Dgms Circular 2010

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Govt. of India
Ministry of Labour and Employment
Directorate General of Mines Safety
No. DGMS (Approval)/AVA/ 01 Dhanbad, dated 25.05.2010.
To
The owners, Agent and Manager
Of all open cast mines
Sub : Audio visual Alarm for surface transport Machinery & other Heavy earth
Moving Machinery.
Several accidents have occurred in open cast mines while reversing of equipment
especially in dumpers/tippers. In most of the equipments the manufacturers provide audio
visual alarm and rear view mirrors for assistance during reversal. Although the Audio-
Visual Alarm gives warning to the work persons, it is a practice in mines that the operator
takes the assistance of a spotter while reversing. The spotters are exposed to danger of
being run over by transport machinery. The audio-visual alarm warning at times fail due
to defective manufacturing and poor maintenance.
Hence to have a better quality of products in mines, the Audio-Visual alarm was
included in the list of approved type and make and was notified in the Gazette of India
vide GSR no 143 dated 25th July 2008.
In the view of experience gathered over a period of time, it has been decided to approve
the design, specification and test procedures of the Audio-Visual alarm by this circular
and shall be treated as a general order. Existing type of Audio-Visual alarms not in
conformity with the design, specification and test procedures and not specially approved
separately should be replaced as early as possible but not later than 31.08.2010.
The manufacturer and Workmanship
The manufacturer shall be reliable, having adequate facility for proper manufacturing and
test facilities of the audio-visual alarms. Every part of the unit shall have good
workmanship and good finish and shall be free from any defect. The manufacturer shall
be fully responsible for the quality of the Audio-Visual alarms and conformity with
prescribed specifications.
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Design
The Audio-Visual alarm shall be provided at the rear of the vehicle which can be actuated
by a pressure switch when the reverse gear is used by the operator. The unit shall be
housed in a fully water proof case which is shock and vibration resistant and suitable for
high pressure washing. The two components shall be connected by a suitable detachable
cable with water proof joints. Two fail safe synchronized speakers should be provided in
the Audio-Visual alarm. Mechanical lock shall be provided to prevent unauthorized
tampering.
Specification
The sound of the Audio Visual Alarm should be more than the surrounding noise level so
that it can be heard distinctly. 110 dB sound level is suitable for Audio visual alarms.
How ever the sound level shall be within +5dB of the value for which the equipment is
designed when measured at a distance of 1.2 meters from the unit and the light intensity
shall be not less than 300 lux when measured at a distance of 300mm from the unit. Red
bright LED of suitable quantity must be used in the Audio-Visual alarm and shall start
blinking when the vehicle is reversed.
Self adjusting back up alarm may be preferred where the sound level is automatically
maintained at 5dB higher level than the surrounding noise level.
Testing
The sample of Audio-Visual alarm shall be drawn by the manufacturer as specified in IS:
13109 (part-1) 1991 & shall be tested as appended below.
The Audio-Visual alarm shall confirm to IS 13947(part I) of 1993 for the following
protection against dust and water.
Degree of protection Test condition as per IS 13947

(part I)-see sub clause
1. Protection against dust and shall prevent ingress of dust C7.5&C7.6

2. Protection against dropping water C 8.1
3. Protection against spraying water C 8.3
4 Protection against splashing water C 8.4
The Audio-Visual alarm shall also confirm to IS 13109 (part I) of 1991 for the
following environmental requirements ;
TEST Test condition

1. Vibration test As per table 1 of IS 13109(part I) of 1991
2. Shock test
3. Bump test
4. Drop and Topple test
5. Cold test
6. Dry Heat test

7. Damp Heat(cyclic) test
The following endurance test of Audio-Visual alarm shall be carried out in accordance
with SAEJ 994.
Test Test condition
(a) Endurance test at high temperature As per Para 7.1
(b) Endurance test at room temperature As per Para 7.2
Light intensity at a distance 300 mm should recorded and mentioned in the test report
Functional Test Requirements : Unless otherwise specified data measurement will be

taken during a minimum test period of 1min operation at ambient temperature of 250c
11oc and supply voltage of 14V DC 0.2VDC for a nominal 12V alarm and 28V DC
0.2VDC for 24V alarm and the performance of functional test should be recorded in the
test report. Sound level shall be checked before and after the above test and shall be
within 5dBA of the value for which the equipment is designed.
Testing shall be carried out in Government labs, Institutes under CSIR, BIS approved test
house and DGMS approved test houses.
Marking :
Each audio visual alarm shall be legibly marked on the body of the Audio Visual Alarm
mentioning the serial number, batch number, date of manufacture. Copies of test reports
for every lot shall be supplied.
Inspection and maintenance:
The user industry shall also be responsible to ensure correct quality and conformity to the
prescribed specification and also take proper care while Audio-Visual alarms are in use.
At least two percent of the Audio-Visual alarms from the lot when supplied to the mine
shall be randomly drawn and tested as mentioned above in a laboratory mutually agreed
between manufacturer and the user industry. If the Audio-Visual alarms fail to conform
to the specifications, the whole lot of Audio-Visual alarms shall be rejected.
A competent person shall check and inspect the Audio-Visual alarms daily. Once in a
week, at least ten percent of the Audio-Visual alarms working in machinery shall be
measured for the sound level and intensity of light and the readings shall be recorded in a
bound paged book signed by a competent person and counter signed by the engineer of
the mine.
Director General of Mines Safety

