[xls] · web viewfailure of strata support system resulting in a fall from height of bolt hardware...

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WEEKLY INCIDENT SUMMARYWeek Ending Id number Incident type Summary Recommendations to Industry/Comments

4/09/2015 317654773001 Fatality

4/09/2015 317654560001 Vehicle collisionInvestigation underway re non-reporting of incident

4/09/2015 317654374001 Vehicle impactLoaded coal truck impacted bund on side of haul road. Superficial injuries. Fatigue related incident.

4/09/2015 317654478001 Roof fall

4/09/2015 317654478001

4/09/2015 317654482001 Workshop injury

11/09/2015 317654635001

11/09/2015 317654681001 Electrical

11/09/2015 317654669001 Electrical

11/09/2015 31764695001Driver sustained mild electric shock

11/09/2015 317654703001 Mobile EquipmentLack of traction on ramps of low-loader and stockpiler

18/09/2015 317654793001 InjuryHand in line of fire when operating timber jack

A machine operator was found by a workmate pinned between a machine and the side wall of an underground extraction drive (tunnel) at the Ridgeway underground mine.

Investigation underway and a full report on the incident will be published at a later date.

A front-end loader reversed into a heavy vehicle road truck. Incident not reported to the Regulator

Roof fall between two fault systems that extended above the bolted zone at the intersection.

Transport management

An LHD was relocating a structure pod when it made contact with and caused damage to an energised 6.6kV high tension cable.

Grizzly bar assembly slipped from workshop bench while being repositioned and broke workers leg

Strata/ Ground Control

Strata failure resulting in 4000t of waste rock to enter a stope from the stope above

Fall caused windblast and area remains off limits pending further investigation

Electrical fire on a water cart. Possible crushing of an electrical harness during installation of a new cab

Fault in assembly, wiring pinched by putting cab on top. Full investigation being conducted offsite

Fire in the cooler room of an excavator. Preliminary visual inspection suggests starter motor terminal block as the source

Auto electrical audit of the mines mobile fleet commenced


A drilling machine made contact with 22kV overhead power lines while being driven. The mask on the drill rig was upright at the time

A stockpiler slipped from ramps and rolled onto its side during unloading from a low-loader

Underground operator’s hand severely crushed by timber jack on rib bolter


18/09/2015 317654795001 Mobile EquipmentOngoing investigation

18/09/2015 317654775001 Mobile EquipmentInvestigation report and review of SWMS pending

18/09/2015 317654827001 Mobile EquipmentInvestigation being conducted

18/09/2015 317654930001 Explosives

18/09/2015 317654934001 Mobile EquipmentUnder investigation

25/09/2015 317655036001 Mech Equipment

Failure to comply with site communication procedures

25/09/2015 317655056001

Roof fall of an intersection which was previously bolted

25/09/2015 317655054001 Gas

25/09/2015 317655084001 Electrical EnergyDump truck struck overhead power lines Dump truck alarm inadequate for elevated tipping body

25/09/2015 317655122001 Electrical Energy

LHD with loaded bucket of stone collided with a parked LHD loaded with a roll of conveyor belt

Mini-excavator toppled over when descending an earth mound

Light vehicle rolled onto side after vehicle rode up onto the haul road bund whilst negotiating a corner.

Misfire - packaged presplit product found during post shot inspection

Investigation and testing to be conducted by supplier on presplit product to determine root cause of failure

Grader operator drove plant into side wall of haulage ramp

Dozer operator’s two-way radio failed when a dump truck was asked to reverse to a dump a load of coal, this lead to the loss of positive communication. Operator failed to maintain the required safe distance between vehicles operating on the ROM as per procedure


Investigation to be conducted as to the cause of roof failure. Bore scopes to be installed in other panel intersections as part of the investigation to determine strata control process

Ignition of flammable gas at the roof of a continuous miner operating the production face

Reduced seam height and failure to follow frictional ignition procedures

A generator supplying a pug mill processing area caught fire. It appears the cable insulation was degraded and had sustained damage, possibly allowing water to enter and provide a conductive path and ignition point. Electrical maintenance procedures are to be reviewed

Operator is reviewing and updating maintenance and inspection procedures for generators on site. Third party investigation report completed


25/09/2015 317655088001 Gas

25/09/2015 317655094001 Injury

2/10/2015 317655618001 Explosion Fire

2/10/2015 317655270001 Gas



9/10/2015 317655628001Fall of roof at 410 metre mark - Failure of roof supports

Goaf fall resulted in uncontrolled emission of high levels of methane into longwall

Prohibition notice issued to mine, prohibiting mining in longwall panel. Investigation into incident and action to comply with prohibition notice completed

A driller suffered a deep laceration to the palm of their hand when reinstalling the core barrel on a steeply inclined uphole

Drill rig stood down until cleared by inspector. Procedure for safe operation was reviewed. Incident under investigation

A 100MVA 132kV transformer and associated equipment was catastrophically damaged due to an explosion and subsequent fire in an electrical substation at a processing plant

Damage was contained to one transformer bay due to good substation design. Site was able to restore power and resume operations after the fire was contained. Investigation is ongoing

Gas outburst induced by shotfiring whilst grunching through a boggy zone adjacent to strike slip structure

Grunching is used as an alternate method of mining through identified outburst control zones. The actual outburst was triggered by the shock of the shotfiring. It would appear that the controls put in place to manage this risk were effective

Whilst in the process of flitting a continuous miner a supervisors was struck by the continuous miner cable that had become tight and then released. This resulted in the cap lamp cord being damaged when the supervisor was struck by the by falling cable

Review of systems of work need to include potential hazards associated with release of energy such as cables under tension

During the overhaul of an explosion protected electric motor sent to a repair facility by a mine, it was identified the motor was fitted with a aluminium fan that did not comply with its certification drawings

The mine has inspected similar motors in service for non-compliant fans, and submitted a non-compliance report to the motor manufacturer. The repair facility has also separately notified the Dept of the non-compliance in accordance with their licence conditions


Assess the total belt road for strata stability. Complete all identified secondary support requirements prior to recommissioning conveyor


9/10/2015 317655470001 Mech Equipment

9/10/2015 317655638001 Mech Equipment

9/10/2015 317655622001 Complaint

16/10/2015 317655726001 Mech Equipment

16/10/2015 317655706001 ExplosivesExplosives misfire underground

16/10/2015 317655718001 Mech Equipment

A rod mill charger cradle loaded with approx. 3 tonnes of grinding rods structurally failed and collapsed while an operator was attempting to move the cradle by manual handling methods. The rods spilled to the floor narrowly missing the operator

Inspection and maintenance procedures failed to identify significant corrosion, and additional faults, in the structure of the cradle.Operating procedures required manual handling of the cradle which placed the operator at risk. Motorisation to be considered by mine

While trying to replace a rod that had fallen out of the drilling rig carousel, a production driller was hit on the helmet & shoulder by a falling drill rod

Current practice to cease pending investigation. Mine to review drilling procedure and discuss potential engineering modifications with OEM

An allegation of bullying has been reported to the department

The mine has a policy on bullying. The department is investigating the allegation

Dozer was conducting clean-up on coal; the operator received a call on the two way radio and stopped at the edge of the bench for approx. 2 minutes. While stationary the coal edge under the right hand track started to give way. The coal edge continued to give way under the track and the dozer slid over the crest of the highwall. The dozer came to rest on its side against the material on the bench below.

Investigation of the incident is still ongoing however preliminary investigation results indicate that the coal on the highwall edge was soft. The dozer was working parallel to the edge

Incident review on site has initiated use of single rows of shots until TARP to deal with the varying nature of the dyke material is determined.

Release of fluid from Roof Support during maintenance. When the fitter removed the side shield hose staple from the hose fitting, the hose end released and struck the fitter. Hydraulic pressure was present in the side shield circuit

The tradesman was examined and it was determined there was no injury sustained. During minor overhaul of Longwall shields including the addition of a secondary isolation arrangement, an additional supply line from the interchock manifold into the shield was not identified. The controls in place, gap analysis, risk assessment, testing, and commissioning missed the hazard which was located in the canopy circuit. Investigation continuing.


16/10/2015 317655795001

16/10/2015

10/19/2015

23/10/2015 317655976001 Gas

23/10/2015 317655980001 Mobile Equipment


Mechanical Equipment/Injury

An operator jammed his forearm between the bottom of the timber jack and the drill head on a miner mounted rig whilst in the process of installing a roof bolt. The working environment was restricted by rib spall which did not allow the fitted rib protection to be extended away from the body of the continuous miner. The operator had difficulty in inserting the bolt into the previously drilled hole, and while attempting to line the bolt up with the hole the chemical cartridge has fallen from the hole. It appears the operator attempted to catch the falling cartridge jamming his forearm in the process.

The Mine is conducting a full investigation into this incident. There were no safety defects with the drill rig. The Mine had just commenced remote mining through a High Stress Zone and the ribs were not as clear as would have been the case if normal operations were being undertaken. The operator suffered swelling to the forearm and was kept overnight in hospital under observation

Prosecution Judgment

Judgment was handed down following prosecution for a fatality at Ravensworth Coal Preparation plant on 18 February 2009. A contract road haulage driver was killed by 10 tonnes of reject rock material falling onto and through the fibreglass roof of his truck cabin

The defendant pleaded guilty and was convicted and fined $80,000. A copy of the full judgment is available at: https://www.caselaw.nsw.gov.au/decision/561b3cffe4b0517a9728163f

On inspection of the drill rig a mining supervisor found off scale (>5%Ch4) methane on gas detector in cut through

All mines should review the adequacy of their documented arrangements for controlling the risk of methane liberation from unattended active drilling operations.

The tilt cylinder on a LHD suffered a catastrophic failure when the rod snapped just below the welded clevis

Owners of LHD machines need to have engineering means to prevent• A structural or mechanical failure of hydraulic cylinders, QDS, and link arms• Potential impact loads and other excessive loads which may initiate a structural crack or weak point.This is safety critical if the LHD is also used as a EWP. A safety bulletin will follow.

FLP isolation operator on flameproof enclosure was found missing

All coaltrams checked for similar issues. Correspondence to go out to all electrical trades. LHD external inspection system under review


23/10/2015 317656014001



23/10/2015 317656022001 Mobile Equipment

23/10/2015 317656143001 Strata control

23/10/2015 Investigation Report

30/10/2015 317656247001 Structural Failure

30/10/2015 317656283001 Explosives

30/10/2015 317656376001 Mech EquipmentApparent cause: unplanned movement of mill.

Strata/ Ground Control A strata failure in the drift resulted in the mine being

evacuated and all work stoppedAll Underground operations should regularly inspect strata support in drifts to maintain safe standards

Uncontrolled fire resulted in a water truck being destroyed. An electrical fire at a crimp fitting resulted in a hydraulic oil steering hose escalating the fire

Initial investigations indicate the fire was most likely caused by a short circuit in cabling to the starter motor. A Safety Alert will be released in the next 7 days

A worker received an electric shock whilst assisting with welding repairs to a chute. The worker was holding the steel wear-plate whilst it was being tack welded into position

Review the SWMS using AS1674.2 and take into account methods of holding and clamping the piece to be welded to ensure effective bonding of all metal, and that the people involved are insulated from the work pieces to be welded.

A rear dump truck had the front wheels start to lift off the ground as the truck was ascending and turning off the ramp. The incident was caused by a change in grade on the ramp that was due to roadway erosion. This caused the truck to drop back a gear. The load shifted causing the truck to sit on its end

Operators need to be aware of the actual ramp grades rather than the average grades and the impact that small grade changes can have on truck gearing, potentially leading to a similar event occurring

Fall of ground; approximately 5 tonnes fell from a wedge failure in the back of the main access decline. Travel pass fall area prohibited. Workers travelled to surface via second means of egress

Operators are reminded of the importance of conducting geotechnical assessments of all main travelways on a regular basis so that high risk areas can be identified and remedial work undertaken prior to a failure of strata

An investigation report into a double fatality at Austar Coal Mine on 15 April 2014 has been published Link to report: www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/incidents/investigation-reports

Build-up of product spillage from conveyor caused the roof to collapse on a storage shed

Operators should review and audit frequency and effectiveness of planned inspections and maintenance

Misfire of shot resulting in potentially 3-4 unfired holes in muck pile following reconnection and refiring

Failure of surface connection line – unknown if faulty product or unsecure connection (operator error) at this stage

Plant operator had fingers jammed in sliding door of mill

http://www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/incidents/investigation-reports


30/10/2015 317656745001 Other

6/11/2015 317656493001 Mech Equipment

6/11/2015 317656630001 Hazardous Materials

6/11/2015 317656558001 Work Environment



Suspected lightning strike on dump truck that was parked with tray up in maintenance area

The site conducted a 24 hour clearance of the area (as per industry standards), post incident the truck in question had no evidence of being contacted by a lightning strike. The site implemented their emergency and incident response processes as a precautionary measure

Rigid dump truck operator reported that a truck had shut down and the fire suppression system fitted to the truck had deployed automatically.The main positive battery cable from the isolator to the starter motor has rubbed through on a clamp attached to the radiator. The fire suppression activation tube was also secured to the radiator housing with a clamp that had no insulationAs a result, the battery voltage travelled through the path of the steel braid in the activation tube creating significant heat. This caused the fire suppression detection tube to fail and triggered the fire suppression system to dep

Cable/tubing routing and insulation should be assessed and installed according to best practiceRefer to MDG 15 Mobile and transportable equipment and AS/NZS 4871-6:2013 Electrical equipment for mines and quarries – Diesel powered machinery and ancillary equipment

Uncontrolled escape of CO2 gas from the fire protection system

The fire system was inadvertently activated and gas was released into the atmosphere due to a gas line fitting not being secured correctly. All personnel were able to exit the area

Operator installing cable bolts underground had cement grout sprayed in their eyes when the connection between the grout pump line and the cable fitter tube burst apartInadequate eye protection was worn (glasses rather than goggles).

Connection between grout pump line and cable fitter tube burst apartEstablish pre-emptive maintenance on high risk components rather than ‘run to failure’PPE standards should be enforced

Employee suffered laceration on a surface drill rig due to hand placement being incorrect.

Engineering changes to steel table to reduce risk of hand in wrong position

A live HT cable was struck by a bucket (duck’s bill) attached to a load haul dump (LHD).

Tight (narrow) location for the operation of the LHD with the duck’s bill. LHD operator was not aware that machine was in such close proximity to the cable.


6/11/2015 317656594001 Mech Equipment

6/11/2015 317656512001 Mech Equipment

6/11/2015 317656552001 Mech Equipment

6/11/2015 317656652001 Mech Equipment

13/11/2015 317656775001 Mech Equipment

13/11/2015 317656805001 Mech Equipment

Collision occurred between an excavator and a dozer while operating in close proximity to one another

Procedures for controlling the risk of collisions not complied with.Miscommunication between operators.Proximity devices in use, though may have failed

While operating a water truck, the operator saw a truck approaching and reversed backAs the road had no barrier (bunding) the truck rolled approximately 5-6m over an embankment

Haul roads should have bunding installed along their entire length.The mine ‘Roads or other vehicle operating areas’ plan should address vehicles passingTrucks must have a seat restraint fitted and it must be worn.Where a risk exists, trucks must have operator protective structures, so far as is reasonably practicable

Uncontrolled escape of pressurised hydraulic oil on apprentices whilst working on an excavator track tensioner accumulator.Excavator was isolated using main isolator valve. It was assumed the circuit was de-energised

Mines need to check isolation procedures of track tensioner systemsProvide correct procedures and drawings to people working on hydraulic systemsProvide appropriate supervision of apprentices.

Loader made contact with an 11kV cable in an underground mine

Sub-standard cable installation, poor signage, no physical protection, and limited appreciation of required installation and protection standard for electrical cables.

Dump truck front right side tyre failed on the inner side wall. The resulting air blast damaged adjacent engine sounds suppression panels and radiator guard.The tyre was damaged by the noise suppression engine bay door while the truck was in motion, the driver failed carry out a walk around inspection prior to driving the vehicle

Mines should ensure that pre inspection checks are carried. The design of the door such that it can rub on the tyre needs to be examined. There was no interlock on the door to prevent the truck moving unless the door is correctly closed

Haul truck was reversing to the tip head when contact was made with a dozer operating in same area

Both truck operator and dozer operator failed to check both sides of their machines before reversing.


13/11/2015 317656835001 Mech Equipment

13/11/2015 317656845001 Mech Equipment

13/11/2015 317656925001 Mech Equipment


First component of the hunting tooth limit switches came free from the shaft and caused the winder to trip on a mismatch with the PLC.

The hunting tooth counter had worn on the shaft and the key way, allowing the hunting tooth arrangement to come free from the shaft and therefore stop rotating. The caused a miss match between the hunting tooth and the encoder causing the winder to stop

Dozer operator was attempting to climb onto a bench via a ramp. The dozer slipped sideways towards the edge of the ramp on a band of hard coal and slid off the side of the ramp, coming to rest on its left hand side. The operator reported that the movement of the dozer on the hard coal caused the machine to move to the left tack spinning until it slid off the ramp

The operator reported that the movement of the dozer on the hard coal caused the machine to move to the left track spinning until it slid off the ramp.

Dozer operator was attempting to climb onto a bench via a ramp. The dozer slipped sideways towards the edge of the ramp on a band of hard coal and slid off the side of the ramp, coming to rest on its left hand side. The operator reported that the movement of the dozer on the hard coal caused the machine to move to the left tack spinning until it slid off the ramp.

The operator reported that the movement of the dozer on the hard coal caused the machine to move to the left track spinning until it slid off the ramp.

After checking the fluid levels on an Eimco a mine worker suffered a serious injury when he fell whilst alighting from the top rear of the machine. As the mine worker alighted he placed a foot on the tow hitch pin. The hitch pin pivoted underfoot causing the mine worker to fall to the ground. The rear of the Eimco was fitted with two grab handles positioned on the top part of the machine. It was not possible to retain a grip on these grab handles whilst placing a foot on the ground.

Mine operators and equipment manufacturers are advised that they should ensure that mobile plant is designed so as to allow mine workers to maintain three points of contact whilst alighting from the plant.


20/11/2015 317657060001 Gas

20/11/2015 317657070001

20/11/2015 317657054001 Strata control

20/11/2015 317656476001

Methane (CH4) concentrations exceeded 2.5% in various areas of underground mine due to a loss of total ventilation for approximately 11 hours and a partial loss of ventilation for approximately a further 5 hours. An extreme storm event caused an external failure of power to site and the loss of an 11kV aerial on site

Mines should ensure that their documented procedures adequately control the risks associated with re-powering operations after extended power outages, caused by events which are outside of the control of the Operator


A roof fall was found during a pre-shift inspection by a mining official. The fall occurred in a part of the mine that has had access restricted to only inspections. The mine has organised for a full geotechnical inspection of the area and has employed additional labour to carry out remedial work.

Mines should assess the appropriate frequency of geotechnical inspections in older areas of the mine that have little or no strata monitoring in place and consider installing monitoring in those areas.

Dozer pushing clay material over a multi-level high wall, with catch benches, to seal old underground workings. The dozer was pushing a large rock over the high wall, lost traction and was unable to reverse. The Dozer operator decided to run down the rill to the catch bench, however, the dozer got caught by a protruding rock ledge stranding the dozer at a precarious angle. The operator was able to exit the dozer safely

Mines should review their procedures and training associated with pushing material over high walls and consider the use of spotters when in high risk situations


An excavator operator dislodged a wedge of material from the high wall face in a large open cut mine while scaling the high wall. The operator moved the excavator away from the high wall and the supervisor was notified. Soon afterwards an estimated 1000t of material fell from a wedge failure across 3 benches. Mining activities were stopped and pit was evacuated. The area was barricaded and detailed investigation commenced. The wedge structure had not been identified prior to the failure

Operators are reminded of the importance of conducting detailed and comprehensive geotechnical mapping, inspections, monitoring and modelling of high walls. Also, implementing an effective Ground Control Management Plan and associated safe work procedures that include immediate withdrawal from the area should a fall of ground be suspected


27/11/2015 317657252001 Mech Equipment

27/11/2015 317657248001 Gas

27/11/2015 317657262001 Gas


4/12/2015 317657312001 Mech Equipment

4/12/2015 317657362001 Mech Equipment

In service failure of SMV park brake due to poor adjustment

Review park brake testing and schedule for park brake maintenance.

