalite, a naturally occurring mineral substance and subsequently when crushed, POLY4, a multi-nutrient fertiliser used worldwide.

The project began launching a Tunnel Boring Machine to commence a 36.7km long tunnel, which was constructed using a single shield machine. This length of tunnel is expected to be a new world record with the tunnel fit out, including a new full length conveyor system.

The Challenge

The project demonstrates the scale of the tunnelling and underground construction capabilities in the UK, also highlighting the need for focus on innovation and social responsibility throughout all processes. The 380 m-deep shafts were constructed using the blind-bore method, not only with the aim of reducing carbon emissions, but also to improve general on-site safety. Extensive air quality monitoring was required throughout the entire project and, notably, Trolex systems were fitted to ensure reliable and accurate monitoring is available and maintained throughout the entire project.

The Trolex plan

A range of Trolex real-time solutions have been identified for use in the STRABAG project for the detection of hazardous gases and dusts in this tunnelling project. 236 devices, including SENTRO 8 Gas detector, SENTRO single Gas detectors and AIR X real-time particulate monitors have been fitted across multiple systems with a total of 824 individual sensors for both gas detection and dust monitoring.

As well as particulate ranges from PM2.5 to PM10 being constantly monitored, logic systems constantly watch for key gases such as CH₄, CO, NO, H₂S, SO₂ and O₂. Local emergency Audio/Visual alarms, Trolex Flow Sensors and Intrinsically Safe Battery Back-Up units have been added to back up the system and add intelligent data to the data all powered by intrinsically safe battery back-up units.

The Trolex solution

Alongside the systems being implemented across the tunnelling project, the Tunnel Boring Machine itself has also been fitted with multiple gas detectors, as well as Audio/Visual alarms and sensors.

Due to the nature of tunnelling projects, with fast paced demolition, excavation and drilling processes, cutting, concrete spraying and transportation generates fine dust and particulates as a by-product of natural materials like rock and sand being disturbed, increasing risk of lung diseases and respirable health issues.

The recognised risk of using combustion engines and diesel-powered equipment often produces carbon monoxide and Diesel Particulate Matter is something the project was increasingly aware of, something the system will flag through data indicators across its broad range of sensors.

Gas sensors are already actively working as the mining machine hits pockets of hydrocarbons which set the unit into alarm, and where necessary lower down the mining machine to avoid risk of explosion.

What it meant moving forward

Providing this pioneering safety technology to STRABAG meant the project has joined a long-standing reputation of safety instrumentation being supplied to workers by Trolex in some of the most challenging environments over the last 65 years.

Like many other underground industry leaders across the globe, STRABAG made the decision to deploy multiple Trolex detectors, monitoring equipment, sensors and alarms demonstrating to their workers that health and safety is a priority on this project, and a superior approach, not only for producing the highest quality throughout the tunnelling project, but also with a conscious effort on the effects relating to the workforce wellbeing and the wider society.

Company & Application 

Specialising in occupational hygiene and air quality consulting across New Zealand, AirMatters are committed to ensuring safe and healthy environments for organisations across the nation. 

Working in industrial and hazardous environments, AirMatters supply services such as Occupational Hygiene and Health Risk Assessments to provide peace of mind and valuable information on health risks to workplaces.  

The Challenge 

Concerned with putting people at the heart of healthy workplaces, AirMatters specialise in occupational hygiene assessments for noise, vibration and, importantly to us, respiratory protection, requiring bespoke, accurate and reliable monitoring equipment. 

So, the opportunity to use XD1+ Personal Dust Monitor alongside their processes and methods was vital for AirMatters, not only to support the work they do but also to gain a better understanding around how effective processes are in relation respiratory and air quality. 

The XD1+ Plan 

The air quality consultants at AirMatters recently deployed XD1+ units across the team’s processes to gain a better understanding of the dust levels they were exposed to when working on occupational hygiene and air quality consultations, as well as for better data support for their consultations. 

The XD1+ Solution 

Thanks to deploying XD1+, AirMatters’ staff have enhanced their knowledge and understanding of dust levels in various workplaces. It’s beneficial for knowing what they’re exposed to and further protecting themselves and other workers, and it’s helped them to improve and implement effective decision making, such as deploying PPE. 

