Mine Safe Global Collision avoidance systems for mining

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Mining Collision Avoidance Systems (CAS)

Mine Safe Global provides advanced mining Collision Avoidance Systems (CAS), Proximity Detection Systems (PDS), and Level 9 Collision Prevention Systems for surface and underground mining operations across South Africa, Southern Africa, and globally. Our CAS technologies use intelligent RF proximity detection, real-time operator alerts, and automated machine intervention to eliminate collision risks across all fleet types — from haul trucks and excavators to LDVs and underground trackless machinery. ISO 21815 certified and MOSH Blueprint compliant, Mine Safe Global is one of South Africa's leading Level 9 collision prevention specialists.

Level 9 collision prevention system installed on mining haul truck at open pit mine — automated braking intervention protecting primary fleet
Mining collision avoidance system CAS on heavy equipment at surface mine — ISO 21815 compliant proximity detection
Level 9 CAS operator display interface inside mining vehicle cab — real-time collision prevention alerts and proximity detection
Mine worker wearing PTU pedestrian proximity detection tag in active CAS zone — Level 9 collision prevention protecting site personnel
Excavator fitted with collision avoidance system CAS — proximity detection active in swing-radius zone at mine site
Underground mining tunnel with CAS collision prevention system installed — protecting workers from LHDs and trackless mobile machinery
Mining truck fleet equipped with ISO 21815 compliant collision avoidance systems CAS — Mine Safe Global Level 9 protection
HaloGuard underground CAS with automated braking intervention — Mine Safe Global Level 9 collision prevention for confined mining spaces

What Is a Collision Avoidance System (CAS) in Mining?

A Collision Avoidance System (CAS) — also called a Proximity Detection System (PDS) or Collision Prevention System (CPS) — is a safety technology that detects vehicles, personnel, and equipment in real time to prevent vehicle-to-vehicle and vehicle-to-person collisions in mining environments. CAS solutions are classified by intervention level under the ISO 21815 and EMESRT framework, ranging from warning-only systems (Level 7) to fully automated machine intervention (Level 9).

Mine Safe Global’s CAS and collision prevention systems are engineered specifically for surface and underground mining operations. Using intelligent RF proximity detection, real-time alerts, and — at Level 9 — automated braking intervention, our systems eliminate the blind spot, reaction time, and human error gaps that traditional safety measures cannot address.

How CAS Levels Work

Level 7, Level 8, and Level 9 Explained

Level 7 collision avoidance provides proximity warnings that require operator action, making it a cost-effective solution for temporary vehicles and contractors.

Level 8 systems add automated alerts with escalating urgency and vehicle integration, preparing braking systems for faster response.

Level 9 collision prevention automatically intervenes when a collision is imminent by applying the brakes and stopping the machine, regardless of operator action. This automated intervention is the critical difference between near-miss and prevented fatality, making Level 9 the emerging standard for primary fleets and high-risk zones. Level 9 is increasingly required by mining regulators and industry frameworks including MOSH, EMESRT, and the South African Mine Health and Safety Act (MHSA), making it the benchmark standard for primary fleets and high-traffic zones.
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Mining Collision Avoidance Systems CAS and Level 9 Collision Prevention Systems by Mine Safe Global

Why Mining Operations Need Collision Avoidance Systems

Traditional safety measures such as speed limits, high-visibility clothing, and operator training help reduce collision risks, but they cannot eliminate them entirely. Mining environments create high-risk scenarios that exceed human reaction and awareness capabilities. Haul trucks may require more than 50 meters to stop while operating with blind spots extending up to 15 meters. Excavators rotate with workers potentially hidden within the swing radius, while night operations further reduce pedestrian visibility. These risks occur daily across mining operations worldwide, making advanced collision prevention systems essential for improving safety, reducing incidents, and protecting personnel.
Collision prevention systems transform mining safety by identifying proximity threats before operators can react. Using real-time data and intelligent sensing technology, the system calculates potential collision paths within milliseconds and alerts operators to hazards hidden within blind spots. In advanced Level 9 systems, automatic braking intervention activates when a collision risk becomes imminent. When properly implemented, collision prevention technology can reduce mining-related collisions by 70–95%, shifting safety from reactive human intervention to proactive, automated protection that safeguards personnel, equipment, and operational productivity.

Which Mining Collision Avoidance System Is Right for Your Operation?

CxD Level 9 Collision Prevention Technology automated machine intervention system

Level 9 Collision Avoidance System (CAS)

Automated intervention prevents collisions when operators don't respond. ISO 21815 certified, highest protection standard for primary fleets.

Level 8 Collision Avoidance System vehicle-to-vehicle machine-to-pedestrian mining

Level 8 Collision Avoidance System (CAS)

Advanced warnings with vehicle integration. Upgradeable to Level 9 anytime—ideal starting point.