During the continuous miner underground operations, a methane gas frictional ignition occurred. While completing the final cutting cycle, trimming 300mm of coal tops from the roof, a gas blower was exposed when the cutter head picks came in contact with the stone roof. This resulted in a small flame emitting from the upper right hand side of the working face.

Mine operators are reminded of the need to prevent frictional ignitions occurring during cutting cycles. The primary controls for these include adequate face ventilation and the prevention of sparking via horizon control, sprays, pick selection etc. Mine operators working under immediate conglomerate roof should also consider mounting first aid fire hoses on all continuous miners

Loss of main ventilation system (back up surface diesel fan failed to start). LW E6 monitor detected up 3.97% CH4 max.

Men were withdrawn as per withdrawal procedures. Ensure that backup power supplies are maintained to a high standard to ensure reliability

A grid power supply fault caused power underground to be lost. Only exit from mine was to walk up drifts.

Consider back up power supplies for emergency man winding systems.

Uncontrolled escape of a pressurised substance resulting in an injury to a worker while undertaking planned pressure testing of pipeline. Mine worker was hit in the leg by the pipe connection manifold

Ensure there is a plan in place that considers potential for failure during pressure testing and covers line of fire and safe positioning of workers.

A truck and dog combination was involved in an unplanned movement while the driver was attending to some paperwork in the office. The vehicle had been parked with the engine running and only the trailer brakes applied. The downhill slope where it was parked was enough to induce movement and it ran away through a fence coming to rest in a paddock some 200m away. The driver suffered a thigh strain in an attempt to chase the vehicle down.

Mine operators should review the ‘roads or other vehicle operating areas’ Principal Mining Hazard Management Plan to ensure that risks associated with parked vehicles and mobile equipment are identified and controlled effectively.Controls may include, but are not limited to, clearly designated parking areas, signage, stop blocks, constructed parking stop blocks, berms or dips


4/12/2015 317657340001 Mech Equipment

4/12/2015 317657350001 Gas

4/12/2015 317657346001 Other



Light vehicle made contact with haul road centre divider island resulting in vehicle rolling 90 degrees onto its left side

This incident highlights the need for operators of all mobile plant to ensure that they are not distracted from their task of controlling such plant

A ventilation change resulted in a reduction of air quantity causing CH4 concentrations to rise. Methane (CH4) concentrations exceeded 2.5% with a maximum of 2.8% detected. A further ventilation change was conducted to adequately ventilate the area

Mine operators should assess the adequacy of their documented procedures to meet the requirements of Clause 61 WHS (Mines) Regulation 2014

While stepping through the drawbar of a lighting plant, the operator lost their footing and fell. Their left leg was caught in the drawbar and took the load of their bodyweight. As a consequence they suffered a broken femur. The operator was short cutting a path back to the light vehicle via the drawbar of the lighting plant

The industry should advise workers of the incident and the banning of crossing to the light vehicle across the drawbar of the lighting plant/trailer. Engineering controls will be considered such as meshing of the drawbar area

An excavator boom came in contact with 11,000kva overhead powerlines, causing the power to trip. While tramming the excavator from the quarry to the workshop, the operator did not notice the overhead power lines across the road

Access to high voltage power lines should be restricted. If travelling under power lines they must be identified by signage, specifying the voltage and minimum clearance.If working near power lines a documented risk assessment must be carried out before any work commences, in consultation with all relevant parties involved in the work and any code of practice.

A slab of concentrate build up on a structural beam in the concentrator dislodged and fell approx. 5 metres to the ground. No injury resulted. The slab was estimated to weigh approximately 20kg. The concentrate built up over a significant time from process overflows. The area was immediately made safe and inspections conducted for other related hazards

Mines should review planned inspection programs to ensure build-up of solids from spilt or overflowed material is identified and eliminated.


4/12/2015 317657410001 Mech Equipment

11/12/2015 31765706001 Mech Equipment

11/12/2015 317657596001 Mech EquipmentFailure of swaged joint under air pressure.


11/12/2015 317657550001 Mech Equipment

Fire in the engine bar area of water cart. The investigation concluded that an electrical harness has fallen from its retaining brackets and contacted hot components on the engine, causing the plastic and surrounding sound proofing material to ignite.

Review introduction to site process for all items of plant. Complete inspection of all segregation of cabling and hoses on all mobile and transportable equipment. Complete inspection of fit for purpose protection on all engine components. Document all inspections. Review all fire risk assessments to verify fit for purpose. Sound attenuation materials are used

Failure of a towing chain on a cable tower that resulted in a broken chain link striking a person

Towing chains should meet applicable Australian Standards and a tow ring should be provided on each tow chain set.For more information on towing chains see Safety Bulletin SB09-03 Broken pull chain results in fatality

See Safety Alert published 17 Dec 2015 – SA15-08 Worker seriously injured when pipe failed pressure test

Smoke observed coming from diesel motor of a pugmill. It appears electrical wiring off the starter motor overheated and burnt off the terminal, causing damage to the cable, split conduit and adjacent cables

Mine operators need to ensure that plant maintenance activities are appropriate for the type of plant, the environment in which it works and the duty cycle of the plant.

A drill rig reversed into a service truck that was about to commence refuelling, pushing the truck approximately one meter to the side

Plant operators need to use positive communication when in close proximity to other mobile equipment

WEEKLY INCIDENT SUMMARYWeek Ending Id number Incident type

1/01/2016 317657693001 Mech Equipment

1/01/2016 317657676001 Mech Equipment

1/01/2016 317657777001 Mech Equipment


1/01/2016 317657883001 Mech Equipment

8/01/2016 317657964001 Mech Equipment



8/01/2016 317657990001 Gas

8/01/2016 317657998001 Gas




15/01/2016 317658120001

15/01/2016 317658080001 Gas



15/01/2016 317658102001

15/01/2016 317658086001 Mech Equipment


15/01/2016 317658138001 Mech Equipment

22/01/2016 317658247001 Mech Equipment



22/01/2016 317658173001 Mech Equipment

22/01/2016 317658227001 Mech Equipment

22/01/2016 317658241001 Mech Equipment

22/01/2016 317658165001 Explosives

29/01/2016 317658323001 Gas

29/01/2016 317658358001 Mech Equipment

29/01/2016 317658289001 Mech Equipment



5/02/2016 317658511001

5/02/2016 317658519001 Mech Equipment





5/02/2016 317658505001 Mech Equipment

5/02/2016 317658529001 Mech Equipment

5/02/2016 317658595001 Mech Equipment

5/02/2016 317658579001

5/02/2016 317658581001 Mech Equipment

12/02/2016 317658643001 Mech Equipment

Mechanical Equipment/Injury


12/02/2016 317658700001 Mech Equipment

12/02/2016 317658696001 Gas


19/02/2016 317658890001 Mech Equipment

19/02/2016 317658337001

19/02/2016 317658806001 Mech Equipment

19/02/2016 317658842001 Mech Equipment





26/02/2016 317659091001 Mech Equipment


26/02/2016 317658914001 Mech Equipment




4/03/2016 317659184001 Mech Equipment

4/03/2016 317659162001 Mech Equipment


4/03/2016 317659125001 Explosives



4/03/2016 317659294001 Strata/ Ground Control


4/03/2016 317659273001 Mech Equipment

4/03/2016 317659238001 Mech Equipment

4/03/2016 317659182001 Mech Equipment


4/03/2016 numerous Electrical Energy

11/03/2016 317659170001 Gas

11/03/2016 317659166001 Gas

11/03/2016 317659164001 Gas

11/03/2016 317659067001 Complaint






11/03/2016 317659513001 Mech Equipment


11/03/2016 317659525001 Mech Equipment

11/03/2016 317659537001 Mech Equipment



18/03/2016 317659613001 Mech Equipment

18/03/2016 317659635001 Mech Equipment

18/03/2016 317659663001 Explosives

18/03/2016 317659687001 Mech Equipment

18/03/2016 317659661001 Mech Equipment

18/03/2016 317659669001

18/03/2016 317659599001 Mech Equipment



18/03/2016 317659712001 Mech Equipment

18/03/2016 317659190001





25/03/2016 317659846001 Explosives


1/04/2016 317660010001 Mech Equipment


1/04/2016 317660000001

1/04/2016 317659996001 Mech Equipment

1/04/2016 317660049001 Mech Equipment



8/04/2016 317660115001 Mech Equipment



8/04/2016 317660184001 Mech Equipment

8/04/2016 317660150001 Mech Equipment


8/04/2016 317660097001 Mech Equipment

8/04/2016 317660142001



15/04/2016 317660258001 Mech Equipment


15/04/2016 317660300001 Mech Equipment

15/04/2016 317660324001 Mech Equipment


22/04/2016 317660391001 Mech Equipment

22/04/2016 317660377001 Other


22/04/2016 317660406001 Mech Equipment

22/04/2016 317660452001 Mech Equipment


22/04/2016 317660404001 Mech Equipment

22/04/2016 317660504001 Mech Equipment

22/04/2016 317660466001 Mech Equipment

22/04/2016 317660478001 Mech Equipment

22/04/2016 317660517001 Mech Equipment


22/04/2016 317660075001 Explosives

22/04/2016 317660130001 Mech Equipment

29/04/2016 Electrical Energy

29/04/2016 Explosives

29/04/2016 Work Environment

29/04/2016 Explosives


29/04/2016 Mech Equipment


6/05/2016 317660704001 Explosives

6/05/2016 317660767001


6/05/2016 317660817001 Injury


13/05/2016 317660899001 Fire

13/05/2016 317660905001 Mech Equipment

13/05/2016 317660930001

13/05/2016 317660928001 Complaint

13/05/2016 317660950001 Loss of Control

20/05/2016 317660962001 Fall

20/05/2016 317660980001 Loss of Control

Escape of pressurised fluid

20/05/2016 31766090001

20/05/2016 317660982001

20/05/2016 317661063001 Fall

20/05/2016 317661020001


20/05/2016 317661057001 Collision

Unplanned Movement

Unplanned Movement

Unplanned Movement

27/05/2016 317661091001

27/05/2016 317661135001 Collision

27/05/2016 Fatality

3/06/2016 317661226001 Incident type


Unplanned Movement


3/06/2016 317661222001 Mech Equipment



3/06/2016 317661319001 Mech Equipment

3/06/2016 317661315001 Mech Equipment

3/06/2016 317661327001






10/06/2016 317661367001 Mech Equipment

10/06/2016 317661361001 Mech Equipment

10/06/2016 317661435001 Mech Equipment

10/06/2016 317661421001 Complaint


10/06/2016 Various events Electrical Energy


17/06/2016 317661584001

17/06/2016 317661507001 Fall



17/06/2016 317661521001 Mech Equipment

17/06/2016 317661557001

24/06/2016 Various events Mech Equipment

24/06/2016 317661670001 Mech Equipment



1/07/2016 317661639001

20/07/2016 SinNot 2016/0031 Dangerous Incident


20/07/2016 SinNot 2016/00027 Serious Injury

20/07/2016

SinNot 2016/0026

Dangerous Incident

20/07/2016 SinNot 2016/00022 Incident type





27/07/2016 SinNot2016/0050 Dangerous Incident


27/07/2016 SinNot 2016/069 High Potential Incident



27/07/2016 SinNot 2016/0080 Incident type




3/08/2016 SinNot 2016/0090 Medical Treatment Injury



3/08/2016 SinNot 2016/0121


3/08/2016 SinNot 2016/00082


10/08/2016 SinNot 2016/0157 Explosives

10/08/2016 SinNot 2016/0141 Complaint

High Potential Incident




10/08/2016 SinNot 2016/0149 Explosives


17/08/2016 SInNot 2016/00170 Dangerous Incident

17/08/2016 SInNot 2016/00192 Serious Injury

31/08/2016 SinNot 2016/0287





7/09/2016 SinNot 2016/0318


Medical Treatment Injury

14/09/2016 SInNot 2016/0358 Explosives


14/09/2016 SInNot 2016/0346


21/09/2016 SInNot 2016/00399 Complaint



21/09/2016 SinNot 2016/00379









12/10/2016 SInNot 2016/00487 High Potential Incident

12/10/2016 SinNot 2016/00482





12/10/2016 SinNot-2016/00506 Dangerous Incident

12/10/2016 SinNot-2016/00498 Dangerous Incident

19/10/2016 SInNot 2016/00545






26/10/2016 SInNot 2016/00590

26/10/2016 SInNot 2016/00625





2/11/2016 SInNot 2016/00645





16/11/2016 SInNot 2016/00756



23/11/2016 SInNot 2016/00786 Fatality


23/11/2016 SInNot 2016/00787

23/11/2016 SInNot 2016/00785





30/11/2016 SInNot 2016/00849

30/11/2016 SInNot 2016/00832




7/12/2016 SInNot 2016/00887

7/12/2016 SInNot 2016/00885






21/12/2016 SInNot 2016/00992 Serious Incident


21/12/2016 SinNot 2016/00974



21/12/2016 SInNot 2016/00970 High Potential Incident

WEEKLY INCIDENT SUMMARYSummary

Water truck with tub full of water rolled over whilst descending minor ramp.

Conveyor pulley falls from skyline conveyor. Preliminary investigation indicates the pulley bearing auto grease hose was not installed correctly causing the pulley bearing to fail and collapse

The bucket of a front end loader impacted with the cabin of a gravel truck whilst loading when the loader toppled over.The loader was working across a slight slope and was partially articulated while discharged into the truck

Starter motor failed causing a direct earth to short. Resulting fire in engine was extinguished by operator

Operator noticed timberjack lowering whilst attempting to drill a hole for roof bolt even though the timberjack ‘down’ function had not been activated

The maintainer was assigned the task to test the air intake system for the engine of a truck for leaks. During the task the maintainer noticed that the blanking assembly that was clamped over the intake pipe, and supplies air for the test, was starting to move off the pipe. The maintainer went to disconnect the hose from the end of the blanking assembly and at the moment he grabbed the fitting to disconnect the airline, the blanking assembly moved entirely off the pipe and contacted his hand

Damaged crib and toilet facility due to severe storm event

A 20 tonne excavator was being used to position a section of poly pipe in preparation for welding. After the pipe had been positioned, the pump operator approached the stationary excavator to unhook the chain that allowed for the pipe to be lifted by the excavator. The chain and excavator position was approximately 10m from the end of the piece of pipe. When the pump operator unhooked the chain, he let it fall to the ground, but it hooked on another section of the chain, which was not noticed by him or the excavator operator. The pumper operator turned and was walking back along the pipe away from the excavator when he was struck in the left leg by the moving pipe, as the excavator started to slew in preparation to move to another area

A number of notifications for methane levels greater than 2.5% by volume have been reported from underground coal mine operations


A lime plant attendant left the cabin of the articulated truck he was driving to collect some samples from the hydration plant. While he was out of the cabin the truck rolled backwards for a distance of approximately 100 metres and collided with the plant maintenance toilet block, causing extensive damage to the building and minor damage to the truck. The truck came to rest in a low point in front of the toilet block. No one was injured

A mechanical maintainer had completed a service on a generator. Upon trying to restart the generator the battery exploded

An arcing fault in the motor control enclosure of an air compressor caused the supply circuit breaker to trip on short circuit. The fault caused the main enclosure door to open under the force of the arc blast

Material from a highwall failure striking the left hand side of a dozer.


Complaint about the risk of access and exit to and from site onto the main road

During mining operations an excavator was removing waste on the northern side when a section of wall on the east side of the excavator failed and contacted the excavator on the off side of the operator’s cabin.

Cylinder rod from the stick assembly of an excavator was ejected from the cylinder barrel during removal for maintenance. The rod fell to the ground and contacted the wheel assembly of the crane being used for the task. *Cl.179(a)(v) - cylinder rod falling from excavator and Cl.179(a)(xv) - cylinder rod contacting crane wheel*.

An electrical worker reported receiving an electric shock while inserting an energised plug into an earth leakage relay. The issue of 'live testing / work' is to be investigated

A truck presented to the dump where a dozer was tending. The truck operator was unsure where to dump the load based on initial communication from the dozer operator and stopped to gain further instructions. The dozer operator believed the truck had passed behind and backed away from the face to start his next push, backing into Pos. 3 tyre on the truck. The tyre was punctured and the rapid deflation cracked the rear window of the dozer.

At approximately 14:25pm a contractors truck operated by the contractors employee arrived onsite to deliver parts to the store. The operator brought the truck to a stop at the front entrance of the store and alighted from the vehicle.Security camera footage shows the vehicle starts rolling backwards as soon as the employee alights.The truck continues rolling backwards (unmanned) past the service area turning upgrade coming to a stop for a short period.It then starts rolling forward (down grade) past the services vehicle area along the mine access route and past the M&M drift entry portal striking the wash down bay highwall protection concrete barrier adjacent to mine portal entry. No injuries

Longwall shearer remote missing from remote cradle. Remote left on longwall by night shift near bretby tray. Remote placed in the holder. Shearer 103 and cleaning work area during down time, noticed that remote was missing from holder.

A scraper rolled over while creating a bund close to the crest edge of a tailings dam wall under construction

The driver of a purpose-built underground transport bus lost control of his vehicle while travelling underground, rolling onto its side. The driver and thirteen passengers were extricated by emergency response personnel, with three occupants being taken to hospital for minor cuts and abrasions. The remaining occupants were treated on site by mine paramedics.

The 4" compressed air steel pipe line that supplies air to the fuel filling station was opened to atmosphere to drain off condensation and as a result the pipe tilted itself back spraying the operator in the face with compressed air and condensation, blowing his glasses and hard hat off.

Breach of blasting exclusion zone by a shotfirer during the firing of a production and trim blast in an open pitNo injury.

A number of notifications for methane levels greater than 2.5% by volume have been reported from underground coal mine operations.

SMV collided with water pump out line - Operator misjudged distance from off side of vehicle to pipe range.

Front end loader backed into a parked utility. Operator could not see the vehicle due to the articulated position.

Small heating and smouldering of material at a conveyor tripper drive when a rib bolt from longwall was caught in transfer.

An underground loader collided with two parked light vehicles. Positive communication between operators was not established, rather assumed.No injuries sustained yet significant damage to property.

Failure of strata support system resulting in a fall from height of bolt hardware - Bending moment on beam sufficient to cause tab failure and tensile/shear failure of roof bolts and cables pinning the beam.

Haul truck reversed through the windrow at the dump. The operator reversed at an angle to the windrow, the windrow was not constructed to the design height and was constructed of poor quality material.

Electric shock in mechanical surface workshop while adjusting operating crane chains.

An instrument transformer (VT) exploded approximately 20 minutes after being energised during initial commissioning. The VT was installed on a 22 kV pole top circuit recloser and as a result of the failure distributed ceramic pieces of VT insulator up to 20 metres from the pole.

A tradesman was using the workshop overhead crane to move electro-hydraulic rig idler. It appears as though the track idler fell, the tradesman tried to catch it which resulted in his finger being caught between the idler and a bracket.

During the course of maintenance activities the owner of a quarry has fallen off a mobile screen to the ground where he has sustained a broken collar bone, fractured ribs and a punctured lung.

During a planned maintenance task on an overhead monorail, the operator was moving the trolley on the beam manually using the chain while standing on a walkway behind some guard railing. Without warning the trolley fell from the beam onto some pipework below and came to rest near the operator.