/
Govt. of India

- -
No.DGMS/CIRCULAR/GENERAL/01 DATED 22-10-2010.
To
All Owners/Agents and Managers of all coal mines.
Subject: Approval of the Indian School of Mines, Dhanbad and Central Mine Planning
and Design Institute, Ranchi as approved test houses for conducing of tests on
cement/resin capsules.
This is to bring to your notice that recently, approval of the test houses of the Indian
School of Mines, Dhanbad and Central Mine Planning and Design Institute, Ranchi were
accorded vide following details.
No. Name of the test house/ Approval accorded Validity period

Institute. for testing of
1. Indian School of Mines, Dhanbad Cement capsules. One year from
30/9/10.
2. Central Mine Planning and Design Cement and Resin One year from
Institute, Ranchi. Capsules. 30/9/10.
It is therefore, requested that all efforts may be taken in giving wide publicity and
encouraging existing and any prospective manufacturer of cement and resin capsules to
conducting tests for cement/resin capsules either at the Central Institute of Mining and
Fuel research, Dhanbad or in any of the above two test houses as the case may be.
Director General of Mines Safety.

Government of India
Ministry of Labour & Employment
DGMS (Tech.) (S&T) Circular No.01 Dhanbad, Dated 21st January 2010
To:
All Owners, Agents and Mangers of Mines
Subject: Respirable Dust Measurements and Control to Prevent Pneumoconiosis in Mines.
Dear Sir,
It is to bring to the notice of all concerned that an integrated effort is being made by the
Government of India to significantly reduce the prevalence of Pneumoconiosis/Silicosis by 2015
and to totally eliminate Pneumoconiosis/Silicosis at workplaces by 2030 in line with the
International Labour Organisation (ILO) and the World Health Organisations (WHO) Global
Programme for the Elimination of Silicosis.
Pneumoconiosis
Excessive or long-term exposure to harmful respirable dusts may result in a respiratory disease
called pneumoconiosis. Pneumoconiosis is a general name for a number of dust-related lung
diseases including:
Silicosis - Silicosis is a form of pneumoconiosis, a disease of the lungs due to breathing of
dust containing silica particles. Silica dust can cause fibrous or scar tissue formations in the
lungs which reduce the lung's ability to work, extract oxygen from the air. There is no cure
for this disease, thus, prevention is the only answer.
Coal Worker's Pneumoconiosis (CWP) - Coal Worker's Pneumoconiosis (CWP) also
called Black Lung Disease is a form of pneumoconiosis in which respirable coal dust
particles accumulate in the lungs and darken the tissue. This disease is progressive.
Asbestosis - Asbestosis is a form of pneumoconiosis caused by asbestos fibers. This disease
is also irreversible.
1.1 Symptoms
There are several stages of pneumoconiosis/ silicosis. Early

stages may go completely unnoticed. Continued exposure
may result in the exposed person noticing a shortness of
breath upon exercising, possible fever and occasionally
bluish skin at the ear lobes or lips. Pneumoconiosis or
Silicosis makes a person more susceptible to infectious
diseases of the lungs. Progression of the disease leads to fatigue, extreme shortness of breath,
1

loss of appetite, pain in the chest cavity which all may lead eventually to death. Acute
pneumoconiosis or silicosis may develop after short periods of exposure. Chronic silicosis
usually occurs after 10 or more years of exposure to lower levels of quartz.
1.2 Defining the Dust

A number of materials hazardous to health are present at the work place in the form of aerosols i.
e. suspensions of solid or liquid particles in air. Dust is generally understood to be an aerosol of
solid particles of size 0.1m and above. Most of the dusts contain particles of wide range of
sizes. Behaviour, deposition and its effect after entry into the human respiratory system depend
on the nature and size of the particle.
Dust consists of solid particles carried by air currents. Coal or Rock
dust originates at impact points (including drilling, blasting, loading,
unloading, crushing and grinding), from previous accumulations, or
from weathering. A wide range of particle sizes can be produced
during a dust generating process. Larger particles settle more quickly
than smaller particles, and the smallest particles can remain
suspended in the air indefinitely. Dust is typically measured in
micrometers (commonly known as microns). Coal or Rock dust can
range in size from over 100 m to less than 2 m. As a comparison,
red blood cells are typical 8 m and human hair ranges from 50-75 m in size.
For the purposes of occupational hygiene, it is important to consider the concentrations of dust
present in different size fractions.
(a) Inhalable Dust It is the fraction of airborne dust that enters the nose and mouth during
breathing, and is therefore available for deposition in the respiratory tract.
(b) Respirable Dust It is the fraction of inhalable dust that penetrates into the gas exchange
region of the lung. It is mostly in the size fraction of 0.1 to 10 m.
2.0 Exposure Limits
In order to ensure that the work place is safe for the workers to work continuously for a period of
eight hours in a shift, many studies and investigations have been carried out world over and the
maximum exposure limits (MELs) have been prescribed. In USA, MEL is prescribed as 2 mg/m3
for eight hours time weighted average provided the concentration of silica in the respirable dust
remains less that 5%. In case the % of Silica content in the respirable dust exceeds 5, the MEL is
calculated to be 10 divided by the % of Silica content in the respirable dust. In India, the MEL is
prescribed as 3 mg/m3 for eight hours time weighted average provided the concentration of silica
in the respirable dust remains less that 5%. In case the % of Silica content in the respirable dust
exceeds 5, the MEL is calculated to be 15 divided by the % of Silica content in the respirable

