PDS implementation on mines

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October 2025 Sensors & Transducers

Level 9 vehicle intervention for collision avoidance has been mandatory on South African mines since 2022, yet the effective roll-out of proximity detection systems (PDS) remains slower than expected. “This is not due to the technical limitations of integration, but to operational readiness on site,” says Booyco Electronics CEO, Anton Lourens.

The Level 9 requirements mandate engineering controls on trackless mining machines (TMMs) to automatically slow down or stop vehicles, preventing both machine-to-pedestrian and machine-to-machine collisions. While PDS technology has advanced considerably to meet these requirements, Lourens stresses that a real challenge lies in how mines prepare to integrate it.

“Many operations are still not ready to operationalise PDS within their daily activities, safety systems or workflows,” he explains. “Successful adoption demands coordinated involvement from all stakeholders, including the mine’s own management, operators and departments, regulators, technology suppliers and TMM OEMs.”

Detailed risk assessments remain a key requirement for mines to identify and mitigate significant hazards around TMMs. Lourens notes that PDS is a valuable tool in this process of mitigation that can provide valuable information, but its implementation must be systematic and aligned to the broader risk framework.

The choice of PDS technology depends on the specific environment and is based on identified risks, whether underground, surface, hard rock or coal. It must be introduced without creating further unintended risks to other operational systems, particularly production.

He explains that a critical starting point includes the mine’s traffic management plan. Reducing vehicle-pedestrian interaction lowers risk and minimises production disruption. Continuous analysis of incident hotspots can guide traffic flow adjustments and sometimes operational plans may need to be revised. Once traffic patterns are optimised, PDS deployments can be aligned to complement these flows. Misalignment risks frustrate operators, creating ‘PDS fatigue’ from excessive warnings which can lead to alerts being ignored.

Operational readiness, therefore, requires full leadership commitment and cross-functional collaboration. Lourens points out that while PDS suppliers often deal with engineering teams, production, finance and human resources must also be engaged. Finance teams need to weigh capital and maintenance costs against safety and efficiency benefits. HR must oversee operator training and production must understand the operational implications.

Change management, he warns, is neither quick nor easy. It requires active communication across the mining ecosystem, ensuring that everyone understands the system’s function and value. “Any new system must be accompanied by a change in behaviour or nothing will improve,” he says. “Unlike when introducing mechanical equipment, PDS operates invisibly through radio frequencies, so early engagement, clear communication and thorough training are essential.”

From induction and operator instruction to ongoing best practice reinforcement, mines must take a structured inclusive approach to PDS adoption if they are to achieve the full safety benefits envisaged by the Level 9 regulations.

For more information contact Booyco Electronics, +27 11 823 6842, [email protected], www.booyco-electronics.co.za

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