By gaining access to real-time data through XD1+ and supporting BreatheMOBILE, it’s allowed AirMatters to determine if the PPE they were originally using was correct for the various situations their staff were in, whether the PPE as necessary and further, more effective controls are required.  

For a company exposed to different scenarios relating to occupational health and air quality, it’s important correct PPE was deployed depending on the hazard or risk. 

What this means moving forward 

AirMatters continue to see the benefit of real-time personal dust monitoring alongside occupational hygiene and air quality consulting. 

Find out how you can enhance your workplace safety by incorporating real-time personal dust monitoring with XD1+  today. 

Company & Application 

 Balfour Beatty has hangers based in Bottesford, Leicestershire. The Bottesford maintenance hangars are used daily to store and maintain groundwork equipment, such as core drills, an environment at risk of excess dust exposure. 

This equipment often returns from hire covered in various aggregate compounds, such as concrete, and needs to go through a rigorous cleaning process where much of the aggregate material is broken off before the equipment is thoroughly washed and cleaned. 

The Challenge 

These processes elevate the potential risk of Respirable Crystalline Silica (RCS) exposure to people operating within the hangars where the equipment is being stored, moved and worked on throughout the day. 

The challenge was to determine the level of risk, if any, to individuals working with the groundwork’s equipment throughout the day, as well as the risk to anyone visiting the hangars. Balfour Beatty also wanted to increase awareness of the dangers of RCS and protect the workforce from hazardous airborne particulates.  

As highlighted by the HSE, elevated levels of RCS are extremely harmful from an occupational health viewpoint, making it particularly important to understand the risks in the working environment and to individual health. 

The AIR XS Plan 

Sunbelt Rentals recorded the RCS levels over a three-week period from 13 – 29 March 2023, identifying and monitoring exposure to workers within the hangars. This solution was supplemented with additional personal dust monitors to ensure a comprehensive data set was collected. 

The Trolex AIR XS uses light refraction properties unique to RCS to determine size, shape and quantity of particulates in real-time and provide a live on-screen value for airborne silica. Key features of the Trolex AIR XS include: 

• On-device display of RCS measurement in mg/m³ or total particles counted per litre of air sampled. Rolling averaging periods based on 15-minute, 1, 4, 8 and 12-hour patterns. 

• On device warnings and alarms based on custom trigger thresholds. 

• Data logging for download and post analysis using the free Trolex BreatheXS software. 

• Reports are easily accessible through the bespoke software allowing the team to take decisive action to keep people safe. 

The AIR XS Solution 

The data collected by the Trolex AIR XS over the three-week trial, showed that exposure to RCS was high throughout the working day due to local activity. With the average exposure level at 0.3 mg/m³, this was three times the recommended level of 0.1 mg/m³ recorded from the HSE. The personal dust monitors also recorded higher than recommended levels, although this was not for prolonged periods of time. 

Whilst it is a site requirement that all workers wear and use the correct RPE, the trial also monitored exposure to visitors outside of the direct operational areas, where there are not the same RPE requirements. 

Analysis of the data gathered from the AIR XS during the trial clearly shows that there is a significant risk of RCS exposure in the work areas, and adjoining areas of the hangars, with the personal dust monitor also supporting these findings. RCS levels remained above the 0.1mg limit for much of every 24- hour period, with not one period average falling below the limit over the monitoring period.  

Overall, the trial was successful in alerting the site to the risk that RCS presents within the hangars, and equipped Balfour Beatty with the data and knowledge that enabled them to implement a number of effective preventative strategies, providing a safer working environment for individuals on site. 

Company & Application 

Worktop Fabricators Federation (WFF) encouraged their members to implement real-time silica monitoring technology to support their existing control measures when working with materials containing crystalline silica. 

The WFF is a non-profit organisation for those using industrial fabrication methods to make worktops from natural stone and similar man-made materials, who promote professionalism, installation and most notably best practice across the worktop fabrication industry. 

The Challenge 

We supplied WFF member Cambrian Granite, a member of the WFF, with Trolex real-time monitoring to use across their processes working with silica-containing materials like engineered stone, such as polishing, cutting and drilling worktops. 

Aiming to consistently follow best practice when working with engineered stone, we spoke to Nigel Fletcher, Operations Manager at the WFF, who have recently purchased an AIR XS Silica Monitor to allow members to actively monitor for and distinguish RCS in real-time, regardless of their occupational environment, when following best practice. 

