A breakthrough underground excavation guard at Aquila Mine is setting a new safety and productivity benchmark for the resources sector.
The new system – dubbed The Armadillo because of its unique shield design and first-of-its-kind adaptability in Bowen Basin coal mines – was developed in partnership with the Jet Group in Mackay.
The Armadillo was born when the mine turned a complex engineering challenge into an opportunity to innovate. The Aquila team needed to retrofit a conveyor dewatering transfer installation underground but had several constraints, including low seam height and the need to keep the conveyor running for production continuity.
Aquila Mine General Manager Braedon Smith said a novel solution to protect the conveyor while allowing shot firing excavation overhead needed to be developed.
“The resulting mobile conveyor excavation guard has redefined how mining operations can safely excavate above live infrastructure without compromising production or safety.”
The Armadillo integrates rolling covers for flexible protection during blasting, a pivoting tipping platform to safely transfer spoil to designated zones, hydraulic controls and a custom rail system – all designed to shield the conveyor while enabling safe excavation and debris removal, a bolting deck that doubles as a secondary safety layer and survey-guided installation for pinpoint accuracy.
“The Armadillo has delivered significant downtime reductions, zero injuries and a blueprint for safer underground excavation across the industry,” Braedon said.
He said the system was trialled and refined through rigorous risk assessments, 3D tunnel scans for precision, and stakeholder workshops.
“The transferability of this first-of-its-kind system makes scaling the innovation and adapting to site-specific needs a value-add development for the industry.
“The Armadillo is already being considered for future applications across the mine site and other Anglo American mining operations in the Bowen Basin. Its modular design and transferability make it a standout for sites facing similar excavation challenges.”
The Armadillo’s innovation was recognised nationally, with the project named a finalist in the Innovative Mining Solution category at the 2025 Prospect Awards.
Anglo American Australia CEO Dan van der Westhuizen said this project demonstrated the value of collaborative partnerships within the industry to achieve an innovative outcome.
“We are proud of the national recognition but, more importantly, we’re proud of the collaboration and out-of-the-box thinking that made this solution possible,” Dan said.
“It’s a testament to what is achievable when safety, engineering and production teams come together.”