dust. It is, therefore essential to determine the concentration of silica in the respirable dust in
order to define the threshold limit (MEL) of the concentration of respirable dust at any work
place. Regulation 123 of the Coal Mines Regulations, 1957 as well as regulation 124 of the
Metalliferous Mines Regulations, 1961 clearly specify provisions therefor.
In many countries, the maximum exposure limits (MEL) for crystalline silica in respirable
airborne dusts has been prescribed to be 0.3mg/m3 for eight hours time weighted average (TWA).
However, in most of the cases, it is reasonably practicable to control exposure to 0.1 mg/m3 (8
hour TWA) or less by engineering or process control.
It is advised that the mine management should ensure that the workers are not exposed to
respirable crystalline silica dust concentrations above this level. If exposure can not be controlled
to 0.1 mg/m3 (8-hour TWA) or below, by elimination, engineering or process control, then the
exposure must be controlled by provision and use of suitable respiratory protective equipment as
provided under sub regulation (4) of regulation 123 of the Coal Mines Regulations, 1957 and that
of the Metalliferous Mines Regulations, 1961.
3.0 Sampling and Analysis of Respirable Dust Concentrations
In order to ensure that the work place is safe and free from the risk of respirable dust, it is
essential to measure and analyse the concentration of respirable dust at the work places. Specific
provisions have been made in this regard under sub-regulation (3) and (4) of regulation 123 of
the Coal Mines Regulations, 1957 and the Metalliferous Mines Regulations, 1961. Provisions for
static monitoring and portal to portal personal monitoring have also been made under these
regulations.
However, it has been found that the determination of respirable concentration of dust requires
weighing of the filters and analysis of the silica content therein, which takes time, during this
intervening period, the persons are exposed to higher dust concentration levels in cases where the
concentration exceeds the threshold level, before any corrective measures and controls are put in
place. Advances in instrumentation for dust measurements have been made and Real Time Dust
Monitors are now available which indicates the actual dust concentration level on the site of
measurements directly but the Silica concentration level is to be determined in the laboratory
only.
There are mainly two standard analytical methods for determination of crystalline silica content
in the dust that are Infra Red Spectrophotometry and X-Ray Diffraction methods. Standard
Methods and Instruments are available for this purpose. Central Institute of Mining and Fuel
Research (CIMFR), Dhanbad and M/s. Startech Labs Private Limited, 2nd Floor, SMR Chamber,
H. No. 1-58/7, Opposite St. Ann's Junior College, Madaniguda, Serilingampally, Hyderabad -
500 050, A. P. have been approved for this purpose. It is however advised that each mining
company having large numbers of mines should have properly equipped and approved laboratory
3

to assess the dust concentration and free silica in the dust so that the delay, in obtaining the
results and follow up actions thereon, is avoided. Detailed Guidelines on the issue of
determination of dust concentration at work places in mines have already been provided in the
DGMS Circular No. 1 of 2004. Companies owning more number of mines having established
such facilities may also extend the services to smaller companies and mines especially in un-
organized mining sector.
3.1 Sample Survey of Dust Control Measures in Mines
The Science and Technology Wing of DGMS have recently conducted airborne dust survey in
some of the mines of Coal Companies as well as Non-Coal Companies during the years 2004 to
2009. During the Survey, the following observations were made:
(i) The Time Weighted Average Concentration 30m outbye of the return airway in a Longwall
Panel was found to be 31.40 mg/m3. TWA concentrations of dust for Face Crew, Shearer
Operator and Helpers measured by Personal Dust Sampler were 5.64, 9.54 and 7.02 mg/m3
respectively.
(ii) SDL & Drill Operators at the Face in depillaring districts of underground coal mine were
subjected to higher level of dust concentrations when measured by Personal Dust Sampler.
(iii) In most of the Opencast Coal Mines, dry drilling was being done and the water spraying
arrangements were either non functional or ineffective, which resulted into exposure of
Drilling Crew, Shovel & Dozer Operators to the level of dust beyond permissible limits.
(iv) System was not established to measure and control the dust exposure to persons within
permissible limits.
In view of the observations made above, it is recommended that
(a) The concentrations of dust and crystalline silica content therein should be determined for
the strata encountered during drilling in Overburden Benches and also for every coal seam
in the mine.
(b) Wherever there is change in the strata condition, the same measurements should be done at
such places also.
(c) In underground workings, the concentration of respirable dust should also be determined
while drilling in the floor as well as into the roof up to a level/depth which are required to
be used for roof bolting, cable bolting or for any other purpose.
(d) Dust Measurements should invariably be done while using new drill bits/picks and while
rejecting the bits/picks so as to know the dust generation profile of the drill
machines/Continuous Miner or any other cutting Machine.

4.0 Occupation Health Survey and Monitoring
In spite of the all the best efforts and system put in place in the mine, it has been found that the
persons working at places prone to generate airborne dust are exposed to respirable dust beyond
permissible limits. Such persons or Group of persons are more likely to get affected with the
diseases caused due to airborne dust i. e. silicosis and pneumoconiosis. The cases of such
affected persons are detected only at the time of medical examinations which are conducted an
interval of five years or on complaints of ailments reported in the hospitals.
In view of the potential danger of dust prone disease existing at the work places/ processes in
the mine, it is recommended that-
(a) The Medical Examination of Identified persons or Group of persons working at places or
operations/processes prone to generate airborne dust should be conducted once in every year
and the Results of such medical examinations should be correlated with the dust exposure
profiles of that place(s) and or process(s).
(b) During the conduct of Medical Examination of such select persons or group of persons, an
Officer of Occupational Health Wing from this Directorate should also be called as an
external member.
(c) In case of any person found suspected for contacting disease due to airborne dust, the case
may be reported to this Directorate immediately in the prescribed format (Form V).
(d) Apart from the above, an independent team of Medical Experts on Pneumoconiosis and
Silicosis may be formed by selecting doctors from outside the companies and such team
should be entrusted with the work of medical examinations at least once in every year for
the above purpose independently.
(e) The Reports of medical examinations of such independent team should be submitted to this
Directorate at the end of every year.
(f) In case, a person is found to be affected with pneumoconiosis or silicosis, the details
regarding his work profile, degree of disability, medical history and expenses, compensation
and the status of health and rehabilitation measures taken by the company etc. should be
sent to this Directorate immediately in the prescribed Form-VA.
(g) Suitable Training Module for imparting training to Medical Officers engaged in conducting
medical examinations for identification of Silicosis/Pneumoconiosis as per the ILO
Classification of Chest Radiograph shall be prepared and conducted once in every year so
that the Medical Officers are adequately trained and equipped to identify the cases of
Silicosis/Pneumoconiosis without any doubts or ambiguity.
5

