In March 2024, Freeport-McMoRan’s Grasberg Mine in Indonesia, one of the world's largest gold and copper mines, faced significant challenges related to underground lighting. With thousands of miners working deep underground in hazardous conditions, ensuring proper illumination and safety was a critical requirement. Miners needed reliable, explosion-proof cap lamps that met international safety standards while offering long battery life, strong brightness, and robust durability.
Green Lighting was approached by Grasberg’s safety team to provide a high-performance Mining Cap Lamp compliant with IEC60079-11 standards, ensuring intrinsic safety in potentially explosive environments. Our expertise in underground mine lighting solutions made us the ideal partner for the project.
Explosive Environment Compliance: Grasberg Mine operates in methane-prone areas, requiring intrinsically safe lighting that meets the IEC60079-11 explosion-proof standard to prevent ignition hazards.
Durability in Harsh Conditions: The underground environment is wet, dusty, and high-pressure, demanding a rugged, waterproof, and impact-resistant cap lamp.
Extended Work Hours: Miners work long shifts of 10-12 hours, requiring a cap lamp with a long-lasting battery that doesn’t lose brightness over time.
Reliable Supplier Support: Grasberg’s safety engineers needed on-site training and continuous technical support to ensure optimal usage and maintenance.
Green Lighting supplied our Premium Mining Cap Lamp, featuring:
✅ IEC60079-11 Certified Intrinsically Safe Design – Explosion-proof and compliant with mining safety regulations.
✅ Powerful Illumination – 10,000 lux brightness ensures clear visibility in deep underground tunnels.
✅ Long Battery Life – 16 hours of continuous operation with a high-capacity Li-ion battery (6.6Ah).
✅ Durability & Waterproofing – IP68-rated, resistant to water, dust, and impacts, ensuring performance in extreme conditions.
✅ Lightweight & Ergonomic Design – At only 420g, the cap lamp provides comfort for miners during extended shifts.
We worked closely with Grasberg Mine’s safety department, services and technical support we provided as following:
On-site product training to teach miners the correct usage and maintenance of the cap lamps.
Technical assistance to integrate our cap lamps with their existing safety protocols.
Regular performance assessments to ensure reliability over extended usage.
After implementing our IEC60079-11 certified mining cap lamp, Grasberg Mine saw a significant improvement in worker safety, efficiency, and comfort:
Zero explosion-related incidents due to the intrinsically safe lighting solution.
35% improvement in miner visibility, reducing accidents and boosting productivity.
Longer shift endurance with the extended battery life preventing mid-shift failures.
Reduced maintenance costs, as the lamps required fewer repairs compared to previous models.
Green Lighting’s mining cap lamps have exceeded our expectations. Their explosion-proof safety, brightness, and long battery life have dramatically improved underground working conditions. Their support team has been outstanding, ensuring our miners are well-trained and that the lamps function optimally. We will continue working with Green Lighting on future mining projects.
By delivering IEC60079-11 certified mining cap lamps, Green Lighting successfully helped Grasberg Mine improve worker safety and operational efficiency. Our commitment to quality, safety compliance, and customer support has reinforced our reputation as a leading provider of mining lighting solutions.
This case study highlights how Green Lighting’s premium cap lamps can enhance safety and performance in underground mines worldwide, ensuring compliance with the highest safety standards while delivering top-tier lighting solutions.
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