It’s essential that workshops using silica containing products adhere to best practice, including implementing control measures to reduce RCS, which poses a threat to workers health, WFF also sees strong value in implementing real-time RCS monitoring to ensure control measures are working to the highest standard to protect workers. 

WFF members themselves have a priority of ensuring that workers and occupational environments remain safe and at minimal risk of RCS exposure. Rob Kunkel, Business Develop Manager at Cambrian Granite said, “when protecting our workers from the dangers of RCS, we always use wet polishing and as much CNC work as possible.” 

The Solution  

For Rob and his team at Cambrian Granite, the benefit of knowing RCS levels in real-time is paramount; “the real-time data helps keep our staff well protected by making sure areas of both the factory and rest areas are safe environments to be in.” 

The goal for the Federation and all it’s members, with this partnership and moving forward to reduce exposure to RCS, is to always enable a safer future and positive workplace environment for all their members. And it’s a goal strengthened by supporting the adoption of real-time RCS monitoring.

For Nigel the Federation’s goal to provide a safer future and positive working environment for all their members is strengthened through our collaboration as we seek to support the adoption of real-time RCS monitoring. 

What this means moving forward 

It’s not just a case of ensuring workplaces are safe from RCS for WFF members, but also to effect positive change when working with RCS in the future, thanks to this partnership.

Company & Application 

A manufacturer of prestigious natural stone, Burlington Stone have quarried for over 200 years across the English Lake District. Meeting each individual clients’ needs for roofing slate, flooring, cladding, interiors and landscapes, Burlington Stone extract and craft a diverse range of signature British natural slate and stone products. 

We spoke to Health and Safety Manager at Burlington Stone, Peter Walker, to understand how deploying personal dust monitoring impacted processes in stone manufacturing and wider quarrying activities at Burlington Stone. 

The Challenge 

Across their range of projects, worker exposure to airborne dust including silica dust is high, so the need for personal dust monitoring can be important across a range of different processes and activities.  

The XD1+ plan 

We provided two XD1+ Personal Dust Monitor devices as part of the XD1+ trial programme across Burlington Stone’s workforce to monitor for dust levels in both breathing zones and high activity areas across the site, to both determine causes of excess dust levels and support with effective dust control. 

Being able to monitor in a variety of different locations and compare the differences in results through BreatheMOBILE is one of the main benefits which XD1+ has over similar products on the market. 

This ability inevitably means trends in dust levels can be tracked and looked into in relation to what task was being completed in what location. 

The XD1+ solution 

For Burlington Stone, the capability to both monitor dust levels and see live data not only helped to make health and safety decisions but also increased worker engagement on why these decisions were being made. 

What this means moving forward 

Deploying real-time personal monitoring isn’t just a short-term solution. It gives the workforce reasons to engage with their own health and safety protocols.

Company & Application 

Since 1976, Timeco have been working in the field of tunnelling, particularly in tunnel boring machine (TBM) excavation and environmental monitoring systems. For almost 50 years, Timeco’s expertise have spanned from major TBM excavation projects to involvement in significant piling and foundations works. 

The Challenge 

Given that underground and tunnelling environments are recognised as hazardous areas (ATEX), TBM workers are consistently exposed to various flammable and hazardous gases throughout their working day, like combustible dust and high levels of RCS, therefore accurate and reliable monitoring of gases and air quality is essential. 

Thanks to experience accrued, the wide spectrum of projects completed and the long-standing partnership with Trolex, Timeco are proud to support and assist customers from the initial design of complex air and/or gas monitoring systems in ATEX areas to the implementation stages during operations, to protect workers from various risks. 

The AIR X plan 

Timeco supply a variety of Trolex gas monitoring systems, including TX9165 Sentro 8 and TX6351-2 Sentro 1 Universal Gas Detector designed to perform in the most hazardous working environments, as well as the highly robust TX6383 Flammable Gas Detector. 

To protect workers from a range of hazardous dusts, Timeco supply ground-breaking Trolex particulate monitors, such as the AIR XD Group I IS Dust Monitor, designed to monitor all types of dust in ATEX atmospheres, and the AIR XS Silica Monitor, which detects levels of RCS in tunnelling environments. 