It is, therefore requested to all concerned that a concerted and integrated efforts in line with the
above recommendations be made at all levels to ensure that the incidence of diseases due to
respirable dust is eliminated from the mining industry.
It is further requested that the expertise and the facilities for dust monitoring and medical
surveillance existing in the organized sector should also be extended to unorganized sector
mines so that the menace of silicosis and pneumoconiosis is eliminated and the miners are
protected from this industrial disease.
(S. J. Sibal)

GOVERNMENT OF INDIA
MINISTRY OF LABOUR & EMPLOYMENT
DIRECTORATE GENERAL OF MINES SAFETY
DHANBAD 826001, JHARKHAND
No. DGMS/ S&T/Tech. Cir. (Approval) No. 3 Dhanbad, the 3rd June 2010
To:
The Owner, Agent, Manager of All Mines & The Manufacturers
Subject: Standard Components and Properties of Steel Roof Bolts to be used in

Mines
Steel Roof Bolts with Nuts, Dome Washer, Bearing Plates and W-Straps are being widely
used in the mines. In making of such steel supports, various types of steel rods, TMT bars
are generally used. In order to ensure the desired strength and durability of such supports,
a study was carried out during the year 2008 and the steel supports including roof bolts
were brought under the purview of approval vide Gazette Notification No. GSR 160 dated
14th August, 2008, and a circular in this regard was also issued vide this Directorates issue
No. DGMS (Tech) (S&T)/Circular No. 3/703 dated 14.08.2008.
The Roof Bolts, Nuts, Bearing Plates & W-straps manufactured by various companies have
also been approved from this Directorate. The Data collected during the testing of such
supports were analysed. After detailed discussions and meetings held with scientists from
Central Institute of Mining & Fuel Research (CIMFR) and Professors from Indian School of
Mines, Dhanbad, a Technical Circular No. DGMS/S&T/Tech. Cir. (Approval) No. 11 dated
17th July 2009 was issued on the standard components and properties of roof bolts to be
used in mines. Based on the standards and parameters specified in the circular, testing of
the steel roof bolts are being conducted at the test house and on the basis of such test
reports approvals are being granted.
During the period of testing, approval and field trials of such roof bolts and bearing plates
including w-straps, various suggestions, recommendations and advices were received from
the scientists from Research & Development Centre for Iron & Steel (RDCIS), Ranchi &
CIMFR, Dhanbad, CMPDIL, Ranchi, ISM, Dhanbad, and CIL, Kolkata. The feedbacks received
Page 1 of 5

from such orgaisations have since been considered and the standard and parameters of the
roof bolts and its assembly to be used in mines are prescribed as under:
1.0 Physical Properties:
(a) Shape & Size:

The Roof bolt shall be of MS Steel or TMT Rebar having circular cross-section with ribs on
circumferential region. The manufacturer of the roof bolt shall specify the design,
calculations, Yield Strength and Ultimate Tensile Strength along with elongation at Yield
and the factor of safety of the roof bolt manufactured by them. The Roof bolt shall be as per
the drawing and dimensions given by the manufacturer.
(b) Length:
Length of the Roof Bolt shall not be more the designed length + 5mm.
(c ) Diameter:
Diameter of the Roof Bolt shall not be more than the designed diameter + 4% by mass as
specified under IS 1786 2008 or as per the standard given in BS 7861 (Part-1) 2008.
(d) Straightness:
The roof Bolt shall be straight without any joint, welding, deviation or deflection. However
if the deflection or deviation cannot avoided due to practical reasons, it shall not be more
than + 0.1 % per meter length of the bolt.
(e) Rib:
The Rib of the Roof Bolt shall be as per the design of the rib with an objective to maximize
the surface area without reducing the core diameter of the roof bolt and having maximum
grip with the grout. However the height of the rib shall be kept within the standard
prescribed in IS 1786 2008 or BS 7861 (Part 1) 1996 or latest revision thereof.
2.0 Physico-mechanical Properties:
Steel for the Roof Bolt:

The roof bolt shall be of thermo-mechanically treated (TMT) rebar manufactured from MS
Grade Fe-500, Fe-600 or above. The Yield Stress, Tensile Strength and % elongation steel
Grade shall be maintained as per the IS 1786 and IS 13920.
However the minimum load bearing capacity (Anchorage Load) of the roof bolt shall be
160 kN.
3.0 Chemical Composition:
Chemical composition of the steel for manufacturing of the roof bolts varies according to
the requirement of strength characteristics and specific applications given by the roof bolt
manufacturer and the end user. However certain chemical constituents of the steel which
influence the required properties of steel are prescribed below:
Page 2 of 5

