Structural integrity, a critical component of engineering asset management, is emerging as a field that remains largely unfamiliar to many engineering managers in the mining sector. Historically, these managers are predominantly mechanical or electrical engineers, with limited exposure to structural engineering principles. Despite its crucial role in ensuring the safety and longevity of mining operations, structural integrity often takes a backseat, posing a real and present danger of catastrophic collapse.
The Overlooked Reality of Structural Collapse
The risk of structural collapse in mining is not a theoretical concern—it is a serious threat that can result in devastating consequences, including multiple fatalities, operational downtime, and reputational damage. Most mining companies have classified structural collapse as a “priority unwanted event,” recognizing the severe implications it carries for safety and production. However, despite this acknowledgment, structural integrity often remains an overlooked aspect of mining operations.
This disconnect arises primarily because structural integrity doesn’t have the same direct impact on production as mechanical equipment such as crushers, scrubbers, etc. While a collapse could result in significant and costly disruptions, the risk often doesn’t manifest in immediate day-to-day production losses. This misalignment in perceived urgency leads engineering managers to prioritize equipment maintenance that directly affects output, inadvertently relegating the structural health of assets to a lower priority—until disaster strikes.
Short-Term Thinking, Long-Term Consequences
The perceived disconnect between structural health and immediate production often results in structural integrity being seen as a non-urgent issue. While machinery breakdowns or electrical faults are quickly addressed to maintain production targets, the gradual degradation of structural elements, which may go unnoticed for long periods, is often deferred. This mindset ignores the latent risks, as failing to maintain or inspect structural assets could lead to catastrophic events down the line.
When structures such as conveyor supports, plant buildings, or mine shafts collapse, the repercussions are immense. Production halts, recovery costs soar, and the financial impact far exceeds what could have been spent on proactive maintenance. A structural incident often serves as a wake-up call for engineering managers, forcing a reactionary response that might prevent future collapses but does little to address the existing culture of negligence.
Why Structural Integrity Is Often Ignored
There is an inherent challenge in managing structural integrity effectively, as it doesn’t fit neatly into the current skill set of many engineering managers. Without a background in structural engineering, many managers are unequipped to understand the specific needs and potential risks associated with these assets. Additionally, the link between structural failures and production losses is not immediately evident until after a collapse occurs. Unlike mechanical breakdowns, which cause instant and noticeable production downtime, structural deterioration is gradual and may not appear critical until it is too late.
This perceived lack of urgency results in structural maintenance often being overlooked both in the short term and long term. Engineering managers, under pressure to meet production targets and cost constraints, focus on maintaining equipment that directly impacts daily operations. However, this short-term focus neglects the long-term risk of structural failure, which, when it happens, can lead to production losses that are far more costly and damaging than anticipated.
Building a Culture of Proactive Structural Integrity Management
The mining sector must shift its approach to structural integrity from reactive to proactive. Raising awareness among engineering managers is the first step toward ensuring that structures receive the necessary attention to prevent failures. Mining companies should prioritize:
- Training and Education: Engineering managers need to understand the principles of structural integrity and how they differ from mechanical and electrical engineering. A culture of awareness and understanding will drive proactive maintenance practices.
- Regular Inspections and Assessments: Ongoing structural health monitoring, including inspections and risk assessments, is essential to identify early signs of deterioration. Leveraging technology, such as drones and sensors, can aid in identifying structural issues before they become critical.
- Integrating Structural Integrity into Asset Management: Mining operations must treat structural assets as foundational to the production process, just like equipment. Proper budgeting, strategic planning, and integrating structural health into the overall asset management plan are critical.
- Understanding Long-Term Value Over Short-Term Gains: Acknowledging that the short-term deferral of maintenance costs will result in long-term pain can help engineering managers make informed decisions that safeguard the integrity of structures. This approach emphasizes prevention over cure, mitigating risks before they escalate.
Conclusion: Structural Integrity Is Everyone’s Business
Structural integrity in mining might currently be the “problem child” of engineering asset management, but it’s a child that requires urgent attention. The industry must prioritize this often-overlooked area to mitigate risks, protect workers, and secure long-term operational efficiency. While it may not seem to have the immediate production impact that other equipment does, structures form the backbone of any mining operation. Their failure has far-reaching consequences.
By fostering a culture of proactive maintenance and integrating structural health into everyday asset management practices, engineering managers can ensure the safety, sustainability, and profitability of their operations. Ultimately, maintaining structural integrity is not just about preventing collapses; it’s about acknowledging that these assets are as critical to production as any other piece of equipment in the mine. Ignoring them is a risk no mining company can afford.