A loss of load in the men and materials drift - failed load retention chain

An operator fell while getting down from an articulated dump truck that was positioned on a low loader trailer, suffering a serious head injury as a result.

While operating the left hand side drill rig the hydraulic oil supply to the rotation unit on the drill rig failed. Hose burst protection was in place and the failed hose released hydraulic oil that was defused (at lower pressure) before making contact with an operator of the drill rig.

Flames and smoke were seen coming out of the retard resistor grill on a rear dump truck. The resistor bank failed with fire consuming insulation on wiring.

Employee received a reported electric shock whilst using a magnetic drill to install a cover plate on a hydrator mixer – possible faulty drill or base. Investigation ongoing.

A night shift operator parked his 240T excavator beside an identical machine to swap units. He was then called away. He returned about 3 hours later and, having changed his plan, accidentally slewed the bucket into the other excavator resulting in significant damage to the engine compartment and fire suppression system

A number of notifications for methane levels greater than 2.0% by volume have been reported from underground coal mine operations.

A longhole production drill was drilling upholes when the drill broke through on the level above in proximity to mobile plant and personnel. The daily work plan had been changed and procedural failure meant the breakthrough area had not been isolated nor advised to the driller - who expected to breakthrough into an open stope. This led to crews being unaware of the hazard.

A work-over crew were engaged in pulling tubing out of a hole. When the driller applied the draw works brake to stop hoisting, a critical pillow block in the brake linkage system failed and the brake was released. The travelling block and elevators descended until arrested by the tubing tong, with the travelling blocks then leaning over and resting on the V-Door. The crew evacuated the work floor safely. The driller did not hit the emergency shut-down device (ESD) which would have engaged the draw works brake and stopped descent of the travelling blocks.

A worker working on a rock filled stope floor was preparing to bore a rib pillar with a jumbo - to enlarge a breakthrough and create a tip head to fill the adjacent stope.On hearing rocks rilling in the adjacent stope he withdrew and turned off the water hose spraying onto the rock fill. On return he saw that the rock fill had slumped beneath the jumbo.During filling of the stope the rock fill had flowed through a window/void into the adjacent empty stope. This created a rill that blocked the window/void and contained the rock fill within the filled stope.Further ore was fired in the empty stope and removed by tele-remote loading which disturbed the rock rill from the adjacent stope and exposed the window/void between the stopes.The application of water appears to have mobilised the fill at the exposed window/void, leading to the slump in the stope.

A worker was in the basket of an elevating work platform at the brow of an open stope. He was checking up-holes prior to charging.A ‘hang-up’ of broken ore material in the stope rilled (slumped down). The material ran over/through the top of the drawpoint safety bund but did not come into contact with the basket or a second worker, who was standing behind a pre-determined 5m safety demarcation line.

The operator of a rear dump truck lost control as the truck was being driven down a ramp, this resulted in the truck sliding approximately 80m impacting the left hand side embankment of the ramp. Excessive truck speed on the ramp in conjunction with a wet, slippery road surface, may have contributed to the incident.

A newly completed cable joint in a PVC junction box caught fire shortly after commissioning.

An electrical fault in the surface 11kv power correction building caused a small fire. A hot joint on a contactor appears to have been the cause.

A operator reported an electric shock through his hands when touching the frame of a continuous miner with one hand & rib mesh with the other hand. Production activities were occurring at the timeA cutter motor cable was found to be damaged.

Two operators had opened the 380 kg door to a cast metal rock box on the inlet to a dredge slurry pump. The hinges on the door suddenly failed and the door fell from the rock box and struck an operator's hand. The hinge design and the procedure for rock box operation were not revised when the original fabricated steel rock box was replaced with the much heavier cast metal rock box

An operator was working beneath a cyanide solution ring main located high within the processing plant. He felt a liquid spray lightly onto his face. As he was in a designated cyanide area he immediately washed his face with water but did not use the safety eye wash station – use of which will trigger an alarm. On close inspection a pin hole in a weld on the cyanide solution ring main was found. The operator has not suffered any adverse symptoms or observable reactions.

When the dozer was cleaning the dig face at excavator, a rear dump truck approached the dig face and then queued 30m from the dig face ready to reverse into the loading bay. The truck operator heard two horn signals and commenced reversing the truck towards the dig face, with the assumption that the two horn signals meant that the dozer had left the area. The dozer was still doing work in the loading bay. The truck contacted the dozer. The position 6 tyre was cut by the fire suppression bracket on the dozer causing the tyre to deflate. The pressure release caused the RHS dozer cab window to shatter.

Cable fell from the roof roller and struck employee on the head and neck

While driving a load haul dump vehicle the driver came into contact with a broken W Strap roof support.

Complaint about safety and planning matters at a small quarry.

Worker’s arm jammed in conveyor lifting device. The device was able to be raised beyond full extend allowing the drive spindle to disengage from the screw block and the unit to collapse.

A contract operator was using a mini excavator and tip truck to remove build-up from under a conveyor. The conveyor and associated stacker was isolated. The reclaimer on the adjacent stockpile was auto-relocated, in the process of relocating the reclaimer made contact with the tip truck.

400gm Booster was noticed missing during shotfiring.

Arc fault on drift conveyor motor on start up after maintenance activities.

66kV power CT catastrophically failed in a surface substation of an underground mine. The CT was an oil filled hairpin style. The explosion resulted in debris being ejected in a 360 degree radius with a significant quantity of the shattered ceramic material landing up to 50m away in a car park were people were present.

An allegation of bullying received from a current worker (operator) at a mine. The worker alleges being bullied by three supervisors and managers

Dozer levelling coal on product stockpile. Dozer tilted to the left when travelling over suspected void on stockpile.

A single 100mm diameter rock fell a vertical distance of approx. 15m onto a lower bench from rill material used to construct an open pit haul ramp windrow. The final position of the rock was 1 metre short of a person who was dipping production holes. No injuries.

The work basket of an underground utility vehicle contacted a parked broken down light vehicle when it moved from a parked position and attempted to drive past it in an underground metal mine. Minimal damage.

Workers waiting at an underground shaft plat heard an object fall down the shaft. The plat doors at the surface are operated by pneumatic cylinders mounted in trunnion brackets. The bolts securing a trunnion bracket failed (evidence indicates failure over a period of time) and the bracket fell down the shaft. No damage in the shaft.

The operator of a front end loader travelling up the main decline of an underground metalliferous mine spotted a truck travelling down the decline. The loader was then driven into a nearby drive to allow the truck to pass and contacted a parked light vehicle. The light vehicle was pushed into a parked telehandler and a fitter had to move quickly to avoid injury. The loader turned into the drive without visual or radio confirmation that it was clear to do so. The dedicated decline radio channel was not being used by the loader operator at the time. No injuries. Significant damage to the light vehicle.

A Contract Ecologist was monitoring bulldozer tree clearing operations from behind the work front at a distance of 50mtrs. Whilst standing in an understory cleared zone a tree branch fell to the ground in close proximity. It appears that the tree branch may have been impacted by other trees being cleared as part of the understory clearing works

Four incidents of damage to cap lamp cords were reported. These resulted from cords being damaged in vehicle doors, caught on broken mesh or snagged on equipment.

General body methane (CH4) concentrations in the main headings exceeded 2.0% for an extended period of time after an unplanned closure of a man door.

General body methane (CH4) concentrations in the longwall tailgate exceeded 2.0% for an extended period of time during preparation for final sealing of the roadway when ventilation was restricted to the area.

General body methane (CH4) concentrations in main headings exceeded 2.0% for an extended period of time during a main ventilation failure caused by a 66kV incoming supply trip

Complaint received via telephone in relation to Work Health and Safety issues at a mine site. The complaint was responded to by the Department.

Wash pad attendant lost balance whilst ascending Dozer.

A former mine employee has made a complaint in relation to an incident that was not reported to the Regulator and resulted in injury.

Complaint and request for information sought by mine employee in reference to Prohibition Notice served on a Mine Operator.

Whilst in the process of turning off a sump mucker, the operator rested his left hand on the control box and received a suspected electrical shock. This plant had NER centre tapped 110 volt controls with no protection tripping device on remote operators in very wet conditions

A complaint received from a current worker at a mine in relation to various safety matters including pit access, road conditions, working in confined spaces, fatigue management and hazardous substances and compliance with relevant legislation.

An excavator was cleaning out a drain when the ground it was on gave way causing excavator to slip to a 45 degree angle. The excavator was standing 3m off the drain. It was expected that the excavator would be cleaning 1m to solid ground however it was over 3m.

A mobile maintenance fitter received an electric shock while using a caddy arc welder. The welding hand piece was damaged, he was wearing damp clothing and kneeling on the wet metal of the bucket.

An ‘on highway’ type water cart travelling fully loaded down a decline into an underground mine experienced partial failure of the braking system. The operator applied the ‘Jacobs’ engine brake and the service brakes. However, the braking systems were not adjusted correctly and were unable to stop the truck. The truck was turned onto a level drive and was then stopped with the service brakes.

While dumping on a stockpile at night one rear wheel mounted previously dumped material causing the tub on the 6 wheel articulated truck to roll on its side. The cab remained upright.

A third-party complaint was received in relation to a number of matters at a mine site including safety standards, management of dust and airborne contaminants and provision of PPE

On the completion of engine bay live test inspections an equipment inspector attempted to move position on the left hand track of a dozer. While transitioning his stance he has fallen onto the push arm landing on the ground outside of the machines footprint.

A fitter was attempting to rotate a crusher drum using a steel bar. The fitter had one leg (right) off the ground, positioned on the crusher, with the other (left) on the ground.As the crusher drum started to rotate, the fitter’s weight went from being placed on the front leg (right) to the back leg (left). As the weight went onto the left leg the fitter felt his left knee give way, followed by pain. The fitter fell to the floorThe fitter was taken to hospital, where x-rays identified a dislocated and fractured (L) patella, and a fractured (L) distal tibia.

The cabin of a 30t articulated truck rolled over during reversing action to tip the load.

A pyromex booster was found while digging the interburden to the coal seam. Some detonation cord had been noticed in the area prior to the booster being located.

A fitter suffered a crush injury to his little and ring fingers resulting in fractures and stitches while he was reinstalling a diesel particulate filter on a bogger. The filter slipped on its sling and struck the fingers against the frame of the machine. He was taken to hospital where he underwent surgery.

A loader slipped sideways pushing through bund and tip ramp

A slip of material (approx. 10,000 bcm) from the wall of an open cut mine. This occurred in an area of previously identified poor/weak ground conditions. The area was being monitored and no people were working in the open cut at the time of failure.

A fire on a dump truck retard braking system – collapse of resistor grids resulted in electrical insulation burning.

A low voltage electric shock occurred following the placement of 1000l oil cubes against 240V outlets. A battery charger unit lead was squashed by the metal frame of the cube.

A operator parked a light vehicle and went to get a dozer to prepare a pad. When returning with the dozer he struck the light vehicle and pushed it around 5 metres.

Approximately 5 tonnes of rock and shotcrete fell onto, and around, the boom of a cable-bolting machine when it commenced grouting 12 cable holes that had been drilled the previous shift. This incident occurred in an underground metalliferous mine in the main decline. The fallen material included steel mesh and resin grouted rock bolts that had been installed when the decline was first developed some 2 years previously. No injuries and minimal damage. The investigation revealed incomplete encapsulation of bolts and a time delay in cable bolt installation after the need for installation of cables was identified.

Safety complaint regarding lack of fencing and accessible steep decline between land owner and mine site

Shuttle car cable damaged when outrigger made contact with the rib. The shuttle car was dumping coal in a cut-through at the time of the incident.

Operator slipped off the bolting platform on a continuous miner and injured ankle

Low voltage electric shock to two people occurred after coming into contact with an exposed wire on a lighting cable.

An investigation was conducted at a mine as a result of explosives found by an external agency at an ex-mine employee’s house. The investigation at the mine did not identify any evidence in relation to this matter.No action was required at the mine.

Loader made contact with light vehicle. Light vehicle operator failed to follow set positive communication rules regarding approaching heavy vehicle.

During the process of fitting a continuous miner an operator was required to access the top of the miner to turn a water tap off. The water hose was hanging high on a hanger instead of the standard position on the floor. When climbing down from the machine he misplaced his foot resulting in a strain injury to his left knee

Conveyor belt system damaged. The delamination of roof strata consisting of 800mm of coal and 1 metre of claystone had fallen around the conveyor belt structure. The roof bolts in the area remained anchored into the conglomerate roof

A man transport vehicle lost control when the driver’s side rear tyre rolled off the rim. This caused the man transport to impact the coal rib as the vehicle was travelling around a 90 degree left hand turn.

Hi-set hose failed on roof support. Hose failed due to age and fatigue.

The tub of an articulated dump truck rolled onto its side while tipping when a rear wheel travelled up a previously dumped load. No injury and minor damage to truck tub.

A hydraulic tensioning device was incorrectly positioned allowing the spindle on the swivel joint to take the load and failing. The release of pressurised oil contacted the equipment and splashed back onto the fitter. No injuries resulted.

Small fire in screen - Timing belts on the screen motor were skipping due to screen being started up under load multiple times. The timing belts melted off falling down into the screen which caught alight the skirting rubber.

A worker slipped and fell to the ground whilst exiting a front end loader resulting in a dislocated shoulder. It appears the worker did not use the correct means of descent. The worker was taken by a work colleague to a local medical centre where he had the shoulder put back into place and was transported home, arm in a sling.

While transferring a section of conveyor belt from a storage frame to a separate frame ready for installation using a telehandler the shaft that was holding the roll of belt slipped off the frame causing the conveyor belt to drop to the ground - falling approximately 1m in height

Small fire to a tail skirt on a conveyor caused by bolts cut from plant above.

Continuous Miner continued to tram forward when the remote control deadman button was released.Remote transmitters had not been upgraded to dual deadman operation for select functions, and the mine was unaware of this option.

Contact made between prime mover of delivery truck and bollard adjacent to the boom gate.

During the course of an overburden stripping program, four rocks (football size) have rolled through some vegetation onto a public road that is used by three quarry neighbours as access to their residence. The rocks were removed and the neighbours advised of the issue.

While continuous miner was in surface workshop for overhaul, the "E" stop junction boxes were being removed for overhaul and it was found the cable sheaths had been cut down to fit into the glands.

Contract employee's right hand became jammed between 2 regulator doors when an unsecured door shut under ventilation pressure.

1000v electrical cable jammed on cable reeler and flashed when moved.

Hot engine oil flowed onto a fitters arm causing superficial burns. The fitter was attempting to take an oil sample from a dump truck by undoing the oil filler cap. The oil reservoir was overfull and oil flowed out onto the fitters arm.

Information provided indicating that tension cracks on the surface beside the wall of an open cut opal mine making the wall potentially unstable.

A scraper hauling topsoil rolled over when the Operator lost control on a wet road surface. Operator did not sustain any injury as a result of the incident.

Operator reported that the pump motor on a flexible conveyor train would not stop when the remote control pump off function was being operated.

An underground truck was travelling down a decline when the operator attempted to stop.A stationary truck had been parked off the decline in decline access. The moving truck skidded approximately 10 metres on an excessively wet road and collided at low speed with the stationary truck and damaged a side cabin window.The road had been watered using a hose due to the water truck being unavailable.

Steel beams supporting the zinc cleaner flotation cells tank in the concentrator have failed along one side of the tank and the tank has rolled to that side by approximately 5 degrees. It appears that the beams at one side of the tank have become corroded and have failed under the load of the tank.

A section of spiral wound steel ducting, which formed part of a dust extraction system underground, fell from its supports to a designated vehicle/pedestrian thoroughfare below. No one was in the vicinity at the time.

Whilst conducting a weekly maintenance inspection LHD did not shutdown during the Low Water Cut Out Test. Pneumatic safety circuit air pressure was set high enough that the run solenoid did not shut down machine as expected.

Complaint from a neighbour regarding access to the site by the general public including children, and other matters.

During the rib bolting cycle an operator activated the gripper jaws and the timber jack extended. Root cause was an out of adjustment counterbalance valve. The rib bolter was replaced the previous shift and had been sitting on the store shelf for 9 months

Operator stopped a personnel transport in roadway, did not apply park brake and alighted from the machine. When the machine door was open the door interlock with the park brake did not activate. After approximately 60 seconds, the machine rolled forward 2 - 3 meters. No person was injured.

A crusher operator was attempting to remove a section of vent bag from a moving crusher feeder conveyor when his thumb became entangled in a length of rope attached to the vent bag. His thumb was broken when the vent bag fell from the feeder conveyor.

Fire detected in the cabin of a delivery truck by a person operating a nearby crane. No personnel were in the truck at the time, and the engine was not running. A small portable fridge and a flashing light were both connected to the vehicle cigarette lighter outlet fitted to the centre console.

During the removal of roof support process as part of the Longwall recovery a 4th year apprentice fitter has been splashed with a small amount of oil, some of which has gone into his eyes. The chock in this case was fully isolated and decayed, isolation permits were completed and verified.

A light vehicle was being driven down a ramp and was driving on a freshly watered section of the ramp. As the operator felt the vehicle drift out he accelerated to keep the vehicle in control. The vehicle suddenly gripped and spun in the opposite direction turning over onto the passenger side of the vehicle.

A low speed collision with high potential occurred between a LHD and personnel transport. Lack of communication, failure to comply with the underground transport management plan (reversing into cut through) and a high level of machine interaction in a confined area were contributing factors. No persons were injured

Uncontrolled release of fluid under pressure event from a CM mounted drill rig head plate. Incorrect length of head plate bolts fitted allowing head plate to come loose from limber jack. The rig was recently fitted after overhaul.

A dump truck lost control while travelling empty down ramp. The tray made contact with tray of fully loaded truck traveling up the ramp. Minor damage and no injuries.Although previously assessed as competent on this particular model of truck, the operator had not driven it for some time and was not fully familiar with its operation.

A jacking shaft that was driving a coal screen exciter failed. The shaft whipped around and smashed the covering guard. The shaft and half of the covering guard then fell to the walkway below. No persons were present in the area. The root cause of failure was determined to be that the flange bolts were not to correct torque. This meant that the flanges of the jacking shaft were not evenly pulled together which allowed for ingress of dirt, together the effect was to create excessive torque which resulted in a failure of the jacking shaft

A misfire occurred when an overburden blast was initiated. The first surface delay on the control row failed, resulting in only the first echelon initiating (of 25 echelons). The new echelon face was then surveyed and it was found that one blast hole (on the new echelon face) had insufficient burden to be fired safely. A decision was then made to fire the remaining 24 echelons without this blast hole connected, resulting in a known misfire.

A rubber tyre dozer (RTD) requested clearance to drive behind a haul truck (HT), to clean up rock spillage in the work area. The RTD operator called the HT for clearance on the wrong two-way channel, the HT operator did not hear the request. The RTD proceeded to cleanup behind the HT without positive communication from the truck. The truck operator began to reverse not realising the RTD was behind them, minor contact was made between the HT and the RTD. Position 6 tyre of the HT contacted the secondary access ladder of the RTD at slow speed. No injuries as a result of the collision.

Issues with emergency stop buttons on drill rigs, not ‘explosion protected’

A complaint was received from an adjoining landholder when the blast at a quarry was not notified to the landholder as per protocol.The need to notify was not communicated to a new staff member with responsibility for doing so

The lifting point on a 1.5t concrete calibration weight failed while being transported. It was not included in the mine’s program for inspecting lifting equipment.

Pre split development shot was unable to be let off due to initiator failure. Shot was slept overnight.

Dozer operator preparing drill prep at base of shot ripping and pushing sandstone rock material. The operator stated he was operating very slowly in low gear and was in the process of reversing, when the dozer came down hard on a rock, jarring him heavily and causing immediate pain to his hip/pelvis area.