The AIR X solution 

As an official Trolex partner and dealer in the Italian market, Timeco offers on-site commissioning services and can supply all the required spare parts. A Timeco spokesperson said about supplying Trolex solutions to tunnelling environments: 

Company & Application 

This case study is a detailed exploration and analysis of a trial ran to monitor respirable crystalline silica (RCS) levels, using an AIR XS Silica Monitor, ran on behalf of our UK partners Sunbelt Rentals.  

 The trial monitored the real-time safety of activity being undertaken by The Central Rail Systems Alliance (CRSA) when replacing damaged track and the accompanying ballast as necessary, for a 12-hour long period, between 25th – 27th March 2023. This case study highlights the key findings of the trial ran by Sunbelt Rentals during this period.  

When rail track is damaged or needs replacing, the ballast surrounding the track is distributed which can release silica – a harmful substance to humans if inhaled. Using the world’s first silica monitor, this project helped provide CRSA with live reporting to assess the real-time safety of their activities. 

The Challenge 

CRSA routinely check their network of track weaknesses, replacing damaged track and accompanying ballast as necessary. During the process individuals working in the area are required to wear appropriate RPE to protect themselves against inhaling harmful substances, particles or contaminants in the air. 

Given the extensive unearthing taking place when replacing track, high levels of RCS can be released, exposing workers in the area to potentially harmful particles.  

The challenge was to measure the level of RCS and accompanying dust being released into the atmosphere during the unearthing process of 425 metres of rail and ascertain the level of risk associated for those working in the immediate and surrounding environments. 

CRSA took a proactive approach to uncovering the levels of RCS involved in such a process, to protect the health of their individuals and raise awareness for others in the market to create a blueprint for a safer working environment moving forward. 

Considering the eventual recording of RCS levels, it would then be necessary to contextualise the risks of RCS exposure so the CRSA could determine whether further implementations should be invoked to protect the individual health of workers. 

The AIR XS Plan 

To uncover the live exposure levels during the replacement process, the world first real-time RCS monitor – the AIR XS – was chosen to record levels over a period of 12 hours between the 25 – 27 March 2023. 

First the AIR XS recorded the levels of dust emitted during the unearthing process, which is valuable data on its own, but the RCS levels were also monitored in real-time and reported back in a live data set so work could be halted if recorded silica levels reached dangerous heights. 

In order to make sure accurate levels were recorded, the AIR XS’ portability was leaned upon so it could be manoeuvred around the site in-line with project progress, so that working scenarios can be accurately represented in the data set. 

Using light refraction properties unique to silica, AIR XS detects every particle flowing through it during the works, and then analyses its size, shape and refractive qualities to provide a live on-screen value of airborne silica. 

Key features of the AIR XS include:

• On-device display of RCS measurement in mg/m³ or total particles counted per litre of air sampled. Rolling averaging periods are based on 15-minute, 1, 4, 8, and 12-hour patterns.

• On device warnings and alarms based on custom trigger thresholds.

• Data logging for download and post analysis using BreatheXS software.

The AIR XS Solution 

Over the course of the 12-hour recording period, the AIR XS measured and reported high levels of silica being released, with the exposure level reaching up to 0.75 mg/m³ for a short peak period, seven times the 0.1 mg/m³ recommended levels as outlined by the HSE.  

Despite this, these peak levels were not active for long periods of time, instead the average exposure level for the site activity was at 0.4 mg/m³, but this still sits significantly higher than the recommended levels for human exposure. 

During the exposure testing, a subsequent AIR XS was placed in the surrounding areas to the site activity which still recorded a peak of 0.45 mg/m³ of dust exposure, and an average of 0.2 mg/m³. 

Meaning those who are nearby, without a perceived risk of needing RPE before now, would’ve likely have still been exposed to higher than recommended levels. In analysing the data recorded by the AIR XS over the 12-hour period it became clear that there is a significantly higher level of silica released when unearthing railway track.  

As well as this, the accompanying ballast, exposed both workers and surrounding people to potentially harmful levels of silica, particularly at peak levels of activity but also with lower levels of activity as well. 

Considering that only dust exposure has been monitored during such activities in the past and silica has not been included in trials, this has given the CRSA a clear breakdown of their worker exposure levels. 

It has helped the CRSA to make give their workers the safest and most health-conscious decisions and other preventative measures are concerned in order to protect their workforce and create a blueprint for a safer working environment moving forward. 