Level 7 Visitor Collision Avoidance Unit portable battery-powered mining CAS

Level 7 Visitor Collision Avoidance

Portable battery-powered protection for temporary vehicles, contractors, visitors. 60-second deployment.

Mine Safe MI Machine Controller Interface universal Level 9 CAS all OEM equipment

MI Machine Controller Interface

Universal solution enabling Level 9 on any equipment—legacy vehicles, mixed fleets, any OEM.

PTU Pedestrian Detection Tag wearable proximity detection mining workers CAS

PTU Pedestrian Detection Tags

Wearable personnel protection. Vehicle systems need pedestrian detection—workers are most vulnerable.

TrackPro fleet management live collision avoidance reporting platform mining

TrackPro Fleet Management Platform

Centralized monitoring, real-time alerts, heat maps, automated compliance reporting.

Five Steps to Successfully Implementing a Mining CAS (Collision Avoidance System)

Successful collision prevention deployment requires structured approach: assess fleet risks, select appropriate protection levels, install with minimal disruption, validate performance, and ensure operator adoption.

Step 1: Fleet Assessment & Risk Analysis

Document all vehicles, identify high-risk zones through incident history, and determine which equipment needs Level 9 automated intervention versus Level 8 avoidance or Level 7 warnings. Assessment reveals integration pathways—OEM interfaces or MI Machine Controller Interface for universal compatibility.

Step 2: System Design & Protection Level Selection

Match technology to risk: Level 9 for primary haul fleet and high-risk zones, Level 8 for moderate-risk equipment, Level 7 for temporary vehicles. Include PTU pedestrian detection—vehicle-only systems leave workers unprotected. Design for 100% fleet coverage to eliminate gaps.

Step 3: Phased Installation & Integration

Protect highest-risk equipment first (4-8 hours per machine). Phase 1: Primary haul trucks. Phase 2: Secondary fleet. Phase 3: Light vehicles and contractors. Configure TrackPro platform and control room alerts. Phased approach delivers immediate protection while minimizing operational disruption.

Step 4: Testing, Validation & Commissioning

Verify detection ranges, warning timing, automated intervention (Level 9), and TrackPro integration. Test in actual conditions—loaded/empty, day/night, various weather. Document baseline performance metrics before full deployment.

Step 5: Training & Continuous Optimization

Train operators on system behavior, warning responses, and Level 9 intervention. Use TrackPro analytics to identify high-alert zones, operators needing coaching, and configuration adjustments. Treat as ongoing safety management, not one-time installation.

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Level 9 CAS Compliance Checklist

South African Mining Operations — 7-section checklist covering fleet assessment, system selection, installation, testing, training, and compliance sign-off.

ISO 21815 MOSH CPS Blueprint MHSA Act 29 of 1996 EMESRT 50+ checklist items

Collision Avoidance Systems (CAS) for Mining Equipment & Operations

Level 9 CAS collision prevention system on mining haul truck — automated braking intervention for primary fleet

Haul Trucks & Dump Trucks

Large haul trucks are among the highest-risk machines on a mine site, with stopping distances exceeding 50 metres and blind spots of up to 15 metres. Level 9 CAS with automated braking intervention is the standard for primary haul fleet protection, integrating directly with CAT, Komatsu, Bell, and Terex truck systems via OEM interfaces or the universal MI Machine Controller Interface.

Excavator or hydraulic shovel at a mine face, ideally with a haul truck or worker visible nearby to show proximity risk. Wide shot showing the swing arc is ideal.

Excavators & Shovels:

Excavators present high swing-radius risks to nearby pedestrians and light vehicles. CAS proximity detection identifies workers and machines within the excavator's swing zone and triggers escalating alerts — or Level 9 intervention — before contact occurs.

Level 9 CAS on light delivery vehicle LDV at mine site — TRL 4 certified collision prevention for trackless mobile machinery

Light Delivery Vehicles (LDVs) & Trackless Mobile Machinery:

LDVs and smaller trackless machines frequently operate in the same zones as heavy equipment. Mine Safe Global holds TRL 4 LDV Surface Certification (independently verified by the University of Pretoria), confirming Level 9 readiness for light vehicle fleets.

HaloGuard underground CAS collision prevention system — 360-degree proximity detection in confined mine tunnel for LHDs and roof bolters

Underground Mining Equipment:

Confined underground environments create unique CAS challenges. The HaloGuard system provides 360-degree proximity detection and automated intervention engineered specifically for tunnels, declines, and underground production zones. Paired with the HaloTag wearable, it protects pedestrian workers in close proximity to LHDs, roof bolters, and other underground machinery.