A fitter was operating a bolting rig and was in the process of putting the bolt in and raising it when the bolt caught on the roof. The bolt flexed out under thrust and pinched his finger between the bolt and the hose manifold on the rig. The fitter had the top of his finger nipped off.

A laboratory technician was exposed to fumes/gases and suffered respiratory distress. A laboratory instrument using an open flame for analysis of gold was not correctly located under the ventilation hood. An associated chemical monitor near the instrument was not working.

A 400g booster was lost down a hole whilst blast crew were carrying out loading activity. Shot firer identified that there was one less booster than downline detonators

A small localised ground failure from an open cut high-wall occurred during night shift. Rocks from the failure fell onto the access ramp. No personnel were in the open cut at time of failure. The open cut had been closed prior to failure due to the rainfall TARP being implemented at start of night shift. The failure was observed by geotechnical personnel doing a pre-shift inspection for the start of day shift. The area was cordoned off and further geotechnical assistance sought.

An electrician undertaking inspections discovered an 11kV high tension (HT) plug with evidence of having been struck by a vehicle. The HT cable was in a cut-through and there was further evidence that the damaged plug was re-hung. The damage was not reported as required

A miner was standing underneath the hopper of a blower attempting to close the door when the dirt fell out and landed on him. The miner suffered a fracture of the vertebral column.

A flat return roller on a steel core surface belt failed and caused the outer lagging of the return roller to catch fireThe roller had been replaced with a non-identical replacement roller and had been in service for only 4 weeks before the incident.

A 15kg underpan from a conveyor fell three metres to a walkway below. No people were in the vicinity at the time

A worker received an oil spray from a miner-mounted roof bolting drill rig when the left hand supply hose ruptured during a normal bolting process

Complaint from a local resident regarding blasting in a nearby pit without notification to resident.

A dump truck wheel chock projected approx. 23m when the truck commenced reversing off workshop apron after servicing. Two people were about 3m outside the line of fire.

A worker slipped on some conduit and fell across an open floor-space inspection hatch when taking photos of a new electrical installation

A service truck lost control on a ramp and collided with the windrow. The ramp had been watered earlier and there were skid marks indicating a loss of traction

An MBF bolter was being used to drill 8m PUR holes on a longwall face. The bolter was anchored to the pan line by a U-shaped bracket that fitted over the spill tray of the AFC. During drilling the drill string bowed and lifted the U bracket off the pan line allowing the bolter to extend into the chock line.

Whilst installing monorail hanging brackets a worker had his finger crushed between the base of a roof bolt and the top of a drill rig dolly. A drill rig on a continuous miner was being used to do the job when the documented process nominated another method.

A supply pipe fell from supports onto a walkway below. Failure of a rotating flange on an 82.5 degree bend that caused the pipe to move as the fluid released under pressure. The movement overloaded the pipe support brackets allowing the pipe to fall.

A serious near miss incident occurred where an equipment operator was grazed by the front wheel of a Cat 785 dump truck whilst he was on the ground conducting pre-start checks on this vehicle. Another operator had incorrectly assumed he was allocated this same truck and after completing his pre-start checks had entered the cabin and drove the truck away from the Go-Line without realising another operator was inspecting the same truck.

A worker was found dazed and disoriented on the ground next to a shuttle car. The apparent (but not yet confirmed) cause of the incident was that he was struck by a plate that had been ejected from an 8m tendon support. The helmet of the injured person had a split brim and the cap lamp holder had been sheared off

Collision between FEL980H and 7408 articulated dump truck. Failure to provide positive communication within the 10 20 30 zone of operation.

Unintended movement of truck. A hire truck rolled approximately 500mm in a surface wash bay area. The operator was half in, and half out, of the cab when he realised that he had not properly engaged the park brake. The park brake on the hire truck differed to those of the permanent site trucks. Furthermore the hire truck did not have the brake alarm fitted to site trucks.

A blasthole drill was being trammed to a location suitable for the drill to be refuelled away from drilled holes. After travelling 30 metres the drill collided with a parked light vehicle, pushing the vehicle 3 metres before being alerted to stop by another drill operator. The driller was focussed on avoiding drill holes while tramming the drill. The light vehicle had been parked there earlier in the shift by the same operator.

Mining fatality in Western Australia. Underground worker crushed between integrated tool carrier work basket and roof of excavation.

A coal outburst caused an accumulation of methane greater than 2%. No people were placed at risk with this outburst as it occurred during a remote mining process

While conducting insulation testing on cables on the longwall monorail, at time of discharging the tested cable, the electrician has come into contact with a phase and received an electric discharge shock.

While unloading a flat top truck of 30 concrete blocks, one of the concrete blocks dropped to the ground. It was found that the lifting chain slipped out of the dog which was used to shorten chains used for the task. This happened after unloading approximately 28 blocks. No workers in the immediate area.

A haul truck was travelling loaded to the dump. A grader was grading the haul road on the incorrect side of the road facing the approaching haul truck. The haul truck and grader collided causing damage to both the haul truck and the grader.

A gold room worker received partial burns to the forehead and ear, and a hot fragment into his eye when turning out a gold bar. The centre of the bar was not fully solidified and reacted with cold water on the floor where the bar was turned out. The worker expected the bar to be cool and had changed from full face protection to safety glasses. High antimony content is causing the melt to behave differently when compared to normal gold smelts.

A contracted fitter received an electric shock when he attempted to power a diesel heater in the workshop.

Operators were elevating a set of three service lines (no more than 100mm) to allow access for a LHD. They released the cumalong after securing the pipes when the air line 6" clamp lever unclamped as the middle pipe levelled. The service lines were not isolated during the task.

An operator was in the process of installing primary roof support off the Continuous Miner. During this process, an escape of fluid occurred from the main supply hose to the drill rig valve bank. This escape of fluid contacted the operator on the left thigh.

While charging an underground development face, a shotfirer was struck on the left shoulder by a 30kg rock that fell from the back, between the mesh and the face.

A CHPP operator was accessing the conveyor tunnel to restart a sump pump in preparation for cleanup activities (a coal spill had occurred due to a vibratory feeder continuing to run when the conveyor stopped). While walking down the tunnel (inclined and narrow access), the operator slipped, landing on his left arm. A fracture of the humerus (arm) was confirmed. Water sprays had been recently used in the area to clean the tunnel which had made the walkway surface wet.

Park brake activation while the dozer was operating in reverse, without it being initiated by the operator, resulting in neck pain to operator following sudden stop of dozer.

Unplanned entry of dozer onto site. The dozer came from a neighbouring property without the operator after the dozer rolled, ejecting the operator, then landed onto its tracks and kept moving uncontrolled.

A machine has struck an energised 11kV cable and damaged it. Damage not reported and found some time after it occurred.

Operator of a haul truck entered the dump to tip the load. They saw a track dozer was tending the dump on the left hand side. This was the sixth load this operator had delivered to this dump. As the truck operator entered the dump the dozer operator told them, via the two-way, to go back to the start of the dump as the truck was too close. The truck operator said they did not hear the call on the two-way. The operator in the truck attempted to position the truck for dumping but lost sight of the dozer on their off side. The proximity detection alarm in the haul truck was alarming but the operator said they did not pay attention to the proximity alarm as it had sounded when on this dump in the past. The operator in the truck reversed towards the tip head and did not check the off side mirror where the dozer was positioned. The dozer operator called the operator in the truck the second time and told them to stop the truck when contact was made.

While driving a light vehicle down the decline, the operator has lost brakes. He has then driven the light vehicle into the wall to slow the vehicle, which has driven up a windrow and rolled the vehicle onto its side. No injuries reported.

A contract electrician was changing out batteries on a rear dump truck in the main workshop. Due to the weight of the batteries, a crane was used to lift them out of the battery boxes and over the top of hand rails. The body of the truck was down which did not allow a straight lift to occur. As the second battery was being lifted the hook of the lifting chain has caught on the "eye brow" of the truck body, bending the hook open and allowing the sling to slip out. At this stage the battery was at the height of the middle handrail and being guided by the electrician. The battery has then fallen onto a new battery waiting to be fitted on the deck, bounced through the handrail and fallen from the front of the truck onto the workshop floor below within the drop zone set up for the lift. The battery has ruptured and slid a small distance outside the drop zone.

An electrical fire broke out at a quarry when a short circuit occurred in an extra low voltage circuit in a control panel.

A large fall of ground (15-20 tonne) fell from an underground development face. The fall occurred while the charge crew were scaling from within a charge up basket approx. 1.2m above the drive floor.Approx. 150kg spilled into the basket causing non-life threatening injuries to the charger. The remaining rock spilled around the IT.The large face (~6.5H x ~5.5W) was not supported and was intersected by a dense pattern of multiple joints increasing the failure potential.

Ampcontrol Burnbrite socket non-compliance

A report of poor hygienic conditions in an underground crib room and other facilities was received by the regulator.

While mucking out silt from a previously flooded area, operator noticed roof starting to fret. Operator withdrew LHD 30m, heard a couple of load cracks and roof fell to a height of 4 - 4.5m at least 6m long. As there is an existing fall across an intersection approximately 10m from the lip of the current fall - it is deemed Iikely these falls have met.

A precast concrete wall (estimated weight 7.4 tonne) being part of the surface crushed stone (precoat) load-out bins collapsed onto an adjacent stacker conveyor leg. The conveyor then collapsed. Prior to the incident two employees were working in the vicinity of the conveyor and stacker.

Failure of flamepath measurement on a junction box during weekly code inspection.

A fire occurred on an underground LHD whilst it was stationary and not in operation. An incorrect battery (smaller) had been installed as opposed to an OEM specified battery. The battery clamp failed to secure the smaller battery, as the securing bolt was missing. This allowed sideways movement and the terminals short circuited against the clamp resulting in the battery catching fire.The fire was extinguished using a hand held dry chemical extinguisher. The battery compartment has been updated in newer versions of loader.

A strain burst caused by a seismic event in the localised region resulted in fall of supported ground. The event was detected by the mine’s seismic monitoring system. A low traffic area, yet possible a person could have been walking near the affected area. High potential incident.

Incorrect quick release hydraulic fittings used - leading to escape of fluid onto operator

The tray of an articulated truck tipped onto its side with the cab remaining in an upright position, whilst carting top soil.

Worker struck by a piece of stone/coal whilst changing Tailgate Shearer picks.

Approximately 100 tonnes of ore failed from a wide brow in an underground metalliferous mine stope. The fallen ore landed predominantly on the rill.

Rollover of rear of articulated dump truck - the truck was handling topsoil and one side of the truck was on the previously dumped topsoil while the rear of the truck sank into the topsoil and rolled onto its side.

Dozer reversed across dump face and made contact with the position 6 tyre of a truck

A belt spindle was being winched up beside a conveyor to a cut-through for recovery. When the spindle reached the winch, it lifted and slewed over striking the spotter and fracturing his ankle.

A cleaner sustained an electric shock when attempting to turn on a domestic light switch in a workshop office.

Contact was made between an LHD canopy and an 11KV cable, tripping the electrical protection. The machine was shunting to allow an oncoming vehicle to pass and was raised up as it ran over rib spoil.

SMV collided with a longwall roof support that was stored on the transport road. An alternative transport route had been set up and communicated to the workforce. While driving into the mine the driver drove through a swilly, putting muddy water on the windscreen and lights. He did not see the no-road tape and subsequently drove through it. The transport then collided with the roof support.

Suspected fluid injection to fitters hand whilst torqueing bolts on dozer track idler

Unplanned movement of equipment. A man was operating an Elevated Work Platform (EWP) tramming onto a low loader truck when the low loader truck rolled away 25 metres before colliding with large skip bins that halted the tuck movement.

Two haul trucks clipped mirrors- both mirrors were torn off. Trucks were driving in opposite directions. Neither driver realised at the time – one noticed at the bin and the other noticed at the digger. Reported to the OCE who found the remains of the mirrors at the incident site. Trucks were then parked up. No issues with the trucks were identified in the preliminary investigation.

Operator was descending from grader when the ladder started to rise and the operator fell to the ground striking his head.

Uncontrolled escape of carbon dioxide into longwall return from a floor break associated with a geologically disturbed area.

Positrack vehicle was being used to clean under a conveyor. The operator was concentrating on the bucket to ensure it did not strike the structure and struck a pipe with the cab smashing a windscreen.

Hydraulic failure leading to a release of fluid – operator sprayed with oil. A hydraulic tensioner was being used to tighten bolt in a rotary breaker during routine maintenance.

While loading rock from a quarry blast a rock, approximately 23 kg in weight, fell approximately 17m out of the face. The rock bounced from the bucket arm of a front end loader and through the operator cab windscreen. The operator sustained minor injuries. The bench height had been significantly increased without reassessing the risk and providing appropriate loading equipment.

An integrated tool carrier (IT) rolled onto its side whilst transporting flexible pipe up a ramp at a surface mining operation. The vehicle had to reverse on a narrow path and the wheels engaged soft material causing it to roll over.The operator was not injured.

Whilst walking backwards directing a fork lift in an oil store, a worker slipped on the oily floor and fell backwards. The operator’s helmet fell off and his head struck the floor. No serious injury.

Uncontrolled release of pressurised substance (hydraulic oil) whilst a person was installing a rib bolt off the LHS of a Sandvic bolter miner. The oil sprayed the operator on the back of his right knee and under his right arm. The hose was sheathed and the oil deflected off an electric motor and cabling prior to spraying the operator.

An operator drove an LHD under ventilation ducting near an auxiliary fan and dislodged it. He attempted to repair it alone with the fan still in operation when the ducting dislodged further resulting in his being sucked into the edge of the ducting. This resulted in lacerations to the LHS of his face.

Fire on conveyor drive head underground. Fires were extinguished with a fire extinguisher but reignited. Water was then used to extinguish the fire and cool the area. Co2 monitor detected 20ppm CO.

930E Truck travelling at low speed down ramp lost control and rear slid to almost 90 degrees to direction of travel. Ramp had just been watered. Truck did not strike any objects or windrows

When conducting a daily inspection on the Longwall tailgate motor, the electrician discovered a gap in the banana plate greater than 0.5mm.

Contact was made between an LHD bucket and an underground 11KV HT cable, tripping the electrical protection back to the surface. The LHD machine was stowing material in a cut-through that had variable heights (approx. 2.4m back to 2.1 metres at the roadway). The bucket was left up as the LHD reversed under the smaller roof height. The cables were installed in compliance with the mine cable management plan.

Person illegally gained entry to the mine site through a gate on the public highway by cutting the lock or chain. Electrical equipment was interfered with.

Claim holder reports that the mullock dump is too steep and too high. His truck lost power on the slope and began to roll back. He jumped from the cabin landed heavily and fractured his femur.

Damage to pyromex boosters as a result of a light vehicle running over them whilst accessing blast exclusion zone.

A resident claims that a blast occurred in a quarry without prior notification. The resident did not hear the pre-blast siren.

Workers who were sent to a tailgate roadway to install secondary roof support found that the roof had already fallen.

A complaint in relation to an incident that occurred at a mine over 2 years ago and was not reported to the regulator. Incident involved an unplanned movement of a vehicle that rolled away after the operator alighted from the vehicle. Vehicle was damaged and later removed from site.

Report to mine operator that explosives may have been left in abandoned underground mine workings. Mine was access by shafts approximately 40 metres deep and has not been worked for over 20 years. Open cut activities are now taking place in proximity to the old underground workings. Explosive consultant engaged to assess hazards from potential old explosives.

Three workers entered an exclusion zone above a trial underground hydraulic mining area at a mineral sands operation. A small sinkhole around 400mm in diameter appeared in the ground surface near the workers. The workers left the scene immediately. The sinkhole area was inspected by a drone and had subsequently increased in size to 3m diameter and 2m deep.

Operator was driving an articulated truck down a haul road when the rear section rolled onto its side bringing the truck to a sudden stop. The driver suffered mild shock.

A bolter operator was struck by coal from the rib causing lacerations to the face and a possible fracture to the arm. The incident occurred at a holing point in a development panel.

In seam drill rig, drilling to confirm fault, struck a gas reservoir causing drill rig power to be tripped via local methanometer and caused greater than 3% methane in return airway. Drill rig was using a stuffing box and standpipe fitted to a 50mm diameter hose. Gas pressure contained by the faulted area was in excess of the envisaged quantity/pressure and exceeded the capacity of the 50mm hose.

The shaft of a conveyor snubber roller has broken, allowing the roller to fall approximately 8 metres to the ground adjacent to conveyor drive house. No persons in vicinity at time.

A worker received an electric shock whilst climbing on-board a Jumbo drilling rig in an underground metalliferous mine. An investigation revealed no defects with the machine. An investigation into a subsequent electric shock to a different operator a week later revealed a light fitting beside the access point to the machine to be damaged with corresponding damage to the insulation of the wiring of the light fitting. The operating voltage of the light unit was 24V. The light fitting was mounted in a position that made for a convenient hand hold for persons accessing the machine.

Fire on the cabling associated with a battery isolator unit on a contractor's road registered boilermaker service vehicle. The fire was extinguished using a fire hose.

The Department received an anonymous complaint that a large quarry was operating without a qualified person nominated to carry out the statutory functions of an electrical engineer.

A diamond drill operator tripped over a drill rod left on the floor of an underground diamond drill cuddy breaking their right ankle in three places

Notification of serious incidents involving explosives or explosive precursors.A stemming truck has driven over a booster.

A water truck collided with the conveyor on a mobile screen.

Suspected air injection injury to the hand\arm of an operator arising from the failure of a threaded connection of an inline lubricating bottle connected to a hand operated pneumatic nut runner. Initial investigation by the mine has revealed the lubricator fitting has unscrewed out of the nut runner as no inline flexible swivel fitting was installed

While adjusting the tynes of a forklift a workers fingers were caught in the pinch point between a tyne and the back board of the forklift.

An allegation has been made that a contract employee was dismissed for raising concerns about non-reporting of incidents. The complainant witnessed a near miss incident involving a supervisor’s vehicle and a grader which was allegedly not reported. Prior non-reported incidents have been alleged. The complaint is being investigated.

A loader bucket hit a power pole while constructing a bund adjacent to the pole. A conductor came free from the insulator causing the power to trip.

Two empty haul trucks were travelling down a decline and a loaded haul truck was coming up the decline. The lead truck travelling down the decline communicated with the loaded truck and the lead truck agreed to pull over and stop to allow the loaded truck to pass. The rear truck collided with the stopped lead truck.

The department has received a complaint in which the complainant believes he has been subjected to bullying & harassment over a period of approximately 18 months

A truck driver fell to the ground from the tray of a truck whilst securing a load. The driver sustained a fractured pelvis.

A contract driller was preparing to drill out part of a trim shot. While walking towards the other driller, some 10 rocks fell approximately 20 metres from the berm above. They landed at the toe (base) of the face. However, one rock approximately 15 cm in diameter flew across the quarry floor some 20 metres and landed approximately 5 metres in front of the driller.

A contractor worker has been struck by a hose knocking him to the ground resulting in a suspected broken arm. The worker was operating a sucker truck. The pressure hose from the truck is used to clear blocked pipes. It appears that the pressure hose has recoiled in some manner, rising up and striking the worker, knocking him over

Excavator bucket has struck the blade and lift cylinder of a passing dozer. No injuries. Passing dozer and excavator had made positive communications.

A top belt slinger roller near the belt transfer has collapsed and hot material has dropped into the fines tray below and ignited the fines. A deputy smelt smoke and he and a fitter found the burning embers in the tray

A light vehicle travelling down an incline has contacted the wall and another vehicle before coming to a stop. No injuries.

A fire on a conveyor burnt through the belt. No-one was in the vicinity at the time and there appears to be no major structural damage.

Two large rocks (approx. size 2m x 1.5m) breached a berm and rolled into an active haul road. A haul truck tipped the material in an active dump which was tended by a track dozer. From the material dumped two large rocks crossed over a rock drain and 5m high berm coming to rest in the active haul road below the dump. The rocks rolled approx. 5m into the road and did not make contact with any vehicles

A top belt slinger roller near the belt transfer has collapsed and hot material has dropped into the fines tray below and ignited the fines.

