Glencore turns blind spots into safe spots with proximity detection tech giving miners another set of eyes and sharper control in the pit

When a digger operator says a new system lets them “see trucks in blind spots you don’t see,” you know it’s more than just another safety add-on – it’s changing how mining crews work.

At the 33rd Mechanical Engineering Safety Seminar (MESS 2025), organised by the NSW Resources Regulator, Glencore mechanical engineer Blade McNaught and electrical engineer Jacob Carey detailed how proximity detection is being rolled out across Mount Owen Glendell Operations (MGO). Their presentation, Proximity Detection Development, peeled back the layers of what many in the industry still view as a black box – showing not just how the technology functions, but how it has been embedded into operating culture.

Beyond plug-and-play

For Blade, the journey began well before the first unit was fitted.

“When collision awareness products first started appearing, we didn’t just rush out and buy the first one,” he explained. “We stepped back and focused on what we actually needed the system to do – both in terms of functionality and performance. From there, we evaluated the options against our criteria and partnered with a supplier to refine and enhance the system.”

That work started back in 2017, years before the NSW Resources Regulator published its latest Traffic Management Guide (TRG). Today, MGO operates a level eight Collision Awareness System (CAS) – a driver aid designed to improve situational awareness without intervening in the operation of the machine.

“It’s important to remember that CAS is part of a broader risk management protocol,” Blade said. “On its own, it will not achieve zero collision risk. It doesn’t replace training or procedures – it’s an extra tool on top of what you already have.”

A maturity model for mine safety

One of the strongest themes in the presentation was that technology is only as effective as the site’s maturity. Blade referenced the nine-layer control model widely adopted across the industry, noting that effective fundamental controls – such as mine design, traffic segregation, and training – form the foundation.

“To implement level eight and nine controls effectively, you need to understand your level one through seven as your baseline,” he said. “Without effective fundamentals, technology may not provide an improvement – in some cases it could even make things worse.”

That framework guided Glencore’s approach to adopting CAS, ensuring that the system was integrated into existing protocols rather than bolted on as a superficial fix.

Engineering reality: not plug-and-play

For Jacob, the challenge was translating the concept into practical installation across a fleet of heavy mining equipment.

“Fitting new technology to heavy machines is never plug-and-play,” he told the seminar. “Every machine is different. We ran into real challenges with space, wiring, and integration. That’s why we used a staged engineering approach – starting with scoping, moving through installation guidelines, then into construction design, inspection, and testing.”

The CAS relies on three positioning technologies:

• GPS, recording data points ten times per second and predicting vehicle paths

• Vehicle-to-vehicle radio, broadcasting ID, speed, and position to machines within 300 metres

• Wi-Fi, linking units back to the mine’s server for data management

“The system is designed with redundancy,” Jacob said. “If Wi-Fi drops out, the vehicle-to-vehicle link and GPS channels will still operate. That resilience is crucial.”

Inside the cab: operator tools

The hardware setup is built around an in-vehicle unit (IVU) and a touchscreen display. The IVU integrates data, processes it in real time, and stores critical information for diagnostics and playback. The display provides a radar-style graphic showing nearby vehicles, along with progressive visual, audible, and voice alerts.

During start-up, a self-test checks system health. “It will tell the operator if the machine is in an acceptable state to use,” Jacob explained. “Even if one positioning channel fails, redundancy from the others ensures it can continue operating safely.”

For contractors without permanent installs, Glencore has built a pool of 40 portable units mounted on magnetic racks. “They’re booked out daily and returned at the end of each shift,” Jacob said. “It keeps availability high and ensures contractors are always fitted out.”

Geo-fencing: virtual barriers in the pit

Perhaps the most innovative element is the system’s geo-fencing capability.

At intersections, for example, a geo-fence can activate automatically when a haul truck enters, triggering “give way” prompts in light vehicles approaching the zone. Similar fences can be built around broken-down equipment, wet-weather areas, or restricted circuits.

“The best thing about CAS is the ability to create geo-fences to isolate circuits,” said one operator. “If we’ve got broken-down machinery, we can put a fence around it that alerts anyone entering. It creates a safe work zone without slowing the whole mine.”

By targeting alerts and restrictions to specific hotspots, geo-fencing helps avoid alarm fatigue – one of the risks of blanket safety systems.

What it looks like in the field

On-screen, the CAS shows a vehicle at the centre of a radar with surrounding beams. As vehicles approach, colours shift from green to yellow to red depending on proximity. Audible cues escalate from warnings to shrill alarms and voice commands such as “Stop breach” or “Don’t move.”

Operators say the visibility boost is tangible.

“As a digger operator, I’ve got a lot of blind spots on my offside and behind me,” said one. “With CAS, I can always see where the dozer is in relation to me. If a truck moves into a blind spot, I know straight away.”

A dozer driver agreed: “It’s really handy every day. You don’t realise how much you can’t see until you’ve got a screen showing you the vehicles around you.”

Another operator highlighted its subtle impact on behaviour: “There are times when, because of CAS, you move something out of the way or notice a hazard you wouldn’t have otherwise. It’s hard to quantify, but yes – it reduces incidents and near misses.”

Integration and maintenance

Rolling out CAS required more than hardware. Blade emphasised the importance of training, role changes, and procedural integration.

“Don’t just base it on your incident data,” he cautioned. “Consider all vehicle interaction scenarios. Deliver simple but thorough training, and explain what the system does – and more importantly, what it doesn’t do. Modify position descriptions, integrate the system into existing procedures, and feed learnings back into your layered control model.”

Planned maintenance schedules were built into Glencore’s SAP system, covering inspections and frequencies. A maintenance Trigger Action Response Plan (TARP) ensures failures are assessed for impact and corrective actions are applied.

“Don’t underestimate what it takes to support this system,” Blade said. “You’re going to need extra people.”

From alerts to culture

At its heart, the CAS project at MGO is as much about cultural maturity as technological maturity.

Operators repeatedly described CAS as “another tool” rather than a replacement for vigilance. Supervisors praised its ability to tailor responses to real-world conditions. Engineers framed it as one layer in a defence-in-depth model that begins with fundamentals like mine design and training.

Together, those perspectives show how Glencore has transformed proximity detection from an off-the-shelf product into a mine-wide system of risk management.

For Blade, the takeaway is simple: “It’s like having another mirror in the cab. It increases visibility, it supports decision-making, and it helps reduce the likelihood of high-risk interactions. But it only works if you’ve got the fundamentals in place.”