Mine Safe Global CAS and HotWorks thermal monitoring system at quarry smelting and heavy industrial site — vehicle and pedestrian collision prevention

Quarries, Smelting & Heavy Industrial Sites

Beyond underground and open-pit mining, Mine Safe Global's CAS systems are deployed at quarries, construction sites, smelting operations, and any heavy industrial environment where vehicles and personnel share operational zones. The HotWorks System adds real-time thermal hazard monitoring for smelting environments, while TrackPro provides centralised fleet tracking and compliance reporting across multi-site operations.

Mine Safe Global PTU pedestrian detection tag — wearable worker protection CAS device triggering Level 9 intervention when personnel enter vehicle danger zone

Pedestrian & Worker Protection

Vehicle CAS systems alone leave workers unprotected — pedestrians must also be detectable by equipped machines. The PTU Pedestrian Detection Tag is a wearable device worn by all site personnel. It communicates directly with Mine Safe–equipped machines, triggering alerts and Level 9 intervention when a worker enters a danger zone. The RF Pairing Unit extends protection to site infrastructure like offices and control rooms near vehicle routes.

Trusted by Leading Mining Operations Worldwide

PPC-cement-mine-safe-global-CAS-collision-prevention-client
Imerys — Mine Safe Global CAS collision prevention system industrial mining client
SBPM — Mine Safe Global Level 9 CAS collision prevention system client
Continental Resources — Mine Safe Global collision avoidance system client
Sibanye-Stillwater — Mine Safe Global Level 9 CAS collision prevention system mining client
Sebilo Resources — Mine Safe Global collision avoidance system mining client
Provest Group — Mine Safe Global Level 9 CAS collision avoidance system client
Sephaku Cement — Mine Safe Global Level 9 CAS collision prevention system client
Glencore — Mine Safe Global Level 9 CAS collision prevention system global mining client
Trollope Mining Services — Mine Safe Global Level 9 CAS collision prevention client
Mokala Manganese Mine — Mine Safe Global collision avoidance system underground mining client
Samancor — Mine Safe Global Level 9 CAS collision prevention system mining client
Zizwe — Mine Safe Global Level 9 collision avoidance system mining client
Tharisa — Mine Safe Global Level 9 CAS collision prevention system platinum chrome mining client
ASB Minerals — Mine Safe Global Level 9 CAS collision prevention system mining client
Scribante Mining Infrastructure and Construction — Mine Safe Global CAS collision prevention client
Sephaku Holdings — Mine Safe Global collision avoidance system mining client
PPC Cement — Mine Safe Global collision avoidance system industrial mining client

Industry Certifications & Compliance

Mine Safe Global solutions meet the highest regulatory and technical standards required across the mining sector.

collision-avoidance-system-CAS-mining.pngISO 21815 compliant — Mine Safe Global collision avoidance and machine control interface certification ISO 21815-Compliant

Ensures full compliance with global communication and functional protocols for Collision Avoidance (CxD) and Machine Control Interface (MCI) integration.

Chief Inspector of Explosives compliance — Mine Safe Global CAS systems certified for operation in explosive zones Chief Inspector of Explosives

Our technology complies with the standards set by the Chief Inspector of Explosives, meeting strict regulatory requirements for safe operation around explosive zones.

ICASA approved — Mine Safe Global collision prevention systems legally certified for South African wireless operation ICASA Approved

All products are officially approved by the Independent Communications Authority of South Africa, ensuring legal operation and reliability.

EMI and EMC compliant — Mine Safe Global CAS systems meet electromagnetic interference and compatibility standards EMI & EMC Compliant

Confirms that collision avoidance systems meet all relevant electromagnetic interference and compatibility standards.

MOSH CPS Blueprint aligned — Mine Safe Global collision prevention system design and implementation standards MOSH CPS Blueprint Alignment

Aligns with MOSH standards for the design and implementation of collision prevention systems.

EMESRT compliant — Mine Safe Global CAS meets Earth Moving Equipment Safety Round Table requirements for mining EMESRT Compliance

Complies with Earth Moving Equipment Safety Round Table (EMESRT) requirements for safe mining operations.

IP66 certified — Mine Safe Global CAS hardware tested for dust and water ingress protection in mining environments IP Certified

Equipment has been tested to comply with the required standards, ensuring long-term durability and safety compliance.

ISERT certified — Mine Safe Global collision prevention systems meet safety reliability and performance standards ISERT Certified

Our solutions are certified through ISERT, confirming adherence to strict safety, reliability, and performance requirements across mining.

MTEx certified — Mine Safe Global CAS systems approved for operation in explosive and hazardous mining areas MTEx Certified

Our systems are MTEx certified, ensuring explosion-prevention compliance for safe operation in hazardous areas.