A complaint has been received that concerns raised regarding high levels of dust within a mine are not being addressed.

Two workers had completed charging of a hydraulic accumulator with nitrogen gas from a G size cylinder. The regulator was opened and the nitrogen cylinder isolation valve turned off. The workers then started to remove the regulator from the cylinder. The regulator was ejected from the cylinder and the cylinder fell over. While continuing to discharge nitrogen from the cylinder, the cylinder bounced over the kick rail and wedged into a cable tray.

A 250 tonne excavator was working on a 4 metre face, when the face slumped onto the excavator. Operator used boom to stabilise excavator and a dozer has pushed material up to further support machine.

A contractor fitter was working on a Moxie water truck air conditioning unit. As he was recharging the unit the sight glass in the air-conditioning system blew out and fragments of glass hit the fitter in the face and chest area.

Fire on surface belt – a fire occurred on a conveyor belt that loads onto the train loader/hopper. It’s believed that the fire was due to the head roller heating up, causing the belt to catch fire and eventually split in half. The belt was not running at the time but had been used earlier in the day.

A haul truck became bogged on a waste dump road that was not in active use. The operator had driven onto the road to allow another truck to enter a nearby active tip head. The operator observed water pooling on the inactive road. However, in order to turn the truck around the operator had to travel through a pool of water. When the truck drove into the water the driver’s side sank up to the tray.Truck operators had been advised at the pre-start meeting not to enter or use the inactive road due to the pooling of water in that area. However, no hard barriers were in place. Significant rainfall had occurred at the mine over previous weeks.

Two trucks collided in a loading area after one truck malfunctioned. The driver accidentally activated the accelerator instead of the brake.

The operator cabin of a 9250 face shovel broke away from its mounts and fell onto the tracks of the excavator. A temporary welding job was undertaken to address a recognised problem with the cabin retention bolts.

A 100 t crane was moving rolls of conveyor belting from one pad to another. While the crane was repositioning, the boom unexpectedly slewed 90 degrees, causing the crane to topple, striking the cabin of an adjacent truck. It was possible the slew lock pin was not positively engaged and the slew brake was not manually activated.

A parked vehicle rolled into another vehicle because of faulty park brake adjustment

An underground coal mine reported a series of methane exceedances greater than 2% in the longwall tailgate

A light vehicle rolled over onto the off driver's side after reversing over the toe of a nearby embankment

A concern was raised in relation to working in an area potentially at risk of flooding during recent bad weather

A tipper mounted water tanker was travelling when the tipper raised, catching on overhead 415V powerlines. The power lines were torn down away from the supply point. Nobody was injured

A contractor ute with two occupants was travelling down a straight road when it rolled and came to rest with the ute wheels over a bund. The ute had rolled four times. The occupants walked to the crushing plant, where an ambulance was called.

A load haul dump operator may have lost consciousness because of failure/fault with an air conditioning unit in the cabin. The operator heard a noise and mist come from the air conditioning unit in the top of the cabin. He stopped the vehicle, radioed in the incident, felt dizzy, got out of the cabin and may have lost consciousness for a few seconds. Another LHD operator in next extraction drive heard his radio call and went to the operator's assistance. Emergency rescue officers arrived and transported him to the surface for assessment.

A drum winder was undergoing pre-start (outbye direction selected at the pit bottom). The operator released the controller right as the pre-start was completing and the winder was going into run. The winder free spooled in an inbye direction for a number of metres before the operator dumped the train. The mine engaged the original equipment manufacturer (OEM) of the equipment to assist with the investigation. It was found that the drive motor control program was not configured to maintain the pre-torque state of the motor so as to hold the drum in a static position until the brake was confirmed as having been applied.

There was a fire on an Atlas Copco MT60. The fire was extinguished by the operator using a hand-held extinguisher. The operator then manually activated the onboard fire suppression system.A coolant hose ruptured, allowing the coolant to soak into the exhaust lagging. The heat generated from the exhaust ignited the coolant.

A dozer was pushing a slot down a 23 degree batter. An object, most likely a rock, smashed through the rear window and cracked the front, right-hand door window. The operator was not injured

A fire destroyed a haul truck. An automatic water-based fire suppression system was activated but did not extinguish the fire. While the matter is still under investigation, investigations have determined that the fire may have originated in the engine compartment. Sound attenuation measures made it difficult for the fire crew to access the engine compartment

There was an interruption to ventilation due to a power supply problem to main ventilation fans at a shaft site. Fans at another shaft site continued to run as programmed. Underground power dropped. Methane exceedances of up to 4.7% occurred. Workers were not withdrawn to the surface. The department issued a S195 notice to the mine to stop operations and withdraw people from mine.

The department has received a complaint in which the complainant alleged they has been subjected to bullying and inappropriate conduct

A 55 tonne Cat truck was hauling at 950 level when the operator noticed flames coming from under bonnet. He shut down the vehicle, operated the on-board extinguisher and also used a hand extinguisher to extinguish the fire. A hose retention bracket came loose, allowing two hoses to rub against each other causing an escape of combustible fluid that contacted a hot surface and ignited

An operator was jump starting a VSI crusher from a loader when the loader lead acid battery caught fire. The operator dropped to the ground and the battery exploded. Nobody was injured

A grader travelling in the underground decline stalled then began to roll away down the ramp. The operator could not stop the grader and turned it into the decline wall to stop it. The grader was damaged but the operator was not injured.The mine investigation determined that the service brakes failed when the engine stalled, the emergency brake pedal was inoperable and the operator was not trained to use the secondary grader emergency brake activation system.

Multiple methane exceedances have been reported at the longwall bleeder monitoring point during falling barometer. The maximum detected methane reading was 3.53%. There were no workers or machines in this area the time of the incident. No production-related activities were being undertaken at the time

An operator suffered a serious injury to his left hand. The operator’s hand was caught in the mechanism while cleaning a grout pump.

The department has received a complaint in which the complainant alleged they were subjected to abusive, insulting or offensive language or comments.

A dump truck with the tub left in the raised position travelled underneath a conveyor on a roadway. The tub collided with the conveyor, causing significant damage to the conveyor. The truck was not damaged and nobody was injured. Initial incident investigation by the mine suggested operator error may be a contributing factor.

An operator was dismantling and recovering 150 mm pipes using a task specific machine when a pipe fell hitting him on the back of the neck and shoulders. This Resulted in the worker receiving hair-line fracture of neck vertebrae.

Whilst positioning to tip overburden from an articulated dump truck the left rear wheels of the machine mounted a pile of material previously dumped by another truck, causing the body of the articulated truck to tip onto its right side

A worker died when struck by a material hoist ore bucket in an opal mine shaft. The hoist system used at the mine was an Agfab Super Hoist system. It was manufactured by Agfab Pty Ltd, a Queensland company that went into liquidation in 2009.

A loaded haul truck was travelling on a slight down ramp in a large open cut mine.The haul road had been excessively watered just before the truck travelled on the ramp. On-board data recording showed the truck was travelling in a high gear and above the stipulated speed. It slid for a considerable distance on the wet road before rolling onto its side.The operator who was wearing a seat belt suffered a bump to the head.

The driver of a loaded truck had a micro-sleep and ran over a berm. The driver drove to a service bay and reported the incident. He reported that the two-way radio was not working. When he reversed over the berm, the fuel quick fill point was damaged

An off-road tyre was placed on a tyre stand or inspection when the rim components fell out onto the ground

A 1400 kg mini excavator rolled over while tramming up a slope adjacent to a fixed plant. There were no injuries.

Series of methane exceedances reported to regulator

A worker who was involved in removing old services within the mine, brushed against a cable gland associated with a lighting circuit and suffered an electric shock. Before isolating the circuit and barricading the scene, an electrician measured approximately 60-70 Vac to earth.

A loader operator was stockpiling product. The operator lifted the bucket of the loader and then articulated the machine. This caused the loader to fall to one side and it came to rest on the stockpile. The operator remained in the machine and was not injured.

A CHPP supervisor suffered an electric shock between the left hand and the right hand when leaning across a rejects screen to adjust a valve on an air hose that was coupled to an air lance. The shock was described as being “like someone had hit my whole body trunk all at once”.The valve had a metal body and handle while the air lance was made of PVC and the hose was a non-conductive rubber.

While recovering 50 mm air hoses, a production mine worker separated a coupling between two hoses without isolating the main air supply and dissipating the residual air pressure from the hoses. This resulted in flailing of the pressurised hose until the hose air pressure was isolated.

Multiple methane exceedances have been reported at the longwall bleeder monitoring point during falling barometer. The maximum detected methane reading was 3.53%. There were no workers or machines in this area the time of the incident. No production-related activities were being undertaken at the time.

Concerns were raised regarding the security fencing around a quarry and local youth having access to deep water

A mining-induced seismic event resulted in pieces of delaminated fibre reinforced shotcrete (FRS) being ejected from the back of an underground crusher tipple area. The FRS was installed to protect the ground support from operating LHDs.A parked light vehicle was damaged by the falling objects. No personnel were injured however workers were in the vicinity at the time and felt the bump. No ground support was damaged.

A worker was operating an LHD when he injured his back. He was delivering equipment when he reported that the machine hit a large rock on a transport road.

A surveyor suffered an electric shock when they made contact with a survey instrument while working under 330kV power lines. The power lines had 11 m ground clearance and the survey tool was 1.5 m off the ground on a ground on tripod

The department has received a complaint in which the complainant alleged concerns about the safety culture at a mine. The concerns are related to a number of factors including not using job safety assessments (JSAs) for hazardous jobs, poor management practices of supervisors and bullying and harassment between workers that is allegedly tolerated by management

A tradesman was using a 5" cutting disk, to cut a section of a when a piece of the disk broke off and struck him in the chest, embedding a piece of the cutting disc in his chest.

Some small rocks fell from a batter face in a metalliferous open pit mine and travelled down about 30 metres onto the main haulage ramp, landing approximately 5 metres from the highwall.No equipment or workers were in the vicinity when the rocks fell. Upon inspection it was noted that other rocks had also dislodged and became caught on a catch berm.

A worker collapsed and lostconsciousness after exiting a confined space work area.The cause of lost consciousness for the worker is still to be determined.

An articulated water truck skidded a distance of about 4 m in the direction of travel on a wet down ramp. It was reported that when the brakes were applied the wheels locked. The truck came to rest without contact with any other structure or berm. Nobody was injured and no equipment was damaged

Timber was placed under a longwall chock pontoon. When finished and resetting chock, a worker used a chain block to lift services out of the way but broke a hydraulic hose. Fluid hit the chock leg and deflected ontoworker's helmet. The worker was cleared of injury by the company’s on call doctor.The investigation found the chain block was being used to support the Maingate cable and hose bretby become entangled around the hi-set isolation valve.

An excavator dug into loaded shot while double benching. It was reported that a 10 m exclusion zone was in place at the time (witches hats and red flashing lights). The excavator operator realised there was a problem when he saw one of the red flashing lights in the dig face.

A collision occurred between a light vehicle and a LHD. The LHD was driving down a ramp in second gear carrying a set of AFC pans. The machine was taking up a significant amount of the available road width. The person driving the light vehicle tried to pass the LHD and assumed the LHD operator had seen his vehicle and would stop, but the LV driver had restricted visibility. The vehicles collided resulting in the light vehicle being damaged. The driver was sent to hospital as a precaution

There was a fall of rock down a bench face close to where there was an operator working on a portable screen plant

A winder cage with several people on board hit something when leaving an underground level plat. No injuries occurred but the cage received minor damage. A fault with the retractable plat where the cage was loaded required that the plat be retracted manually. The plat was retracted manually while the cage was still engaged with the plat and just as the cage was starting to go up the shaft. This caused the cage to swing and strike the shaft wall and the next level plat

An operator in an underground metalliferous mine was using a Jumbo drill rig to drill a development face when flames came out of two drill holes. The flames came out for several minutes and then went out. The flames were from an ignition of gas from the geology, released via the drilling. The operator backed the drill rig away and out to the decline edgeThe operator was not injured or affected by the flames and the drill rig was not damaged. The operator had a gas detector that did not alarm before or after the flames appeared.

WEEKLY INCIDENT SUMMARYRecommendations to Industry/Comments

Potential for heavy vehicle rollover needs to be considered as part of operator training, in selection of vehicle and design of roadways

1. Provide access to both sides of conveyor pulleys for inspection and maintenance2. Provide access to both sides of conveyor pulleys for inspection and maintenance3. Conveyors should comply with AS/NZS 4024.3610 & AS/NZS 4024.3611

A risk assessment of all loading/tipping operations must be carried out that includes, but is not limited to, potential toppling of the loader through loader articulation while the bucket is elevated, the slope of the work location and fit for purpose truck/loader configuration

A missing cover plug on the starter motor allowed dust and dirt ingress which caused the electrical fault and subsequent fire. Such plugs should be in place and effective

It has been identified that the spool monitoring was out of adjustment after reassembly of the rig and control bank. Spool proximity sensor calibration to OEM specifications is now on the commissioning check sheet

Review pressure testing procedure. Ensure Work health and safety regulation Part 3 is reviewed and understood:- adequate supervision requirements to be implemented- fit for purpose equipment to be utilised

Mine operators are reminded of the need to ensure that the foundations and securing methods for demountable buildings are designed in accordance with appropriate civil engineering standards

Mines should have a safe work procedure for lifting, relocating and welding poly pipe. A risk assessment should be carried out and include the use of fit-for-purpose equipment, appropriate safety zones and positive communication

Underground coal operations are reminded of their obligation to control methane levels through the use of adequate ventilation quantity, methane capture and monitoring. Monitoring includes the selection of detection equipment that is suitable for the environment in which it must operate. This includes suitability for installation in high air velocities or for continual exposure to elevated levels of CH4, as determined by operational requirements for the mine. This may also require consideration be given to the use of sample pumps to provide controlled air flow over monitors while allowing for mounting of the monitors in locations that allow for maintenance and calibration activities

Underground coal operations are reminded of their obligation to control methane levels through the use of adequate ventilation quantity, methane capture and monitoring. Monitoring includes the selection of detection equipment that is suitable for the environment in which it must operate. This includes suitability for installation in high air velocities or for continual exposure to elevated levels of CH4, as determined by operational requirements for the mine. This may also require consideration be given to the use of sample pumps to provide controlled air flow over monitors while allowing for mounting of the monitors in locations that allow for maintenance and calibration activities

Mine operators should review the procedures for heavy mobile plant and ensure operators understand the shut -down procedure for the equipment being used at the mine

Mines should ensure batteries are installed on mobile and transportable plant in accordance with the guidance contained in AS/NZS4871.6 and manufacturers recommendations. Mines should also ensure maintenance procedures for mobile plant provide an appropriate level of detail to allow personnel to safely and correctly determine battery condition

Electrical panels on the surface of a mine must be built and installed to the principles of AS/NZS 3000. Where a gauge change in wires occurs this must have adequate electrical protection. Creepage and clearance distances must be maintained along with adequate arc fault prevention standards (barriers, added insulation). Consideration should also be made to adequate thermal dissipation and enclosure free space. The intro to site process must ensure the above with regular auditing to ensure compliance

Audit all highwalls to ensure that they are safe to work near, particularly in relation to water ingress / degradation. If they are deemed to be unsafe, then implement appropriate controls to restrict access to those areas. Ensure hazard plans are in place and comprehensive

Industry should ensure they put in place adequate ventilation controls for gas levels when carrying out maintenance on their gas drainage plants.

Operators should ensure that entrances to their operations comply with the appropriated regulatory authority. Particularly (but not limited to) design, visibility and appropriate signage for light and heavy vehicle interaction

Industry should make their operators aware of the hazards when operating equipment in close proximity to low / high walls.

People were clear of the area at the time of the incident. Safe work procedures for this type of maintenance task should take into account the possibility of such a failure and have no-go zones defined accordingly

Mines are reminded that live work, including energised testing, is not permitted at a mine site except in exceptional cases as allowed by legislation.

The industry should enforce the need for positive communication when plant is operating in close proximity to other plant.

Operators to consider installing hard stops to control unplanned movement of vehicles when parked. Furthermore, appropriate training and additional signage regarding ‘safe parking procedures’ should be reviewed and communicated to all employees, contractors and delivery drivers

Mines should review risks and procedures to ensure the safe transport, storage, operation, set down and defect management of shearer remote controls.

Mines must undertake a specific task risk assessment that identifies risks of potential rollover when using scrapers adjacent to edges. In this specific incident a scraper is not deemed fit for purpose for the actual methodology adopted on site. In future, scrapers will be used to lay material at an appropriate distance from the crest edge and a dozer or excavator will create the protective bund. Industry should note that risk assessments must be comprehensive and cover the full 'life cycle' of the mining process being assessed.

An investigation is in progress that will examine contributing factors, including the mechanical condition and maintenance history of the bus.Other identical vehicles have been stood down pending the outcome of the investigation.

Mines should confirm that compressed air drain pipes are fixed in position prior to releasing pressure.

Mine operators must ensure that the blast management plan and firing procedures are fully documented, communicated and effectively implemented – particularly following revision.

Operators should review the adequacy of gas drainage and ventilation systems such that methane levels in areas where people work or travel are as low as reasonably practicable.

Ensure infrastructure installed in transport roads is above machine height where possible, or adequately delineated to reduce the risk of collision.

Mine operators need to ensure that positive communication occurs during light/heavy vehicle interaction and that light vehicles have designated parking away from the heavy vehicle movement.

Where possible capture rib bolts at the face and position magnets to reduce the likelihood of bolts passing transfers.

Mine operators must consider the impact of organisational and human behaviour factors when assessing risk and determining effective critical controls.

Mines should consider risk of strata forces causing sudden shearing of bolts, allowing support hardware to fall where people may be present. Control measures such as propping/slinging steels should be considered where the risk may be present.

Operators should review dumping procedures and consider providing instruction such that: 1. Dumps are maintained in a straight line with windrows being constructed of predominantly dry, competent material to a specified height.2. Drivers are to reverse into the dump at a safe speed with the truck perpendicular to the tip face. The windrow must not be relied upon to stop the truck. 3. Regular inspections are carried out to monitor active dumps and ensure that correct dump standards are maintained

Mines with overhead cranes must undertake regular maintenance on the earthing systems of the crane to ensure earthing remains effective, particularly were the crane uses sliding brushgear. Mines should also consider 30mA RCD's were practical.

The mine’s commissioning procedures must include checks that verify electrical equipment is suitably rated and correctly installed for the proposed installation, and original equipment manufacturer support documentation is available to confirm the equipment ratings and installation. When a contractor is engaged for electrical work, the mine’s commissioning procedures must also apply to the work performed by the contractor.

Risk management processes for such tasks should include consideration of ergonomics in relation to crane control pendant position, selection of chain/sling appropriate to task and body position in relation to suspended load.

Mines must develop and implement procedures for working alone and working at heights.

Lifting apparatus, including monorail trolleys should be inspected by competent personnel on a regular basis in accordance with an appropriate standard and/or original equipment manufacturer instructions and should always be inspected prior to use in a lifting capacity.

In this case the mine had a documented standard for load retention specific to this task that was not followed. Mines should consider human factors in task design, need for refresher training on rigging/dogging standards and importance of supervision/task observation programs.

Plant operators should descend vehicle ladderways by facing towards the ladder and using the three points of contact.

Consider hose burst protection for hoses in high risk areas where physical guards are not possible. Refer to MDG 41 – Fluid power system safety for more information.

Maintenance schemes for such plant must include regular inspection of the resistor grid mounting systems, the integrity of the resistor grids and associated terminations by competent persons. This is in addition to regular cleaning activities.