Sl No. Constituent Percentage by weight
1 Carbon 0.25 (Max)
2 Sulfur (S) 0.05 (Max)
3 Phosphorous(P) 0.05 (Max)
4 Manganese 1.5 (Max)
5 Other Alloying/micro alloying elements 0.50 (Max)
In this regard, reference may be made of IS 1786: 2008 for considerations and testing.
Thread on the Roof Bolt:
(a) The thread on the roof bolt shall be M20 cold rolled thread conforming to IS 4218
(part- 2 & 3) and no cut thread shall be used. The minimum length of the thread shall be
150 + 5mm and the tolerance class designation of 8g. The thread shall conform to
tolerance class of 7H.
As a routine test, one thread in every 50 produced shall be checked using a go/no-go
gauge.
(b) Non-threaded end
The non threaded end of the rock bolt shall be formed by cropping or sawing and shall be
free from burrs and edges which protrude beyond the profile of the rock bolt.
As a routine, one rock bolt in every 200 produced shall be checked for straightness.
(c) The Nut shall be of hexagonal shape of thickness not less than 30mm conforming to IS
1363 (Part-3) and the thread shall conform to tolerance class of 7H.
(d) Pull Test: Thread and the Nut on the roof bolt shall be subjected to pull test
which should not slip at the yield strength/load of the roof bolt.
Bearing Plate
(a) The Bearing Plate of the roof bolt shall be Dome Washer Plate of dimension 150 x
150 x 8 (minimum) mm with compatible central hole of required size and angled side to
accommodate the conical seat and nut.
(b) The minimum load at which the Domed Washer Plate will become flat should be at
least 14 Tonnes.
Conical Seat
(a) Conical Seat shall be of forged steel of required dimension
(b) The Conical Seat shall not deform at 1.20 times the Yield stress of the roof bolt.
The roof bolt, thread, nut, conical seat, domes washer plate as well as domed bearing plate
shall be subjected to tensile test and type as specified in BS 7861 (Part-1) 1996 or revised
edition.
4.0 Tensile Test of the Roof Bolt Assembly
(a) The Roof Bolt Assembly shall be subjected to Tensile Test and should not fail up to
16 Tonnes load.
Page 3 of 5

Subject to the condition that System Stiffness of the Roof Bolt assembly shall be within 20
KN/mm -System stiffness between 50 to 150 KN.
5.0 Other Properties & Parameters
(a) Weatherability:
The Roof Bolts and its components or parts shall be subjected to Accelerated Weathering
Test in mine water condition for 20 days. No deterioration should occur on the Assembly.
(b) Accelerated Weathering Test shall also be conducted in acidic water condition for 20
days during which no deterioration should occur on the Assembly.
[Note: The AWT under mine water condition generally is at pH > 4 and that under acidic water
condition is considered at pH-2 (5 % HCL aqueous solution) during testing. The test limit is that the
loss of weight shall not be more than 5%]
(c) Corrosion Resistance Test:

The Roof Bolt Assembly shall also be subjected to Field Exposure and Corrosion Resistivity
Test as per IS- 5555: 1970 to test the resistance to corrosion of the steel of the roof bolt
and its parts. The Roof Bolt should pass the required test.
6.0 SAMPLING & TESTING
In order to check the composition and required parameters during manufacture, it shall be
required that the random sampling be done @ of 2 roof bolts per 1000 pieces of roof bolts
and its accessories manufactured in a batch which shall be subjected to the required set of
tests as prescribed in the previous paragraphs above and the data shall be kept recorded in
a bound paged book kept for the purpose which shall be signed by the persons carrying out
the test and shall be countersigned by the quality control officer posted at the
manufacturing unit(s).
6.1 The user shall carry out Physical examination tests as far as possible but shall
conduct Tensile Test of the Assembly for every batch of Roof Bolts & its Accessories
received at their end before use and keep the records in a bound paged book kept for the
purpose.
In case the Roof Bolts or any of its accessories fail to pass the required tests at the users
end, that batch or lot of the manufacture shall not be used in the mine and intimation
thereof shall be sent to the manufacturer. A record in this regard shall be maintained at the
mine/company.
6.2 The Chief Inspector of Mines or an Inspector of Mines may inspect, check and
examine the manufacturing facilities at any time and get samples tested during the course
of inspection or send such samples for testing at any national test houses/laboratories at
the cost of the manufacturer.
examine the roof bolts and its accessories at any time in the mine or the area of the mines
Page 4 of 5

and get samples tested during the course of inspection or send such samples for testing at
any national test houses/laboratories at the cost of manufacturer or user.
7.0 General Requirement
All the Owner, Agent and Manager including the manufacturers and suppliers shall be
required to comply with this standard and any deviation or defects found in the product
supplied or used in the mine, shall be bought to the notice of this Directorate.
Manufacturers and the Users including the Test Houses, who are engaged for testing of
such material, are therefore requested to ensure the above mentioned Standard and
Parameters before supplying and using at the mine.
The Standard, Parameters and Testing of Steel Roof Bolt assembly as mentioned
above, in this circular shall be considered as approved by the Chief Inspector of Mines
by a general order as provided under regulation 181(3) of the Coal Mines Regulations,
1957. This is being issued in continuation of the gazette notification No. GSR 160
dated 14th August, 2008,
Yours Faithfully,
Page 5 of 5

Govt. of India
" ~m
No.DGMS (Technical circular)! 0 5".
The owners, Agent and Manager

Of All Coal & Metalliferous mines
Sub: Safety features to be incorporated in Tippers / Trucl{S.
The most common mode of transport of coal/lore and materials in opencast

mines whether big or small size is trucks qr tippers and their use is on
increase. Unfortunately, the incidence of accidents due to such vehicle is
alarmingly high in opencast mines.
The analyses of accidents revealed that majority of them have occurred due
to: - I
Collision either due to Head on or head to tail