Mineral Council of South Africa — Mine Safe Global collision avoidance systems endorsed by the South African mining industry body Mineral Council of South Africa

The Mineral Council of South Africa supports, promotes, and advocates for the South African mining industry.

Mine Health and Safety Act compliant — Mine Safe Global CAS systems enable MHSA Act 29 of 1996 compliance Mine Health & Safety Act

Enables our customers to comply with the South African Mine Health and Safety Act (Act 29 of 1996).

TRL 4 LDV Surface Certification — Mine Safe Global Level 9 CAS independently verified by the University of Pretoria TRL 4 LDV Surface Certification

Independently verified by the University of Pretoria, this TRL 4 certification confirms our fire-tested LDV safety systems are technically validated and Level 9 ready.

Which Collision Avoidance System Is Right for Your Operation?

Not sure whether you need Level 9 automated intervention, Level 8 avoidance, or Level 7 warnings? Fill in the form, and a Mine Safe Global expert will assess your fleet, recommend the right protection levels, and design a solution for complete coverage.
  • Level 9/8/7 expertise
  • Works with CAT, Komatsu, Hitachi & all OEMs
  • Industry leader in collision prevention
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Frequently Asked Questions

What is a collision prevention system in mining?
Created by potrace 1.16, written by Peter Selinger 2001-2019 Created by potrace 1.16, written by Peter Selinger 2001-2019
A collision prevention system is a safety technology that detects vehicles, equipment, and workers in real time to prevent vehicle-to-vehicle and vehicle-to-person collisions.
Mining CAS levels are defined under the ISO 21815 and EMESRT framework. Level 7 provides audible and visual proximity warnings requiring operator response. Level 8 adds escalating alerts with vehicle integration to prepare braking systems. Level 9 — the highest and most protective level — automatically applies machine intervention (braking, throttle cutoff) when a collision becomes imminent, regardless of operator response. Mine Safe Global offers solutions across all three levels.
A Proximity Detection System (PDS) detects the presence and proximity of people or objects near a machine and triggers alerts. A Collision Avoidance System (CAS) uses that proximity data to actively prevent collisions through warnings (Levels 7–8) or automated machine intervention (Level 9). In practice, “CAS” and “PDS” are often used interchangeably in the mining industry, though CAS more specifically implies the active collision-prevention capability.
The South African Department of Mineral Resources and Energy (DMRE) has been phasing in requirements for collision management systems across mining operations. The MOSH CPS Blueprint and Mine Health and Safety Act (Act 29 of 1996) set the compliance framework. While specific mandates vary by mine type and operation, Level 9 is the recognised benchmark and is required for primary fleets in high-risk zones at many operations. Mine Safe Global’s systems are designed for full MHSA and MOSH compliance.
CAS stands for Collision Avoidance System. In the mining industry, CAS refers to technology that uses proximity detection, real-time alerting, and — at Level 9 — automated machine intervention to prevent vehicle-to-vehicle and vehicle-to-person collisions. It is also referred to as a Collision Prevention System (CPS) or Proximity Detection System (PDS).
A Level 9 CAS uses the Mine Safe MI Machine Controller Interface to connect directly to a vehicle’s braking and throttle systems. When the CxD proximity detection unit identifies an imminent collision risk, based on the speed, direction, and distance of approaching people or machines. It automatically applies the brakes and cuts throttle without requiring operator input. This intervention happens within milliseconds, far faster than human reaction time, and is the defining feature that separates Level 9 collision prevention from lower-level avoidance systems.
Collision avoidance warns operators of hazards and provides alerts. Collision prevention goes further by automatically intervening and applying machine controls when a collision becomes imminent.
Level 9 systems automatically apply braking or machine intervention when a collision risk is detected.
Requirements vary by country and mining regulations, but many operations align with industry frameworks and safety standards.

Yes, it features secure cloud-based data logging for reliable auditing and regulatory compliance.

Yes. Mine Safe Global’s MI Machine Controller Interface (MCI) is specifically designed to enable Level 9 automated intervention on any machine regardless of age, manufacturer, or electronic architecture. This includes older non-intelligent legacy machines with no existing onboard control systems. The MI interfaces between the CxD detection unit and the machine’s mechanical controls — braking, throttle, and steering — without requiring OEM support. Legacy fleets running CAT, Komatsu, Hitachi, Bell, or any other brand can achieve full Level 9 CAS compliance through this universal interface.

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Global Footprint

We operate across Southern Africa and key regions including North America, United Kingdom  and across Europe.

As one of South Africa’s leading collision avoidance partners, we’ve helped mines boost safety and efficiency through advanced, integrated safety technology.