Portable tools and extension leads used by a mine are to be routinely tested and an inspection tag attached. As part of pre-start inspections, equipment and leads without an in-date tag must be tagged out of service and not used. Consideration should be given to the use of battery powered tools over low voltage (240V) tools and permanent magnet over 240V electro-magnetic drill bases.Refer to previously issued safety alert SA10-02 – Severe Electric Shock from Power Tool.

Procedures should include safe machine operation and parking including: designated parking areas; excavators being parked more than their swing radius from other plant; mandatory walk around pre-start up checks.

Operators should review the adequacy of gas drainage and ventilation systems such that methane levels in areas where people work or travel are as low as reasonably practicable.

Multiple formal controls should apply at each step of any process (mine planning through to drilling) that involves drilling into potentially accessible voids. Controls should include formal approval; exclusion zones; clear drilling plans and sections as well as a breakthrough plan. Drilling should only be authorised after confirmation by a competent person that the appropriate controls are in place.

Where pillow blocks are critical components of a draw works brake linkage system, or any other system critical to the safe operation of a rig, they should be considered in routine quarterly non-destructive testing (NDT) inspections. Driller’s awareness in respect of emergency responses should be reviewed, in particular, the use of ESD.

The risk of destabilising the fill in the stope had been recognised and addressed via a Tele-Remote Risk Assessment (TRRA) which was not implemented.Multiple formal controls should apply at each step of any mining process (i.e. mine planning through to drill/blast/muck/fill).Controls should be such that a failure at any one point will trigger a reaction e.g. loader operator (& supervisor) refuses to load out without a valid TRRA. This means employees must be empowered to stop the job when a system failure is detected.In this case the problem was exacerbated by failures in communication and a relaxed safety culture at the mine meaning procedures were not rigidly enforced or adhered to.

Risk controls where work is conducted in proximity to a drawpoint brow (particularly beyond a safety demarcation line) should include bund design that specifically considers the stope geometry, drawpoint dimensions and the practicality of constructing the bund.Purpose built bund construction equipment may be required to achieve design bund height

The maximum travelling speed of trucks and other vehicles should be established for each site, taking into account the vehicle load, roadway gradient and surface conditions. Additionally, information should provide operators with steps to be taken to recover control of the vehicle in the event of loss of traction.

The electrical engineering control plan for a mine must provide for visual inspections of electrical installations to be undertaken as per Chapter 8 (clause 8.2) of AS/NZS 3000 prior to a circuit being energised for the first time. As part of these inspections, connections must be checked as correct and secure

Maintenance and inspection systems for electrical plant and installations need to include checks that verify the integrity of circuit connections at frequencies that are appropriate to the type of equipment and to the duty cycles for that equipmentInstallation and modification works undertaken by contract organisations must be reviewed by the mine to ensure that works undertaken attain the standards required by the mine’s management systems

Inspection and maintenance procedures must include the routine inspection of machine (motor) cables as well as enclosures, to identify issues such as build-up of fines or other debris that may cause damageFailure to adequately inform personnel of modifications to electrical plant had led to practices of resetting power following protection trips, without effective testing.Procedures for restoration of power following a protection trip must include methods that are to be followed by all personnel to identify the cause of the trip prior to restoring power.

Mines must ensure that equipment is designed and fit for purpose prior to installation.Should equipment be replaced or modified relevant operating procedure must be reviewed as part of a change management process

All rigid pipelines that convey hazardous materials must be designed, designated and installed to minimise the risk of deterioration in positions that facilitate regular inspection and testing.Mines may conduct a survey to better understand workers’ motivation for not using emergency equipment.

In excavator truck operations, the excavator operator must take control of his work area and ensure that procedures are followed by all persons in his area.In dozer clean-up operations around an excavator, positive communication must occur between dozer operator and excavator operator before the dozer enters the swing radius of the excavator and after the dozer exits the swing radius of the excavator.

Ensure cable management considers the potential for cables to fall of roof rollers taking into consideration all cable handling activities

Mine operators need to ensure that all plant or machinery at a mine site is inspected prior to going into service. The inspection should verify that the overall dimensions are within tolerances for driving machines or towing plant through the mine without colliding with roof or infrastructure. The inspection process should include authorisation from relevant management personnel.An Investigation Information Release will shortly be published to provide more detailed information to industry. It will be available from: http://www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/incidents

Mine Operators should provide adequate warning signage, and dispose of redundant plant items.

The supplier of the device has issued a safety alert to its customers. Mines should comply with recommendations of the safety alert.

Mine operators should consider implementing a contractor work permit system such that contractor supervision, impact of work activity and interaction with other operations at a workplace are identified, communicated and understood prior to commencing work

Where wound rotor motors are used, mines should:• review brush gear/slip ring maintenance frequency and cleaning methods, ie vacuuming, blowing, washing with solvents to effectively remove carbon and copper dusts and other residues. • perform thorough inspections post maintenance of the SR enclosure prior to repowering.• explore arc venting options for the slip ring enclosure with the motor OEM.

Have rigorous systems to safeguard and account for all explosives products and accessories. These systems should be regularly audited.

Where mines have high voltage switchyards, they should:• review maintenance strategies for oil filled ceramic/porcelain CTs. • review suitability of hairpin style CTs against other designs• review fencing and barriers in the switchyard to minimise injury or damage in the event of catastrophic failure of switchyard components. • minimise exposure of persons by limiting number and duration of activities where personnel are required to access the switchyard, or work in proximity to the yard.

The Division of Resources and Energy publishes information on bullying in the workplace on the following webpage: http://www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/topics/bullying-in-the-workplace. Safe Work Australia also publish guides to preventing and responding to workplace bullying and a worker’s guide to dealing with bullying. http://www.safeworkaustralia.gov.au.

Stockpile control valve monitoring systems should include audible and visual alarms to 1. Detect unintended movement of valves from the closed position. 2. Detect coal loading onto a conveyor without coal valves being selected to open.

Conduct detailed inspections and monitoring of high walls and associated windrows/ bunds to identify and eliminate potential rock fall hazards. Regular reviews of haul road and windrow construction is essential to assess compliance to design criteria.Consider potential rock falls when working adjacent to and below high walls. Controls such as modified work practices, stand-off distances, retention berms or physical protective barriers will mitigate or eliminate the risk

Dedicated parking areas should be identified and utilised whenever possible.Broken down vehicles parked outside designated parking areas should be clearly identified by reflective tape, warning triangles or some form of lighting.Before moving a parked vehicle, inspect, and be fully aware of, their surroundings and any potential hazards

All moving components of a shaft system should be included in the planned inspection / maintenance system.Consider the installation of retaining / locating mechanisms that eliminate the risk of critical components falling down a shaft should they fail.

Consideration should be given to adopting a vehicle proximity system.Before driving ‘blindly’ into a drive or crosscut operators should pass by the junction to enable a visual check for other vehicles.Review parking procedures to ensure effective visibility of vehicles through use of dedicated parking areas and vehicle mounted and portable warning lights.Established radio protocols in main vehicle travel ways must be strictly enforced.

Tree clearing procedures at mining operations should include provision for conducting an inspection for unstable trees or parts of trees that have the potential to harm persons or damage plant or equipment prior to allowing entry to personnel.

Mines should re-inforce the following in relation to cap lamps:• pre-use inspection for damage/defect.• awareness on exiting machines, including cords being caught on seats and being shut in doors resulting in cut leads.• awareness when working around rib mesh, bolts and other snagging hazards.• awareness when working around rotating machinery such as secondary support bolters.• wearing the cap lamp and battery so as to minimise excess looping at the rear.Mines should consider having leads shortened to a more manageable length.

Mine operators should consider reviewing adequacy of all ventilation control devices (VCD’s) with a particular focus on components and/or methods of installation that are fit for purpose.

Mine operators to ensure ventilation modelling is completed and communicated prior to major ventilation changes including sealing all or parts of the mine.Furthermore, proposed ventilation changes should be reviewed and authorised prior to being implemented.

Mine operators must ensure emergency management plans include withdrawal procedures and that workers are familiar with those procedures. The failure of incoming power supply is not an uncommon occurrence. Mine operators should consider the use of auxiliary power supplies to support the mines ventilation infrastructure

Mine operators are reminded of their obligation to identify risks to health and safety and implement control measures in the event of unauthorised persons gaining access to the site

The complaint is being investigated by Mine Safety.

Fit for purpose equipment such as a work platform or scaffolding should be provided to allow safe access to plant or equipment whilst carrying out maintenance or cleaning activities. All sites should review current procedures in light of this incident.

Mine Operators are reminded that the legislation requires them to post all notices issued by an inspector on a notice board that is easily accessed by all workers and contractors.

Legacy plant needs to be reviewed to latest standards and legislation.

An investigation was undertaken. Some concerns were substantiated and actions taken as a result. The person raising the concerns has been advised of the outcome and any actions taken. Mine Operators are reminded of the duty to consult workers when identifying hazards and assessing risks to health and safety arising from the work. Consultation requires that workers be given a reasonable opportunity to express their views and to raise work health or safety issues.

The changing conditions should have triggered a review of the methodology for cleaning the drain.

Mines should ensure that all welding equipment is inspected prior to use and is maintained correctly. Damp clothes or gloves increase both the likelihood and severity of electric shock when welding. Clothing, including welding gloves should be in good condition and dry.Insulating mats should be used where contact with the work piece cannot be avoided. Fatalities have occurred under these conditionsRefer to Safe Work Australia ‘Welding Processes’ Code of Practice for guidance in work practices and to AS 1674.2 for guidance in selection and maintenance of welding machines.

If ‘on highway’ types of truck are to be used in a mine they should be first subject to a comprehensive ‘fit for purpose’ risk assessment and modifications made that meet the required duty in the mine environment.Pre-operational, periodic and pre-start inspections should be completed by competent persons to ensure that mobile equipment is fit for purpose and all safety critical systems are fully functional.Pre start checks should include in-service performance brake tests.Consideration should be given to utilising brake testing ramps prior to entering a mine ramp or decline system

Mines should ensure that the work area where articulated dump trucks are used at night are well illuminated and the risk of overturning the tub is minimised through elimination of uneven roads and uneven dumping areas.Tipping points should be planned and clearly designated and / or controlled through close supervision.

An investigation was undertaken and many of the issues identified in the complaint verified. A WHS improvement notice was issued to the Mine Operator (in relation to more than one mine) and a meeting was held with company management to communicate the regulators concerns. Mine Operators are reminded of their duty in relation to managing risks from airborne contaminants – to ensuring exposure standards for substances and mixtures not exceeded and to monitor airborne contaminant levels by air monitoring.

Mine operators should ensure workers are provided with safe access points whilst inspecting / working on equipment. In the event of a slip or fall, restraints and/or safety chains should also be considered

Safe systems of work should consider minimising a workers exposure to stored energy that could be potentially harmful to workers whilst carrying out a task. In consultation with original equipment manufacturers, it is recommended that mine operators review the use of engineering controls where practicable whilst carrying out work on equipment. This should include the use of suitable devices or tools.

Plant must be driven at appropriate speed when manoeuvring in reverse on uneven ground.

Sites must maintain effective explosives management systems. These systems should include safe work procedures and signed off checklists that minimise the potential for misfires and / or unaccounted explosives devices.

The use of fit-for-purpose lifting lugs on small heavy items is recommended where practicable. When lifting without lugs, rigging / slinging work should be conducted by competent workers holding appropriate high risk work licences.

Wash-down water around plant must be appropriately drained away so as not to cause damage to road and ramp infrastructure.

An effective ground control management plan was in place that included regular inspections and monitoring of bench walls. Mines should ensure geotechnical information and associated controls such as modified work practices, stand-off distances, retention berms or physical protective barriers are effectively communicated to and implemented by operators

Maintenance inspections of retard braking resistors should include the inspection for integrity of resistor mountings and the resistors themselves. Development of appropriate inspection frequencies should be in consultation with the original equipment manufacturer and include consideration of a change out/overhaul programme with intervals to ensure safety from failure of retardation system and fire.

Complaint being investigated by Mine Safety.

When a change in work practices takes place, sites must make an assessment of risks and implement controls to manage any additional hazard or risk to workers health and safety.

Mines should ensure compliance with light vehicle/heavy vehicle stand-off distances and light vehicle parking rules.

Mines should ensure that pull test results are analysed and effective action plans are implemented to immediately address any unexpected results. Ground control management plans at underground metalliferous mines may be reviewed with reference to MEX-009 – ‘Mine ground control management plan audit tool’ which is available on the Department’s website at www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/publications/tools

Operators are reminded that whenever changes to work practices are made, an assessment of risks must be undertaken so that any new hazards are identified and effective controls are put in place prior to commencing work.

Mines should assess risk of slipping from work platforms including consideration of the height of kick-boards and positioning of hand-rails.

When installing lights, or other electrical apparatus, consideration must be given to the location of cables with respect to pinch points or exposed areas with the potential for damage.

Mines should regularly audit compliance against the mine explosives security plan. Particular focus to be directed at stock reconciliation, authorised access to explosives, detonators and explosives precursors.Metalliferous and extractives mines may refer to MEX-01: Explosive management system audit checklist for metalliferous and extractive mines and quarries.The SafeWork NSW Security plan guide is also a relevant reference.

Refer to Incident Information Release IIR16-02 on our website

Position isolation valves, including water taps so they are accessible from ground level. Where this is not possible, items at height should be accessed from safe work platforms, ladders or purpose designed alternatives.

Mine operators need to consider the possibility of localised strata failure in all parts of the mine accessible to workers. Particularly older areas of the mine where deterioration of support systems is likely to occur.

The mine identified running air filled tyres assists in mitigating vibration injuries to passengers. When running air filled tyres mines should check compatibility between tyres and rims and have maintenance systems to check tyre condition.

Hose integrity is the single control measure for the prevention of an escape of pressurised fluid into the work area.Mines should have effective hose management systems to ensure hose integrity. This should include consideration to the recommendations in Section 7 of MDG 41 Guideline for Fluid Power System Safety at Mines.

To prevent truck rollovers while tipping, tipping areas need to be level.Operators should conduct regular inspections and supervision to monitor active tipping areas such that rough or uneven ground and potentially hazardous tipping positions are identified and eliminated.

High pressure hydraulic tensioning devices should be inspected prior to use and personnel should be competent in their operation especially in relation to correct positioning of the reaction arm.

Plant should be designed and maintained to start under loaded conditions. The mine should have systems in place to allow for starting under overloaded or abnormal conditions.

Falling while getting into or out of heavy equipment can cause serious injuries. Maintaining three points of contact at all times reduces the likelihood of slipping and falling. Never use tyres or wheel hubs as a step, ensure good footwear, don’t rush and always exit and enter facing the operators cabin

Fit for purpose equipment must be used for handling of loads, ensuring that designs and procedures are appropriate for the task.

Hot work procedure at mine should consider all areas above and below, that can be potentially impacted by hot work process.

Mines using remote controlled equipment should have robust maintenance/cleaning procedures for associated remote control transmitters, including documented pre-use checks. Mines should also have, and use, document control systems to ensure that safety and technical bulletins relating to equipment are passed to the correct personnel to ensure any recommendations around equipment upgrades and improvements are properly considered and assessed.

Drivers of delivery trucks to mine sites should be made familiar with entry procedures. Bollards should be clearly visible from the range of vehicles expected to negotiate them.

All mine sites should implement appropriate control strategies to ensure that material resulting from mining activities is not able to leave the boundaries of a mine where it may effect ‘other persons’ or members of the public.

Coal mines should ensure their electrical trades and engineers are trained and assessed as competent for work on explosion protected hazardous area equipment. Maintenance inspections should detail checks for correct glanding of cables into explosion protected enclosures.

Mine Operators should review their Ventilation Control Device standards to ensure controls to prevent such an unplanned door closure are in place. Such controls may include a chain or other means to securing open doors and signage. All UG personnel should be made fully aware of the risk and controls.It is recommended that an engineering control be considered which would secure the door without the person having to remember to manually attach a chain or other such means

Mine Operators are urged to re-enforce with their workforce that just because a machine appears to be un-powered does not mean it is effectively isolated. Before working on / removing damaged trailing cables from mobile equipment, such cables need to be de-energised and physically removed from their source of supply and appropriate safety tags applied to the cable. This is particularly the case with machines which can start automatically.

Mines should have in place processes which remove the need for the tradesperson to directly access the engine bay to take samples of hot engine oil such as a remotely mounted sampling point.Procedures should be in place which allow for the engine to cool down before removing the engine oil filler cap.Mines should reinforce the need to check sight glasses and other indicators for fluid levels before removing filler caps.Tradespersons should wear gloves and long sleeve shirts when removing oil filler caps.

Regular checks should be made on the surface adjacent to wall faces and any signs of instability should be remediated or, depending on the circumstance, controlled.Control actions may include exclusion zones to prevent any person / machinery being able to access an area at risk of being struck by falling material.

Mine operators should ensure that operator training and procedures provide instructions on driving equipment on wet roads. Road watering procedures should also include guidance on leaving dry-lines. Mobile equipment such as trucks and scrapers should be fitted with speedometers.

Radio remote controls for mining machines are required to be of the highest integrity and “any” failures to operate as expected requires investigation to identify the failure so the OEM/ user can continue to make improvements. Mines should enforce their Go/NoGo zones and review new technologies (proximity detection systems).

Road surface construction and maintenance should minimise the risk of creating excessively slippery surfaces on the application of water.Changing conditions should be monitored and reported to affected persons.

Mines with ageing infrastructure, particularly in corrosive environments, should implement an appropriate inspection and maintenance regime, commensurate with potential risks and should be carried out by competent people in order to ensure, so far as is reasonably practicable, the provision and maintenance of safe plant and structures.

A regular, planned and effective inspection regime should be implemented for pipes and ducting to ensure structural integrity is maintained. The frequency should take into account the material or fluid conveyed the environment and the potential for corrosion

Mines should consider lockable or tamper-indicator devices on valves which are integral to safety circuits or systems.

Mine should restrict access to the site by the general public. Mines should use fit for purpose equipment.

Mines should have a formal commissioning procedure. The commissioning procedure should take into account torque settings and pressure settings.

Mines should require safe parking practices without reliance on door interlock brake application. Safe parking behaviours should be reinforced through training and supervision.

The controls identified in the risk assessment for removing waste material from a crusher feeder conveyor must include application of the hierarchy of controls such that operating procedures eliminate the need for manual handling – particularly whilst the belt is moving.

In addition to normal reporting requirements, incidents that highlight potential safety issues with the design/manufacture of road registered vehicles should also be reported to the vehicle OEM and to the Australian government Department of Infrastructure and Regional Development. For additional information, refer to https://infrastructure.gov.au/vehicles/reporting/index.aspx

Mines should review hydraulic circuits for the potential of entrapped fluid and update procedures were this occurs.

The maximum travelling speed of trucks and other vehicles should be established for each site, taking into account the vehicle load, roadway gradient and surface conditions. Additionally, mines should ensure that road watering procedures include leaving dry areas for increased traction on ramps.

Mines should review their transport management plans and specific vehicular procedures in high traffic areas (such as longwall recovery) to ensure shunting and all communications between vehicle drivers are controlled in a safe manner.

Mines should confirm with repair / overhaul workshops Quality Assurance Systems for work completed. In this case that correct length bolts are fitted.

Equipment operators should undergo regular equipment re-familiarisation training and competency assessment before they operate different vehicles or different model of vehicles that they have not operated for some time.

Mines should examine jacking shaft flange bolt holes for imprint of the bolts threads in the flange bolt holes to determine if the bolts were loose ( if found loose have the jacking shaft tested for cracking)Mines should examine the jacking shaft flange faces are mated properly and that they are secure. If they have not been pulled up square there will be ingress of dirt. (If found not to be mated properly then have the jacking shaft crack tested)

Sites must implement and maintain effective explosives management systems that include the safe transport and storage of explosives components. OEM’s are reminded to regularly review the effectiveness quality control measures during the manufacture of explosives and associated equipment

Mines should ensure that positive communication procedures are implemented and maintained at all times. These procedures should include the requirement for the incoming operator to be acknowledged by other operators prior to entering the work area. Additionally, verification of correct radio channel usage for all vehicles would be prudent for each worker prior to operating vehicles or plant in the working areas of the mine.

