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In underground coal, compliance comes before anything else. National Plastics & Rubber is an Australian manufacturer of FRAS polyurethane products for underground mining vehicles, including hungry boards, sheaves, compartment covers, and wheel arch flares for Joy Global shuttle cars. We’ve held FRAS certification since 2014 and have consistently maintained compliance since.
Alongside our FRAS range, we supply patented quick-release bumpers for underground vehicles, and we can design and manufacture custom components when a standard part won’t do the job.
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FRAS stands for Fire Resistant Anti-Static. Both halves matter in a potentially explosive underground atmosphere:
FRAS materials help minimise occupational hazards and prevent ignition events underground. Getting the material right is only part of the job. In 2020, Queensland’s mines inspectorate and the NSW Resources Regulator both issued safety alerts after testing found that some FRAS-rated products either failed to meet requirements or could still pose ignition risks when installed incorrectly. For underground procurement and compliance teams, documented, compliant materials and correct installation go hand in hand.
For a deeper explanation, read our article what is FRAS?
In NSW, the key reference for non-metallic materials is TRG 3608 Non-metallic materials for use in underground coal mines and reclaim tunnels in coal mines (Version 5.0, July 2024), published by the NSW Resources Regulator and formerly known as MDG 3608. TRG 3608 references the following test methods and requirements:
In NSW, a notice made under section 90 of the Work Health and Safety (Mines and Petroleum Sites) Regulation 2022 requires non-metallic ventilation components and belt conveyor accessories in underground coal mines to be FRAS, with testing to TRG 3608. In Queensland, the Coal Mining Safety and Health Regulation 2017 requires FRAS material for certain equipment, including belt conveyors, brattice and ventilation ducting. For vehicle parts such as hungry boards and wheel arch flares, FRAS is specified through TRG 3608’s broader scope for non-metallic materials and each mine’s risk management obligations.
Correct installation matters as much as the material. NSW Safety Alert SA20-10 found that FRAS products with a surface resistivity below 300 MΩ could cause spark ignition if not bonded to earth, and that unearthed metallic fittings on higher-resistivity products could also cause ignition. The alert notes that chains, while conductive, may not provide reliable earthing, and that any change in a FRAS material’s composition or manufacturing technique, including a change of colour, requires re-testing.
Our shuttle car parts are designed as aftermarket replacements for existing OEM parts on Joy Global shuttle cars. All four are manufactured from FRAS polyurethane and can be made to order or customised to your requirements. As with any aftermarket part, we recommend confirming dimensions before ordering.
Our hungry boards are made from certified FRAS polyurethane and are made to order.
Part number | Size | To suit |
NPR05670-00 | 2450 x 450 x 19mm | Joy Global 10SC32 |
NPR05808-00 | 2330 x 450 x 25mm | Joy Global 10SC32 |
NPR05236-00 | 2400 x 450 x 16mm | Joy Global 10SC32 |
NPR06519-00 | 3700 x 315 x 16mm | Joy Global 10SC32 |
NPR05361-00 | 1750 x 392 x 16mm | Joy Global 15SC32 |
Designed to replace existing OEM sheaves that guide the conveyor ropes, our FRAS polyurethane sheaves are available in Ø360mm (NPR06136-00) and Ø254mm (NPR06523-00) diameters, both with a Ø38mm inside diameter and a 116mm dimension, along with a matching Sheave Insulator (NPR05254-00).
Our FRAS compartment covers replace the OEM covers on conveyor rope winches. The range includes Cable Reel Compartment Covers (NPR06526-01 and NPR06526-02) and a Left Hand Cable Reel Compartment Cover (NPR06972-00).
Engineered to replace OEM parts and prevent mud splatter, our FRAS polyurethane wheel arch flares are available as a Rear Wheel Arch Flare (NPR06524-00) and a Front Wheel Arch Flare (NPR06525-00).