Company & Application 

Pennine Aggregates are one of the largest specialist aggregate and mineral processors in the UK. Based in Buxton, Pennine Aggregates are a global supplier to a wide range of companies, including ABC Industries as well as Sherwin-Williams, Cemex and Hanson’s in the UK. 

The Challenge 

A growing problem in this industry is the threat of silicosis. Silicosis now causes a huge number of deaths across an increasing number of industries, from clothing manufacturing to construction, and the aggregates industry has one of the highest risk profiles for this disease.   

This meant that Pennine Aggregates grabbed the opportunity with both hands to trial the world’s first real-time respirable crystalline silica (RCS) monitor, the AIR XS, to see how they could integrate it into their existing dust suppression processes.  

The AIR XS Plan 

Dangerous crystalline silica particles can be anywhere at any time when you are working in dusty environments. So, for Pennine Aggregates, it wasn’t that they didn’t have dust suppression in place, it was that they didn’t know exactly how much dangerous dust each of their processes were producing.   

Current RCS monitoring requires samples to be sent over to a lab for analysis. This makes it difficult for businesses to accurately target dust with the right dust suppression as the results often take weeks to come back. 

Pennine Aggregates are a growing business meaning that they are continually adding extra bits of plant to what they have currently running and investing in dust suppression systems to make these new processes as safe as the old ones.  

The AIR XS Solution 

Pennine Aggregates ran the AIR XS over a six-week period on each of the processes where they had put in place new dust suppression systems. These areas included a large number of processes as the site is spread over several acres and runs a huge number of different pieces of plant. 

One unexpected benefit of the trial was increased worker engagement in their own safety. Thompson made a point throughout the trial of showing workers the fluctuating data on the real-time read out stating that:  

“I wanted to show everyone in the business that we we’re expanding in many ways, but at the same time that we’re also expanding our attention to staff welfare, health and safety. 

And that really worked as for the first time the guys on the equipment were asking me to tell them about what the business was doing to protect them. And that was great as staff retention is quite high on our agenda right now.” 

What it means moving forward 

With access to this information and data, the business is now able to plan ahead for the future, knowing their levels of RCS content and that their dust suppression methods are working. 

Dickinson said: “As a management team it’s given us a structure on what we need to plan for around dust extraction and PPE, that’s an area of significant investment for us and this data means that we can spend the right money in the right place and have an engaged workforce who will stay with us for the long haul.” 

It’s a clear and simple presentation of responding to the facts. That’s why Trolex and AES are working to provide further support to Australia’s mining, tunnelling, quarrying and construction industries, where workers are at risk of exposure to dangerous dust. 

The AIR X Solution 

This common goal of providing and expert knowledge and specialist equipment to industry is the drive needed to inevitably reduce instances of occupational lung diseases to save lives. This collaboration does exactly that. 

The approach taken by businesses within these industries must now change. With new legislation on exposure to harmful dust in Australia, new dust monitoring methods are needing to be implemented. 

By using Trolex’s advanced dust monitoring technologies, small changes can have a huge impact. As the war on silica dust grows ever stronger by the day, more needs to be done. 

With strict exposure limits coming into effect across Australia, particularly hard on respirable crystalline silica (RCS), real-time monitoring for silica dust is important, retaining live data and providing an instant alarm the legislated threshold is breached. 

Whilst the ability to retrospectively assess levels of silica dust in facilities is available to industries where deadly silica dust is prevalent, the ability to monitor for silica dust in real time is not. 

What this means moving forward 

Aleks also commented on Trolex’s real-time silica monitor, AIR XS, which allows for accurate and reliable monitoring of hazardous RCS in workplace environments: 

“We are really excited to be a part of this project to be able to detect silica in real time, and we’re proud to be distributing it throughout Australia. The project was produced with the support of the Centre for Work Health and Safety in NSW proving just how important and potentially life-saving the new technology will be.” 

And with the talk of real-time, wearable silica monitoring devices a possibility in the future, of course it makes perfect sense for all industries to be increasingly focused on detection possibilities. 

Together, Trolex and AES are providing real solutions for real problems in Australia. 

If you’d like to speak to one of our experts about integrating real-time dust monitoring technology into your working environment, then you can use the contact form below to get in touch with one of our experts today.