Mines should ensure that detailed inspections of explosion protected electrical plant include verifying the correct retention of push button and rotating switch operators

Mine operators should ensure policies and procedures for blasting are developed and followed which may include the prior notification of blasting activities with adjoining or affected landholders.New staff members should be fully briefed on roles and responsibilities associated with implementation of safety systems.

The mine operator must ensure all lifting equipment and attachments are regularly inspected and tagged.An effective record system must be maintained.

Mines should ensure the explosives handling conforms with ”AS 2187.2-2006 Explosives - Storage and use - Use of explosives” recommendations and a thorough risk assessment is conducted prior to blasting activitiesMines should ensure security of explosives conforms with the Explosives Act 2003 and Explosives Regulation 2013.Shotfirers must have direct control over the explosives and they must keep adequate records.

Mine operators should ensure seat belts are installed and operators are wearing them at all times whilst operating machinery.

Mines should review their operational risk assessments on bolting operations with particular focus on human factors.

Mechanical ventilation is a primary control to manage the hazards of fumes mists and dust in laboratories. Mechanical ventilation is only effective when used in accordance with design criteria and maintained in good working order. Chemical monitoring devices must also be regularly maintained, inspected and tested to ensure the safety of workers Mines should ensure security of explosives conform to the Explosives Act 2003 and Explosives Regulation 2013. Shotfirers must have direct control over the explosives and they must keep adequate records

The mechanisms for all slope failures should be investigated and established by competent personnel. Back analyses of the failures should be compared with mine design criteria, and actual construction, and corrective actions implemented if similar future failures could present a health and safety risk to personnel.

Electrical equipment and cables need to be physically protected in areas such as cut-throughs where vehicles are permitted to shunt and/or park. Mine employees should be reminded of the need to report such damage and be made aware of the inherent hazards in handling energised HT cables.

Where there is potential for material to fall from a height and result in injury, the area should be classified as a danger zone and appropriate guards and warning signs must be provided.Workers should be trained and competent in the use of blower extraction systems and the equipment should be fit-for-purpose.

Where non identical rollers are used to replace failed rollers the mine operator needs to be satisfied the replacement rollers are capable of preforming equally to the original specified roller.Where a change has taken place, a change management review needs to be undertaken to ensure any additional hazards have been identified together with appropriate risk controls.The long term storage of spare rollers needs to provide protection from environmental elements, such as heat, cold, rain, in some instances snow/ice as well as ultra violet light.

Corrosion of conveyor components and the fastening of those components should be included in routine maintenance tasks.Regular structural audits of conveyor systems would also assist in identifying the onset of corrosion.

Routine hose maintenance inspections should include a condition assessment of hoses with particular focus on wear, impact and squashing between the equipment

The department has a duty to investigate all complaints reported by the public. Blasting must only be undertaken by competent operators and the mine manager must also have the competency to manage blasting contractors and develop appropriate risk management controls. The mine also breached its DA and environmental conditions and is under investigation by other relevant regulators.

Mines should maintain clean truck servicing locations. Prestart inspections after servicing should be reinforced including a general walk-around machine by the driver.

Mines should review their Contractor Management Plans and SWP’s with particular attention to supervision, risk management and maintaining housekeeping standards. Open hatches should be clearly identified and have barriers in place to prevent falls

Mines should review vehicle operations on roads and ramps with a focus on safe driving during and after inclement weather and road watering operations. Heavy and light vehicle operators need to be aware of changing road conditions and rules that apply.

Mines should ensure that any such anchor bracket is designed to provide restraint in all directions in which force may be applied. In this case a restraint against vertical movement was added.

Mines should consider alternative methods for installing ancillary items on to roof bolts other than the CM drill rig. Drill rigs should only be used for the design function. Any variation of use of drill rigs should follow change management procedures.

Mines should regularly inspect the integrity of all pipe mounting brackets/ hanging supports.When designing infrastructure involving piping/ brackets/fastenings, consideration must be given to the total weight of the pipe and its contents being suspended

The mine operator must ensure, so far as is reasonably practicable the workplace or means of entering or exiting the workplace are without risk to the health and safety of persons. The mine operator must also ensure the provision and maintenance of safe systems of work and ensure adequate instruction, training and supervision is provided to protect all persons from risks to their health and safety. Management have a duty to identify hazards and implement risk control measures to minimise the risk to the health and safety of workers. Examples of risk controls are: appropriate segregation distances between trucks; delineated walkways; formally allocated trucks; sequencing of truck/operator despatching.

In areas where there is a large roof displacement consider the need for an inspection of the tendon bolt plates in the area looking for signs of the barrel/wedge arrangement pulling through the plate. Consider developing a support or restraint (suitable for the force of release of the plate) for those plates at risk of failure.

Operators should be reminded of the importance to inspect workplaces to ensure suitability of safe standoff distances between operating plant. Review site traffic management plans and ensure that controls are being followed by operators.

Although the truck operator had been made aware of the difference in park brake activation between the hire truck and site truck, he has been habituated in the use of the standard site truck. Mine operators must consider human factors when identifying risks. Generic pre-starts and contractual specification of the hire truck did not mandate a park brake alarm as per site standard. Mine operators should ensure that standards are maintained and new equipment is subject to a stringent pre-use audit against site requirements.

Mines should review vehicle parking arrangements for all relevant areas of the operation. The parking arrangements should allow for safe movement of operational vehicles clear of those that are parked-up.

Link to incident report: www.dmp.wa.gov.au/Documents/Safety/MSH_SIR_241.pdf

The mine has reviewed its control measures for managing the outburst risk to ensure integrity of the process.

Mines should ensure insulation resistance (IR) testing is only performed by competent electricians that are trained assessed and appointed.Operational risk assessments for the IR testers should be available on-site along with user manuals and site procedures for their safe use and storage.Gas clearance certificates should be obtained prior to taking and using IR testers in a hazardous zone.Electricians should ensure prior to their use that the test instrument and kit is fit for purpose.

The work area was under the control of a certificated dogman and rigger. It came to light that the haulier arrived at the site earlier than expected and that long chains, which were being used for another task, were used to unload the blocks in order to expedite the departure of the haulier from site. The integrity of the dog and chain linkage was not inspected for every lift.Mine operators should ensure that fit-for-purpose lifting tackle is used for each particular task at hand, despite operational pressures.

Mine operators should have procedures in place that require workers verify proximity detection devices are functioning as designed prior to operating machinery. Mine operators are also reminded to review the effectiveness of controls applied to fatigue management.

Mine operators should review their gold room procedures with particular attention to supervision, risk assessments, task observations and PPE compliance. Full face protection should be mandatory at all times whenever handling hot bars. Cooling off areas should be clearly defined and maintained in a clean dry state with minimum cooling off periods enforced.

A cover screw was found to have penetrated the insulation of 240V wiring in the heater unit. The heater had recently been off-site for repairs. Mine operators should ensure repairs on electrical equipment are only undertaken by competent persons. Mine operators should also ensure these units are subject to regular detailed inspections by competent electrical tradespersons.

Mine operators should develop a commissioning checklist system to confirm safety clips are installed in quick release style coupling after each installation and before energising. Mine procedures should consider isolation and depressurisation on air lines when lines are worked on.

Mine operators should be reminded of the benefits of hose sleeve protection (mine sleeve), which in this case protected the worker from the potential of a serious injury.

This incident highlights the very important requirement for mine operators to frequently review scaling crew competencies and levels of supervision while scaling at the face. Competency training should include site specific geological and geotechnical issue awareness. In adverse conditions a permit to work system for post scaling tasks should also be considered.

When designing and installing conveyor systems, mine operators need to consider the risks associated when walking or working alongside conveyor systems. Walkways should be designed so that persons can walk normally without impediment. Furthermore, conveyor systems should also include appropriate guarding (compliant with Australian standards), hand rails and non-slip surfaces for steep grades.

Mine operators should consult the OEM whenever proposing changes to plant design, operating systems or procedures. Also, operators should apply change management which may include assessing risks, implementing additional controls. This must be done in consultation with workers.

Mines must have Safe Work Method Statements (SWMS) about operating plant on sloping ground. Plant operators should wear seat belts. Roll Over Protection Structures (ROPS) do work.

All cabling should be positioned in roadways and shunts such that they will not be struck by vehicles and loads being transported. Effective management systems should be in place to manage load sizes and to audit cable positioning in transport roadways and shunts.

Mine operators should ensure proximity devices (where installed) are operating as intended at all times when equipment is being operated. Testing and maintenance must be carried on a regular basis. Positive communication procedures should be reviewed and communicated to all relevant workers, especially whenever operational changes take place and/or significant incidents occur.Defect management systems should be implemented and workers need to be encouraged to report all defects when they occur.

Investigation concluded that corrosion of the brake line caused the incident, by allowing the pressurised fluid to escape when the brake pedal was applied. Mine operators should review their planned and preventative maintenance schedules in order to ensure that a comprehensive inspection or replacement is conducted of all critical safety system components including, but not limited to, braking systems, according to OEM manuals and further adapted for the harsh mining environment. Vehicle operators should have access to FFP vehicle washing facilities in order to allow the vehicles to be cleaned underneath to prevent the build-up of mud and hence corrosion around these components.

Mines are advised to consider providing assistance to operators whilst lifting heavy loads such that sufficient clearance is maintained around ‘catch points’.It should also be noted that ‘no go zones’ are to be identified and inadvertent access to these zones is maintained at all times during the lift.

Mines are advised to ensure that regular maintenance of electrical installations is carried out to reduce the risk of fire through short circuit. All control panels should be cleaned on a regular basis to ensure that contaminants do not build up inside.

Mine operators must ensure that workers are trained to observe and understand the geological and geotechnical characteristics of their work environment in order to assess prevailing and possible hazards. The mine operator should consider the possible adverse effects of geological structures as they are known, and as they become known, and reduce risk ALARP at the initial planning stage and as an on-going monitoring and review process. Geotechnical controls should be both predictive and reactive.If a change/deterioration in the work environment occurs then the change needs to be risk assessed and appropriate ground control protocols implemented to ensure workers are not exposed to risk.

As part of their introduction to site process, managers of electrical engineering for underground coal mines should have a rigorous review process for documentation associated with the testing, repair and overhaul of explosion protected electrical equipment.Where it is identified that explosion protected electrical equipment in use in a hazardous zone does not comply with its Certificate of Conformity, mine operators should take the appropriate steps to address both the risks arising from this non-conformity, and the requirements to comply with the applicable clauses of the NSW WHS(M&P)R 2014.

Mine operators and PCBUs must ensure the provision of adequate facilities for workers including toilets, drinking water, washing and eating facilities. The facilities must be maintained in good working order, and be clean, safe and accessible.

Mines that decide to recover older areas for re-use need to consider deterioration of physical conditions then adequately plan and prepare the recovery process to include inspections, geology, strata support and ventilation to ensure the safety of persons in the area.

Mine operators must ensure that all structures are designed and installed to recognised standards to be without risks to the health and safety of persons at the workplace.The designers of a structure must also supply adequate information to the mine operator to ensure that the construction, installation and commissioning of such structures is undertaken so as to meet the intended purpose for which it was designed. This may include results of calculations and conditions for use.

Explosion protected electrical equipment must be maintained to a high standard at all times to prevent the likelihood of a methane explosion. To ensure standards are maintained, mine operators should review maintenance procedures and consider including verification inspections and/or audits.

Mine operators must ensure that thorough and comprehensive planned and preventative maintenance inspections are conducted. Consideration must be given to the installation and maintenance of batteries on heavy mining plant in accordance with AS/NZS4871.6. Electrical equipment for mines and quarries - Diesel powered machinery and ancillary equipment. Maintenance personnel should be provided with the correct components specified by OEMs.Mine operators are also referred to the following safety publications: Safety Alert SA15-05 and Safety Bulletin SB16-02, both on our website.

Mine operators must ensure that mining induced seismicity is appropriately monitored, recorded, and the data analysed and interpreted. Stress modelling should be undertaken in order to predict seismically active zones. The design and reviews of ground support regimes should consider the likelihood of rock bursts and the requirements for yielding and appropriate surface support.

Mine operators should have systems in place that minimise the risk of introducing unsuitable/ mismatching fittings. Additionally, procedures should be in place which require the dissipation of fluid prior to conducting repairs or maintenance activities.

Roads and vehicle management systems should consider the manoeuvrability of vehicles in relation to maximum operating speeds, the impact of road design which includes grades, camber and radius of curves.

Maintaining equipment on a longwall face may expose workers to unsupported ground. Mine operators should have systems in place that prevent persons entering and/ or working in any area of the mine where there is no ground or strata support. Regular inspections, supervision and temporary support should be considered as minimum control measures

Mine operators should ensure that a system is in place to identify & verify that ground support is being installed as per the mine design. All mine designs should consider and allow for known and prevailing local geological structures and geotechnical issues. A QA/QC system for ground support installation should be in place and monitored for compliance.When considering matters to be considered in developing control measures to manage the risks of ground failures mine operators must refer to the WHS(M&P)R Schedule 1 (1).Metalliferous mines may wish to refer to the Mine Safety Operations publication MEX-009 – Mine ground control management plan audit tool.

Roads and vehicle management systems should consider the manoeuvrability of vehicles in relation to maximum operating speeds, the impact of road design which includes grades, camber and radius of curves.

Mines should ensure that positive communication procedures are implemented and maintained at all times. These procedures should include the requirement for the incoming operator to be acknowledged by other operators prior to entering the work area.

When tasks are undertaken requiring the movement of loads by winch rope or chain, the task should be assessed and the safe position of persons identified.

Industrial light switches with insulating membrane separating the operator from possible electrical contact are readily available from electrical wholesalers.

Where a cut-through contains high voltage transformers, belt starters and/or other major electrical plant – mine systems should provide for demarcation barriers to be installed and maintained to a standard that restricts vehicle access and protects electrical cabling and equipment.

Mines should consider barricading standards (e.g. jersey barriers) or signage (eg flashing lights) for use on main transport roads when the road is obstructed. All vehicle operators should be reminded to keep their machine fit for purpose during use - clean windscreen and clean lights were an issue in this case.

Mine Operators should have clear instruction for the safe and proper use of tools that include pre-use equipment inspections. Furthermore, proper equipment storage and transport using fit for purpose covers and/or cases is also recommended.

Transport management systems should include procedures for vehicle park up. In all cases, the vehicle operator should ensure the vehicle is fundamentally stable by applying the park brake and engaging the gears as a minimum. Wheel chocks should also be considered, particularly when parking on a grade.

Glare from the sun can impact on a vehicle operator’s ability to identify oncoming vehicles and/or other obstacles on the road. All vehicles should have visors or other devices made available such that visibility is not impaired whilst driving towards the sun. Mine Operators should remind vehicle operators to slow down or stop the vehicle if visibility is impaired. Additionally, roadway design should consider segregation of traffic flows to eliminate the potential for collision with oncoming traffic.

Mine Operators should remind workers of their obligation to follow the correct operating procedures at all times. This may involve routine inspection by supervisors to verify correct operation in line with SWP. It should also be noted that correct maintenance strategy should align with OEM recommendations.

Mines should review relevant control measures for ventilation of extraction panels including targeting of gas drainage down-holes at geological structures with potential of higher gas release. The ventilation system should be designed to manage such gas pushes from floor breaks and the safety of personnel.

Machines used for work in areas with restricted access should be fit for purpose. In such cases the work area should be assessed for hazards which may impact the use of the machine.

For devices such a hydraulic tensioners that can generate high pressures and at times are used irregularly, regular maintenance and pre-use inspections are important.

Mobile mining equipment should be fit for purpose and be matched to the work activity undertaken.Supervisors and workers should inspect the workplace at regular intervals to ensure the workplace is safe and without risk.Risk assessments and Work Method Statements for loading from blasted rock piles should assess the risk of rocks/material falling from height.

Mine Operators should ensure that workers conduct effective risk assessments. In this incident a JSA was not conducted and consideration was not given to the ability of the IT to complete the task of moving up the ramp with the flexible pipe load.

Poor housekeeping led to an ‘oil on concrete’ slippery surface. The worker walking backwards added to the risk/injury outcome. Mine Operators should ensure planned inspections are conducted and consider bunds to contain spills/ drips and measures to mitigate oily surfaces

Mine operators are reminded to review hydraulic hose maintenance management systems at regular intervals and/or when an incident occurs that places workers at risk. Inspections should consider checking for hose wear points and the removal of a build-up of fines that could potentially cause premature damage or wear.

Identifying hazards in the workplace prior to commencing work is a fundamental step towards minimising the risk of injury. Mine operators are reminded that workers should conduct a pre-work assessment for each task that is undertaken. Also, routine tasks such as replacing ventilation tubes should have a safe work procedure in place

To minimise the likelihood of catastrophic component failure on conveyor belt systems, maintenance procedures should include routine temperature monitoring and routine vibration analysis

Strip watering techniques should always be applied to ramps/ grades to increase traction and reduce the potential for loss of traction. Consideration should also be given to current weather conditions prior to watering

To ensure design standards are maintained, mine operators should review maintenance procedures and consider including verification inspections and/or audits.When checking Ex enclosure gaps as part of daily inspections and post maintenance, the feeler gauge used should be less than the max allowable gap for the enclosure.

The aim of well setup and coordinated network electrical protection is to trip at the first system in-line closest to the damage on any HT cable. Risks require management when stowing material in cut-throughs where HT cables are run and there is the possibility of machine contact. Consider controls such as cable re-routing, additional mechanical protection and/or isolation.Mines should also consider the implementation of a formalised stowage procedure and permit system.

Mines should review site security, take reasonable steps to prevent unlawful entry and put in place controls to protect unwanted access to equipment.

Operators responsible for mining trucks need to ensure that they are fit for purpose and properly maintained. Overloading of trucks is to be avoided and gradients are to be within acceptable limits for loaded trucks

Mine should ensure procedures regarding blast exclusion zone include specific detail on restrictions of vehicle movements within these zones, and that relevant personnel are trained in the use of these procedures

Mine Operators should ensure that effective notification, communication and warning systems are in place to ensure members of the general public are informed of intended blasts.

Mines should review the critical controls in their strata failure Management plan so as to identify and quickly respond to any area of concern. Some mines have implemented A Strata Defect system including TARPs which mandate timely response which is considered very good practice and has reduced the incidence of roof falls at these operations.

The complaint is being investigated by the Resource Regulator.Mine operators should make themselves aware of all legislative reporting requirements.

When mine operators are informed of unexpected potential hazards a detailed investigation including a risk assessment should be undertaken to identify and control the potential risks to the current operation.

Operators must ensure that adequate subsidence exclusions zones are established, properly signed, communicated and enforced. This should occur prior to potential development of cracking or sinkholes that may lead to exposure to a subsidence hazard.

Heavy mobile plant is to be operated within the manufacturer's specifications with regard to speed of operation and other parameters. Drivers should be trained to be aware of the different characteristics of articulated trucks compared to those of rigid dump trucks.

The importance of complying with the mine’s documented strata management plans around roadway holing points should be emphasised to ensure ribs are adequately trimmed before being safely secured. Effective supervision of such operations is stressed. Mechanical rib protection, where available, should be used in accordance with equipment design and functionality.

Industry should design drill rig set ups and the associated hose/pipe range such that the system can cope with abnormal gas makes.

Mine operators should ensure that replacement parts installed on plant are to the correct specification with regards to design, dimensions and material quality.