Failure of brakes.
Over speeding or rash driving by operators
While reversing
Fire
Driving of the vehicle while body still raised.
Short circuit due to problems in Auto-electrical system
A model code of practice was circulated vide circular no 11 of 1973 and was
required to be enforced by the management. Mine managements have since
been further reminded by various circulars. .
l
The matter has since been again examined in this Directorate. It has beenl
decided to ensure that in every mine where tipping trucks are being engaged
either in opencas~ workings or on !surface ?perations~ the followi~~ s~fetYI
features shall be Incorporated so tThat.the rIsk of aCCidents are mInImIzed.
I
These features are applicable to all types / model/ capacity of truck! tippers
i
I
- " I

Safety features required) in tippers/ trucks
I
Cabin Guard Extension:

Canopy shall cover the operator's cabin fully.
Exhaust/ Retard Brake:

Device to control the speed of tmck while operating down the gradient. Refer
DGMS (Tech) circular 02 of 2004.
Propeller shaft guard:

Propeller shaft guard as specified in DGMS (Tech) circular 10 of 1999.
Tail gate protection: I
Protection of operator against collision either by head on or head to tail
Limiting speed device: I

Enable mine management to decide the maximum speed of vehicle to be operated
in mine. The device may be Electronic or mechanical type speed governors.
Audio-visual alarm while reversing:

The audio-visual alarm provided should confirm to DGMS {Tech.) Circular No 01
of20l0.
Provision of two brakes:

One of brakes shall be fail safe. For details refer DGMS circular 09 of 1999.
Body lifting position locking arrangement: \

A hooter along with an indication is provided to indicate the body is still in lifted
position. I
Fire resistant hoses at hot zone:

To decrease chance of fire
Electric Wires and sleeves are to be of fire resistant quali'ty:

Turbo Charge Guard and eXhau~t tube coated with heat insulated paint:
. To decrease chance of fire '

Battery Cut off Switch:
Retro reflective reflectors on all sides:

For visibility of truck during night
Seat belt reminder

To alert operator for using the seat belt
Proximity warning device

To alert operator when approaching after vehicles I obstruction.
Rear Vision System

To assist operator during reversing .Refer DO Circular No. 12 of2009
Auto dipping System

To reduce glaring on eyes of operator during night operation.
I
Load Indicator and Recorder

Enables management to detect and prevent over loading
The management shall ensure that the safety features listed above are
provided in trucks! tippers and shall be a part of inotice inviting tender for , . "
new procurement and,action shall be tql<ento provide the safety features in
existing trucks within a specified time frame but riot later than bne ye~r
from the date of issue of this circular. The same features shall be included in
contractor's agreement also while out-sourcing so that the trucks! tippers
are provided with required safety features before putting in to operation in
the mines. I
In the interest of safety all the Owners, Agent and Managers of the mine in
which such transport vehicles are being used are requested to comply with
the aforesaid safety requirement so that the accidents due to this cause ar1e
minimized and eliminated.' ~
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GOVERNMENT OF INDIA
No. DGMS/ S&T/Tech. Cir. (Approval) No. 2 Dhanbad , the 3rd June 2010
To:
Subject: Standard Components and Properties of Rigid Steel Props, Chocks & Cogs
to be used in Mines
Steel Supports such as rigid steel cogs, chocks and props are being widely used in the
mines. In making of such steel supports, various types of circular or square section hollow
steel tubes, angles, frames etc. are being used. In order to ensure the desired strength,
stability and durability of such supports, a committee was constituted comprising of mine
management, trade union, CIMFR and officials from DGMS to look into this issue in depth.
On the basis of such study conducted by the committee, a technical circular vide DGMS
(Tech)).S&T/Cir/No.1 dated 5th January 2007 was issued from this Directorate. The
Circular prescribes the minimum test standard for such supports before using in mines.
After due technical considerations and to check the quality of support being used in the
mines, the steel supports including roof bolts were brought under the purview of approval
vide Gazette Notification No. GSR 160 dated 14th August, 2008, and a circular in this regard
was also issued vide this Directorates issue No. DGMS (Tech) (S&T)/Circular No. 3/703
dated 14.08.2008.
The Cogs, Chocks and Steel Props manufactured by various companies have also been
approved from this Directorate. The Data collected during the testing of such supports
have been analysed. Several meetings and discussions were held with scientists from
Mines, Dhanbad,
During the period of testing, approval and field trials of such supports, various suggestions,
recommendations and advices were received from the scientists from Research &
Page 1 of 4

Development Centre for Iron & Steel (RDCIS), Ranchi & CIMFR, Dhanbad, CMPDIL, Ranchi,
ISM, Dhanbad, and CIL, Kolkata. The feedbacks received from such orgaisations have been
considered and the standard and parameters of the steel chocks, cogs and Props to be used
in mines are prescribed as under:
Materials
Manufacturer shall specify the steel grades and characteristics from which the steel support has
been made/manufactured.
(a) The tensile strength of the steel grade used shall be at least 1.08 times the measured yield
stress.
(b) Elongation prior to fracture A of the steel grade used shall not be less than 10%.
(c ) The manufacturer of the support shall specify the design, calculations, Yield Strength
and Ultimate Tensile Strength along with elongation at Yield and the factor of safety
of the supports. The Steel support shall be as per the drawing and dimensions given
by the manufacturer.
Dimension
Dimension of the support shall be as per the design and the tolerances specified in the IS:
1852 1985 or any other Standard as applicable.
Chemical composition of the steel for manufacturing of the steel supports varies according
to the requirement of strength characteristics and specific applications given by user.
However certain chemical constituents of the steel which influence the required properties
of steel are prescribed below:
1 Carbon ( c) 0.25 (Max)
3.1 At least two prototype samples shall be tested for type test at a National Test House
or Laboratory.
3.2 At least 0.5% of the production shall be subjected to routine test or production test.
3.3 Axial Load test:

Page 2 of 4

The Steel Prop, Cog or Chock shall be set vertically in a testing machine and the designed
load is applied. The load-yield characteristics shall be obtained.
3.4 Eccentric Load Test:

The test shall be conducted on the Square Steel Prop, Cog/Chock by putting the support
with an eccentricity of about 54 mm at the upper end.
3.5 Overload Test:
An overload test shall be conducted by subjecting the Steel Prop, Cog /Chock to a load
equal to 1.20 time the designed load. The test shall be conducted for at least five loading
cycle.
Minimum performance requirements:
There shall be no visible deformation, distortion or failure of any part of the support.
The minimum load bearing capacity of Steel prop shall be 20 Tonnes and for
Cog/Chock 30 Tonnes.
However, the support can be manufactured and used of higher capacities as per the
requirements of the user.
4.0 Welding and Weld Tests
All the parts and components of the supports structure if joined together by welding shall
be welded with following the specified code of welding prescribed under various BIS. The
welding stresses shall also be calculated and tested as prescribed under various BIS.
(a) Weatherability:
The support and its components or parts shall be subjected to Accelerated Weathering

The Support shall also be subjected to Field Exposure and Corrosion Resistivity Test as per
IS- 5555: 1970 to test the resistance to corrosion of the steel support and its parts.
6. Marking:
Steel Prop, Cog or Chock shall be marked with the manufacturers name and/or registered
trade mark, serial number, size and the designed load of the Square Steel Cog Stool/Chock.
Page 3 of 4

7.0 In case the support or any of its part fail to pass the required tests at the users end,
that batch or lot of the manufacture shall not be used in the mine and intimation thereof
shall be sent to the manufacturer. A record in this regard shall be maintained at the
mine/company.
examine the supports at any time in the mine or the area of the mines and get samples
tested during the course of inspection or send such samples for testing at any national test
houses/laboratories at the cost of manufacturer or user.
The Standard, Parameters and Testing of Steel props, cogs and chocks as mentioned
Yours Faithfully,
Page 4 of 4

GOVERNMENT OF INDIA
No. DGMS/ S&T/Tech. Cir. (Approval) No. 3 Dhanbad, the 3rd June 2010
To:
Subject: Standard Components and Properties of Steel Roof Bolts to be used in

Mines
Steel Roof Bolts with Nuts, Dome Washer, Bearing Plates and W-Straps are being widely
used in the mines. In making of such steel supports, various types of steel rods, TMT bars
are generally used. In order to ensure the desired strength and durability of such supports,
a study was carried out during the year 2008 and the steel supports including roof bolts
were brought under the purview of approval vide Gazette Notification No. GSR 160 dated
14th August, 2008, and a circular in this regard was also issued vide this Directorates issue
No. DGMS (Tech) (S&T)/Circular No. 3/703 dated 14.08.2008.
The Roof Bolts, Nuts, Bearing Plates & W-straps manufactured by various companies have
also been approved from this Directorate. The Data collected during the testing of such
supports were analysed. After detailed discussions and meetings held with scientists from
Mines, Dhanbad, a Technical Circular No. DGMS/S&T/Tech. Cir. (Approval) No. 11 dated
17th July 2009 was issued on the standard components and properties of roof bolts to be
used in mines. Based on the standards and parameters specified in the circular, testing of
the steel roof bolts are being conducted at the test house and on the basis of such test
reports approvals are being granted.
During the period of testing, approval and field trials of such roof bolts and bearing plates
including w-straps, various suggestions, recommendations and advices were received from
the scientists from Research & Development Centre for Iron & Steel (RDCIS), Ranchi &
CIMFR, Dhanbad, CMPDIL, Ranchi, ISM, Dhanbad, and CIL, Kolkata. The feedbacks received
Page 1 of 5

from such orgaisations have since been considered and the standard and parameters of the
roof bolts and its assembly to be used in mines are prescribed as under:
(a) Shape & Size:

The Roof bolt shall be of MS Steel or TMT Rebar having circular cross-section with ribs on
circumferential region. The manufacturer of the roof bolt shall specify the design,
calculations, Yield Strength and Ultimate Tensile Strength along with elongation at Yield
and the factor of safety of the roof bolt manufactured by them. The Roof bolt shall be as per
the drawing and dimensions given by the manufacturer.
(b) Length:
Length of the Roof Bolt shall not be more the designed length + 5mm.
(c ) Diameter:
Diameter of the Roof Bolt shall not be more than the designed diameter + 4% by mass as
specified under IS 1786 2008 or as per the standard given in BS 7861 (Part-1) 2008.
(d) Straightness:
The roof Bolt shall be straight without any joint, welding, deviation or deflection. However
if the deflection or deviation cannot avoided due to practical reasons, it shall not be more
than + 0.1 % per meter length of the bolt.
(e) Rib:
The Rib of the Roof Bolt shall be as per the design of the rib with an objective to maximize
the surface area without reducing the core diameter of the roof bolt and having maximum
grip with the grout. However the height of the rib shall be kept within the standard
prescribed in IS 1786 2008 or BS 7861 (Part 1) 1996 or latest revision thereof.
Steel for the Roof Bolt:

The roof bolt shall be of thermo-mechanically treated (TMT) rebar manufactured from MS
Grade Fe-500, Fe-600 or above. The Yield Stress, Tensile Strength and % elongation steel
Grade shall be maintained as per the IS 1786 and IS 13920.
However the minimum load bearing capacity (Anchorage Load) of the roof bolt shall be
160 kN.
Chemical composition of the steel for manufacturing of the roof bolts varies according to
the requirement of strength characteristics and specific applications given by the roof bolt
manufacturer and the end user. However certain chemical constituents of the steel which
influence the required properties of steel are prescribed below:
Page 2 of 5

1 Carbon 0.25 (Max)
Thread on the Roof Bolt:
(a) The thread on the roof bolt shall be M20 cold rolled thread conforming to IS 4218
(part- 2 & 3) and no cut thread shall be used. The minimum length of the thread shall be
150 + 5mm and the tolerance class designation of 8g. The thread shall conform to
tolerance class of 7H.
As a routine test, one thread in every 50 produced shall be checked using a go/no-go
gauge.
(b) Non-threaded end
The non threaded end of the rock bolt shall be formed by cropping or sawing and shall be
free from burrs and edges which protrude beyond the profile of the rock bolt.
As a routine, one rock bolt in every 200 produced shall be checked for straightness.
(c) The Nut shall be of hexagonal shape of thickness not less than 30mm conforming to IS
1363 (Part-3) and the thread shall conform to tolerance class of 7H.
(d) Pull Test: Thread and the Nut on the roof bolt shall be subjected to pull test
which should not slip at the yield strength/load of the roof bolt.
Bearing Plate
(a) The Bearing Plate of the roof bolt shall be Dome Washer Plate of dimension 150 x
150 x 8 (minimum) mm with compatible central hole of required size and angled side to
accommodate the conical seat and nut.
(b) The minimum load at which the Domed Washer Plate will become flat should be at
least 14 Tonnes.
Conical Seat
(a) Conical Seat shall be of forged steel of required dimension
(b) The Conical Seat shall not deform at 1.20 times the Yield stress of the roof bolt.
The roof bolt, thread, nut, conical seat, domes washer plate as well as domed bearing plate
shall be subjected to tensile test and type as specified in BS 7861 (Part-1) 1996 or revised
edition.
4.0 Tensile Test of the Roof Bolt Assembly
(a) The Roof Bolt Assembly shall be subjected to Tensile Test and should not fail up to
16 Tonnes load.
Page 3 of 5

Subject to the condition that System Stiffness of the Roof Bolt assembly shall be within 20
KN/mm -System stiffness between 50 to 150 KN.
(a) Weatherability:
The Roof Bolts and its components or parts shall be subjected to Accelerated Weathering

The Roof Bolt Assembly shall also be subjected to Field Exposure and Corrosion Resistivity
Test as per IS- 5555: 1970 to test the resistance to corrosion of the steel of the roof bolt
and its parts. The Roof Bolt should pass the required test.
6.0 SAMPLING & TESTING
In order to check the composition and required parameters during manufacture, it shall be
required that the random sampling be done @ of 2 roof bolts per 1000 pieces of roof bolts
and its accessories manufactured in a batch which shall be subjected to the required set of
tests as prescribed in the previous paragraphs above and the data shall be kept recorded in
a bound paged book kept for the purpose which shall be signed by the persons carrying out
the test and shall be countersigned by the quality control officer posted at the
manufacturing unit(s).
6.1 The user shall carry out Physical examination tests as far as possible but shall
conduct Tensile Test of the Assembly for every batch of Roof Bolts & its Accessories
received at their end before use and keep the records in a bound paged book kept for the
purpose.
In case the Roof Bolts or any of its accessories fail to pass the required tests at the users
end, that batch or lot of the manufacture shall not be used in the mine and intimation
thereof shall be sent to the manufacturer. A record in this regard shall be maintained at the
mine/company.
examine the roof bolts and its accessories at any time in the mine or the area of the mines
Page 4 of 5

and get samples tested during the course of inspection or send such samples for testing at
any national test houses/laboratories at the cost of manufacturer or user.
The Standard, Parameters and Testing of Steel Roof Bolt assembly as mentioned
Yours Faithfully,
Page 5 of 5

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The manufacturer and Workmanship

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Degree of protection Test condition as per IS 13947

1. Protection against dust and shall prevent ingress of dust C7.5&C7.6

TEST Test condition

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Functional Test Requirements : Unless otherwise specified data measurement will be

Inspection and maintenance:

Director General of Mines Safety

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No.DGMS/CIRCULAR/GENERAL/01 DATED 22-10-2010.

All Owners/Agents and Managers of all coal mines.

No. Name of the test house/ Approval accorded Validity period

Director General of Mines Safety.

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All Owners, Agents and Mangers of Mines

Subject: Respirable Dust Measurements and Control to Prevent Pneumoconiosis in Mines.

There are several stages of pneumoconiosis/ silicosis. Early

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1.2 Defining the Dust

2.0 Exposure Limits

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3.0 Sampling and Analysis of Respirable Dust Concentrations

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3.1 Sample Survey of Dust Control Measures in Mines

In view of the observations made above, it is recommended that

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Subject: Standard Components and Properties of Steel Roof Bolts to be used in

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1.0 Physical Properties:

(a) Shape & Size:

2.0 Physico-mechanical Properties:

Steel for the Roof Bolt:

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(c) Corrosion Resistance Test:

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Director General of Mines Safety

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The owners, Agent and Manager

Sub: Safety features to be incorporated in Tippers / Trucl{S.

The most common mode of transport of coal/lore and materials in opencast

Collision either due to Head on or head to tail

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Cabin Guard Extension:

Exhaust/ Retard Brake:

Propeller shaft guard:

Tail gate protection: I

Protection of operator against collision either by head on or head to tail