Our patented quick release bumpers (AU Patent 2016101202) come in a variety of sizes and shapes to suit underground vehicles. Locking tapered pins allow the bumper to flex without tearing, leaving the backing plate undamaged, so only the polyurethane bumper needs replacing and the backing plate can be reused. The quick-release concept reduces labour costs, machine downtime and the risk of workplace injury.
We also offer a traditional range of polyurethane front and corner mine-vehicle bumper blocks for Joy Global shuttle cars, with custom sizing available.
National Plastics & Rubber is an Australian-owned and operated manufacturer that has supplied polyurethane, rubber and industrial plastic products to the mining industry since 1997. Our FRAS polyurethane is designed for demanding underground applications, including coal mining, and is available in a variety of compounds, colours and customisable options. Many of our underground parts are made to order, and every production run undergoes strict quality assurance.
If you need a part that isn’t in our range, our Brisbane facility offers in-house CAD design, prototyping and custom manufacturing capabilities. We’ve manufactured polyurethane, rubber and industrial plastic products for Australian and international heavy industry since 1997. Learn more about what is polyurethane?, browse our technical resources and brochures, or explore our mine site case studies.
Our wider range, including MineChock™ wheel chocks and cable and hose crossovers, isn’t listed as FRAS certified. Please speak with our team about suitability for underground use.
To request certification documentation or discuss your requirements, call 1300 160 875 or email sales@nationalplastics.net.au.
FRAS stands for Fire Resistant Anti-Static. Fire resistance means the material resists ignition and flame spread. Anti-static means its electrical resistance is low enough to dissipate static charge, rather than creating an ignition source in a potentially explosive atmosphere.
In NSW, the operative document is TRG 3608, Non-metallic materials for use in underground coal mines and reclaim tunnels in coal mines (Version 5.0, July 2024), published by the NSW Resources Regulator and formerly known as MDG 3608. It references AS 4606-2012 Grade S, ISO 4589-2 (oxygen index), AS 1180.13A (electrical resistance) and AS 1334.10 (ignitability).
Under section 90 of the Work Health and Safety (Mines and Petroleum Sites) Regulation 2022 (NSW), a notice from the NSW Resources Regulator requires non-metallic ventilation components and belt conveyor accessories in underground coal mines to be FRAS. Vehicle parts such as hungry boards and wheel arch flares aren’t named in that notice. Their FRAS requirement comes from TRG 3608’s broader scope for non-metallic materials and the mine’s general risk management duty.
TRG 3608 requires an oxygen index of no less than 28% (ISO 4589-2). Electrical resistance is tested to AS 1180.13A, for example no more than 1 MΩ for conveyor idlers and 1 MΩ/m for ventilation ducting. Testing must be carried out at an ISO/IEC 17025 accredited facility.
NSW Resources Regulator Safety Alert SA20-10 (October 2020) found that products with a surface resistivity below 300 MΩ could cause spark ignition when not bonded to earth. Products above 300 MΩ could cause spark ignition from un-earthed metallic fittings, and bonding only one of several fittings wasn’t enough. The alert recommends secure mounting to an earth-bonded structure or a dedicated earth lead.
The Coal Mining Safety and Health Regulation 2017 (Qld) requires FRAS material for certain equipment, including belt conveyors, brattice and ventilation ducting. Beyond those, obligations sit under the regulation’s general suitability and risk management duties. When RSHQ issued its 2020 safety alert on FRAS-rated equipment, products were assessed against MDG 3608 (now TRG 3608) requirements.
Contact our sales team to request certification documentation for the FRAS products you’re ordering.
Our FRAS-hungry boards, sheaves, compartment covers, and wheel arch flares are designed to suit Joy Global shuttle cars, including hungry boards for the 10SC32 and 15SC32 models. Our quick-release bumpers come in a variety of sizes and shapes for underground vehicles, and we can custom-manufacture parts for other equipment.
View individual Stacko™ Configurations to see load ratings.