While the electric shocks received in both instances were from a source of Extra Low Voltage (24Vdc), the environment in which these machines operate (warm, damp and humid) enhance the effects of an electric shock. In addition to electric shock, there is also the risk of a person falling from height due to the unintended response to the shock.Mines need to ensure that the pre use and maintenance inspections are appropriate, personnel are effectively trained in the inspections and the inspections are undertaken in a thorough manner. Investigations into incidents also need to be undertaken in a coordinated and controlled manner.

Battery Isolator Boxes should be positioned so the IP rating, cable rating and isolator rating cannot be compromised due to;-ingress of moisture; excessive build-up of foreign material; excessive cable lengths or incorrect ratings of box and isolator.

Mine operators are reminded that all mines and quarries which utilise high voltage and/or have a connected load greater than 1000kW must nominate a qualified electrical engineer to fill this statutory role at the mine as a key statutory position subject to the reporting provisions for such positions.

Mine operators should ensure that risk assessments and standards that identify and eliminate risks in drill cuddys are developed, implemented and reviewed.Planned inspections should be conducted to ensure standards are maintained.

All sites should have a traffic management plan/JHA specific to every shot to ensure control of vehicles in that work area. The plan should include reference to which vehicles should be allowed into the area and where and when they should be operating

Operators of mobile plant need to pay particular attention to the position of other mobile equipment prior to moving a vehicle

Mine should check equipment is fit for purpose and set up correctly for each application. Pneumatic hand tools should be fitted with inline flexible fittings which reduces the likelihood of threaded connections unscrewing. Threaded connections fitted with anti-tampering devices such as tape should be designed in a manner to make it obvious to the end user that the thread has commenced to rotate.

Mines should ensure that pinch points around forklift tynes are clearly identified and that forklift tynes are regularly maintained and lubricated and can be safely repositioned by a single operator.

The attention of Mine Operators is drawn to Part 6 Division 1 of the NSW Work Health and Safety Act 2011. Dismissal of a worker or termination of a contract for services with a worker is deemed discriminatory conduct where the reason is a prohibited reason, such as raising an issue or concern about work health and safety with the PCBU.

Where overhead powerlines (OHLs) cross a mine site, OHL corridors should be established with restriction of activities within the corridors. The corridor should extend a sufficient distance from the extremities of the OHL so that contact with the aerials, poles or support structures (including stay wires) is prevented under normal operating or foreseeable abnormal circumstances.Reference should be made to Australian standard AS/NZS 3007:2013 for recommendations relating to OHLs and associated corridors

Mine operators should ensure that vehicles operating in underground workplaces, especially in declines, maintain safe distances between vehicles - particularly on corners. Safe distances should be determined through risk assessment and reflect the worst case scenario.Radio communications in underground mines provide a significant control in the prevention of vehicle collisions. Effective radio communication systems and protocols with diligent monitoring of radio calls are essential for maintaining a safe place of work.Operating procedures at mines should be effectively communicated to all relevant workers and monitored by mine supervision.

The complaint is being investigated by the department. Information on bullying & harassment is available on our website at: www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/topics/bullying-in-the-workplaceSafe Work Australia also publishes guides to preventing and responding to workplace bullying and a worker’s guide to dealing with bullying. See their website for more details: www.safeworkaustralia.gov.au

Review all tasks that are performed at height and consider ways to perform them at ground level, or from a solid platform. Where possible, configure loads so there is no need to access the tray or trailer. If the task cannot be done on the ground or from a solid platform, consider a fall protection device such as a temporary work platform or guard rail. Minimise the use of chains and webbing by using systems to reduce or eliminate the need for chains and webbing. eg coil containment system, pin, pegs, posts, headboards or goose-neck on a drop-deck trailer to help block the load. If chains must be used, use chains with non-rebounding tensioners.

Mine operators should ensure that all highwalls are regularly inspected and monitored for potential areas of instability/poor ground conditions. Inspections should include detailed geotechnical assessment.Safe Work Procedures should be implemented when working in proximity to high walls. Audits should be conducted to ensure that procedures for working near highwalls are effectively implemented.

When using such equipment, a SWMS should be prepared which considers how the suction hose is extended to the work site. Loops and kinks in the hose should be avoided and the consideration given to securing the hose end in use

Mine Operators should stress the importance of positive communications with machines in proximity. The circumstances and protocols of machine entry into the swing radius of a bucket excavator should be clear and well understood.

Mine Operators should consider temperature monitoring of critical high speed rollers. Chutes designed to collect and transfer fines should be fitted with positive clearance systems

Operators must identify the hazards associated with driving underground and implement effective controls – including use of low range gears and appropriate vehicle speeds especially in areas with limited line of sight visibility, and ensuring effective radio protocol is used. Mine operators should continue to investigate technologies that may assist in collision avoidance

Mines should assess surface conveyors and assign regular inspection schedules based on risk. Defects noted in inspection reports should be acknowledged in the system and actions assigned.

Dumping above any active working area is poor practice and should be avoided if possible. If it is not possible, the mine should implement additional controls to ensure no risk to those working below from those above. As a minimum, the controls should include more rigorous inspection regimes, increased supervision and improved barriers.

Mines should consider temperature monitoring of critical high speed rollers. Chutes designed to collect and transfer fines should be fitted with positive clearance systems.

Mine operators are required by law to eliminate exposure to airborne dusts, so far as is reasonably practicable. Controls stipulated in the Work Health and Safety (Mines and Petroleum Sites) Regulation 2014 include• implementing a principal hazard management plan for air quality or dust or other airborne contaminants• ensuring the exposure standards for respirable and inhalable dust are not exceeded• implementing a ventilation control plan to ensure effective ventilation• implementing air quality, monitoring and ventilation arrangementsThe management of airborne dust at mines will be the subject of targeted assessments. These assessments will focus on how mines prevent worker exposure to potentially harmful levels of respirable dust

Mine operators should ensure robust safe work procedures are in place and personnel are competent and aware of hazards associated with the use of pressurised fluids.Gas cylinders should be appropriately restrained and pressure regulators, isolation valves and connections should be fit for purpose, maintained and kept as clean as possible to minimise contaminant ingress.

Risk assessment and operating procedures should consider changing geology and weather events such that the bench can support the weight and movement of the excavator while top loading. Dimensions of bench mining should be specified that trigger movement of the excavator to stable ground if necessary.

Mine operators should ensure that equipment is fit for purpose, subject to inspection, testing and maintenance and compliant with relevant standards and codes of practice where required. Workers must be competent and licenced where required

Mines should assess surface conveyors and assign regular inspection schedules based on risk. Defects noted in inspection reports should be acknowledged in the system and actions assigned.

Mine operators should ensure waste dump design, construction methodologies and procedures are established that consider the strength, size distribution and consistency of the materials to be used in the construction of waste dump. This should include geotechnical consideration of the potential for voids, slumping and subsidence areas to form, particularly following significant rainfall events. Formal planned inspection of waste dumps should be undertaken by competent persons to ensure the dumps are constructed and operated to the mine design and operating standards.Hard barriers should be maintained in place to prevent access to identified exclusion zones.

Mines should review procedures related to equipment working in close proximity, particularly in and around dig and dump areas. Where safe distances cannot be maintained, protocols should be in place for people working in the area so they are aware of the hazards and able to fully control the risks. Although only a direct contributing factor to this incident, sites should review the adequacy of their management systems in relation to responding to equipment faults

The person with management or control of the plant at a workplace must ensure that the maintenance, inspection and, if necessary, testing of the plant is carried out by a competent person. Temporary repairs to identified mechanical defects must be under the supervision of the statutory mechanical engineer or mechanical engineering manager (for coal mines), or otherwise competent engineer (for non-coal mines).

Cranes should not be moved with jibs raised unless there is no practical alternative. All OEM instructions should be complied with including having the lock pin in place and the slew brakes applied. Dead-man functionality should be tested at pre-start and other maintenance periods.

Operators should monitor contractor light vehicles to confirm appropriate pre-start checks and maintenance is being done on service and park brakes. Parking procedures for light vehicles should reflect site conditions and the risk of a vehicle rolling away.

An intervention by the regulator conveyed a zero tolerance position to production-driven exceedances. Mines should assess ventilation and methane drainage systems to provide positive control of methane levels. TARPs relating to methane levels should be set such that production activities are stopped without an exceedance resulting.

All workers must take reasonable care for their health and safety and comply with the mine operator’s safety procedures and standards on site, e.g. they should comply with maximum speed limits. Mine operators should consider risk controls that include contingencies for operator errors, e.g. bunds and delineated exclusion zones

The site was inspected by a Mine Safety inspector and no imminent risk of flooding was observed at that time. However, mine operators are reminded that mine designs and operating plans should consider all foreseeable hazards. If flooding is identified as a hazard, then appropriate controls should be put in place to manage the risk.See recently published Safety Bulletin: SB16-04 Mines and severe weather events[1]

This incident highlights two categories of control measures that were not present or effectively operating on the day of the incident:The first was the protection of the overhead powerline from vertically extendable equipment, and the second was protection from operating mobile plant while the tipper was raised.This is a timely reminder to all mines that most hazards are controlled by multiple layers of safeguards, and the unwanted event occurs when all of the safeguards fail together, either at the time, or are permanently in the failed state. Duty holders must be vigilant and have effective arrangements to identify and correct absent or failed controls

Operations should review their traffic management plans to ensure that ramps and roads have adequate bunding; well-maintained surfaces and drainage; appropriate speed limits; suitable widths; adequate signs and lighting; and have grades that do not exceed the capabilities of mobile plant used at the mine. It is also important to reinforce site traffic rules with mine workers and to review fitness for work protocols.Ensure seat belts are being worn at all times.

The investigation found that over time, vibration had loosened the air conditioning unit and the hose connected to it had rubbed against other components, allowing a fluid escape. The mine operator is working closely with the OEM to engineer a solution.Mine operators should ensure that good maintenance practices are carried out including ensuring any visual inspections are thorough, including removing covers where they obscure components. The OEM should be made aware of any potential design issues whenever there are any incidents such as these.

It is important to undertake thorough risk assessments and develop functional specifications as part of the design phase of the plant, and ensure that commissioning processes verify that all risk controls identified during design have been implemented and are effective.The importance of control code reviews and audits cannot be understated.It is essential that trained and competent staff maintain plant.An incident-reporting culture should be actively encouraged. Where plant is found to be operating outside of normal parameters, it must be reported - as the cause of this incident dated back to the design and implementation phase of the winder

Good maintenance practices are essential in preventing the ignition of combustible fluids from hose or pipe failures. Where practicable, hoses should be segregated from hot surfaces using hard barriers along with the use of non-flammable coolants. Consider guidance in Australian Standard 5062:2016, Fire protection for mobile and transportable equipment.

Machine operators should inspect their work area to identify hazards, in this case rocks, with potential to fall/roll onto the machine. MDG15 Mobile and transportable equipment recommends all cabin windows be fitted with safety glass or equivalent

Mine sites should review mobile plant fire risk assessments in relation to the effects of noise attenuation. The review should consider:• the ability to access the fire with a water cart• emergency response trainingguidance in AS 5062:2016

Mines should identify, through a risk assessment, all events that would require withdrawal of workers from the mine. An uncontrolled circumstance where elevated methane is present and is trending to the explosive range should initiate a controlled withdrawal of people to the surface.The ventilation control plan must include procedures to be followed in the event of the failure of the main ventilation system including details of the circumstances requiring the safe withdrawal of people from the mine. (cls 62 of the WHS (Mine & Petroleum Sites) Regulation 2014)

The complaint is being investigated by the department. Information on bullying and harassment is available on our website at: www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/topics/bullying-in-the-workplaceSafeWork Australia also publishes guides to preventing and responding to workplace bullying and a worker’s guide to dealing with bullying. See their website for more details: www.safeworkaustralia.gov.au

· Good maintenance practices are essential in preventing the ignition of combustible fluids from hose or pipe failures.• Where practicable, hoses should be segregated from hot surfaces using hard barriers along with the use of non-flammable coolants.• Consider guidance in AS 5062:2016, Fire protection for mobile and transportable equipment.

Lead acid batteries need to be maintained, and in particular the electrolyte levels checked/ maintained where possible. Low electrolyte levels can lead to excessive heating, fire and the explosion of batteries. For this reason, sealed or ‘maintenance free’ batteries are not always suitable for heavy vehicle applications. When replacing old batteries, it is important to only use the battery type and capacity as recommended by the original equipment manufacturer. Fit-for-purpose battery ‘jump starting’ facilities should be provided and used in preference to jumper leads.Refer to NSW Safety Bulletin SB16-02 and QLD Mines Safety Bulletin no. 150.

Mines should ensure that plant safety critical systems, including brakes, are regularly inspected and maintained and are appropriate for the particular mine environment, refer SA06-12 Maintenance of Safety Critical Systems - Braking, Steering & Warning Systems. Operators should be trained, assessed and competent to use all plant safety critical systems.

Mines that are subject to elevated methane readings in accessible roadways during a barometric change should review ventilation control measures. Ventilation control measures should be designed to limit methane below statutory limits.

Mine operators should reinforce the need for appropriate isolation of hydraulic power sources prior to the removal of any guard. Refer AS 4024 part 1, Safety Bulletin SB12-03 and MDG 40. Mines should also review arrangement for hydraulic control levers and guarding against inadvertent activation

The complaint is being investigated by the department. Information on bullying and harassment is available on our website at: www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/topics/bullying-in-the-workplaceSafeWork Australia also publishes guides to preventing and responding to workplace bullying and a worker’s guide to dealing with bullying. See their website for more details: www.safeworkaustralia.gov.au

Mine operators should identify and eliminate potential situations where mobile equipment passes beneath structures. Where this is not possible, risks should be mitigated through appropriate warning devices and interlocks when truck trays are in the raised position. Refer to MDG 15 and SA04-03 Dump truck trays hit overhead structures.Traffic management plans and procedures should be reviewed on a regular basis. Refer to Safety Bulletin SB15-05.

Mine operators are reminded that systems of work should be designed to minimise the expose workers to risks associated with suspended loads.This should include positioning of workers when the system of work is being used and appropriate training of workers in the system of work.All workers are reminded of the need to identify additional risks when there is a change in the task procedure.

Mine and petroleum site operators are reminded that articulated vehicle roll-overs continue to be reported to the regulator at elevated levels. The hazards associated with articulated vehicles are well understood and mine and petroleum site operators are reminded of the recommendations from a previously released Safety Alert.www.resourcesandenergy.nsw.gov.au/__data/assets/pdf_file/0004/67459/Safety-Alert-03-01-Articulated-Dump-Truck-Roll-Overs.pdf

Any opal mine operator with the same or a similar hoisting system should contact the NSW Resources Regulator – Lightning Ridge Office on 02 6829 9200 immediately. Workers should not undertake any task in a shaft under suspended or unsecured shaft equipment. Material hoists may fail at any time. They are not designed to carry people or have people working directly underneath the material hoist bucket.If work is to be undertaken in a shaft, the material hoist bucket must be secured, either at the bottom of the shaft or at the surface, with the hoist system isolated and protective guarding installed to prevent the bucket or other items from falling down the shaft.

Road watering standards should include spot spraying and consideration of potential hazards associated by saturation.Mine operators should analyse on-board data to identify and report procedural compliance and non-compliances. This information may then be used to encourage compliant behaviour by mobile equipment operators.

Mine operators are reminded that fatigue management forms part the health control plan of the Safety Management System at the mine or petroleum site. The health control plan should consider appropriate systems should be used to check on the fatigue levels of operators during the course of the working shift.

Mine operators are reminded that when designing systems of work it is important to include potential for items of equipment to become dislodged. Safe work zones should be incorporated in to the procedures

Mine operators are reminded that assessment of the work environment needs to include suitability for the mobile plant to work on grades. If the slope is identified as a potential hazard, then job design needs to address either the appropriate piece of mobile plant to do the task or preparation of the worksite to allow the mobile plant to operate within the design parameters.

Unearthed, exposed, conductive parts of electrical installations and wiring systems may be subject to induced voltages. AS/NZS 3000 requires that these parts are effectively earthed to prevent this voltage build up. Commissioning processes at the mine should verify that exposed conductive parts that are required to be earthed, such as cable glands, are earthed prior to initial application of electrical power to the equipment. The earthing of these parts should also be verified during maintenance inspections

Mines should train loader operators on:• loaders not being articulated whenever a loaded bucket is elevated• loaders not being articulated on uneven ground with a raised bucket• only operating loaders within their designated load rating chart• understand the tipping lines of a loader• pre-start checks for loaders confirming correct wheel pressures. Note: this is particularly important for the front tyres of loaders.Refer also to Safety Bulletin: SB15-01 Rollover of load shifting equipment.

Mines that are subject to elevated methane readings in accessible roadways during a barometric change should review ventilation control measures. Ventilation control measures should be designed to limit methane below statutory limits

Compressed air flowing through hoses will cause static charge to accumulate on metallic parts of the compressed air system. Parts such as valves must be effectively earthed to prevent the charge build-up. This may be through the use of a FRAS hose or by dedicated earthing of the parts.While a static shock will not normally cause injury to a healthy person, it is capable of causing gas or dust ignition, or may cause a person to fall if working at heights.

A number of recent incidents have involved a failure to isolate and/or dissipate stored hydraulic or air pressure before undertaking a task. Mines should make sure safe work procedures identify this hazard and reinforce this process with the workforceEffective isolation /energy dissipation is a critical risk control that requires all of the following steps:1) Isolation of energy 2) Locking of the isolation point 3) Energy dissipation of all circuits on the downside of the isolation valve 4) Verification (test for dead) that there is no residual pressure in the circuit.

Mines that are subject to elevated methane readings in accessible roadways during a barometric change should review ventilation control measures. Ventilation control measures should be designed to limit methane below statutory limits.

The department receives regular complaints about inadequate fencing. It is the quarry operator’s responsibility as the PCBU under the WHS Act to ensure the protection of workers and others against harm. A PCBU must ensure, in so far as is reasonably practicable, that persons are not put at risk as a result of the conduct of their operations

Mine operators should identify all areas subject to seismicity where shotcrete has been applied in order to protect installed ground support. The hazards associated with instantaneous ejection of shotcrete, and gradual deterioration over time, must be risk assessed and appropriate controls implemented.Controls may include: excavation (re)design; formal exclusion zones; post shotcrete support such as meshing.

Mines should:-• Regularly check travelling roads for identification and removal of hazards to people travelling e.g. rocks and other objects. • Following the recommendations in SB15-06 Analysis aims to reduce injuries while travelling underground and use SB15-06 Appendix B Fillable questionnaire for vehicle-related injuries.Remind people transporting stowage and materials throughout the mine to check their loads so as to reduce risk of material falling out onto transport roads.

Work activities in and around high voltage and extra high voltage overhead lines must give consideration to the effects of both capacitive and inductive coupling of metallic objects and structures (including hand tools and vehicles) that are required to be used, in addition to direct contact with the lines. (Refer to AS/NZS 3007)Mines should consult with recognised competent earthing specialists when developing management systems for work in proximity to these overhead lines.

The complaint is being investigated by the department. Sites need to be aware of the need to risk assess work prior to commencement.Information on bullying and harassment is available on our website at: www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/topics/bullying-in-the-workplace.SafeWork Australia also publishes guides to preventing and responding to workplace bullying and a worker’s guide to dealing with bullying. See their website for more details: www.safeworkaustralia.gov.au

Before using cutting disks, mines should:• consider various work methods and equipment so the safest is selected including PPE. Train operators in the use of cutting disks including: o awareness of the disc may kick back, and o the steel work that is being cut jamming the cutting disc. e.g. from the steel bending as the steel is being cut.o Two-handed operation of cutting disc.• check the work area is secure and stable, • check equipment is inspected, in good order, has a handle and fit for task to be performed• check cutting discs are not worn down beyond their limits’• confirm steel work is cut being square.

Mine operators should ensure that all highwalls are regularly inspected and monitored for potential areas of instability/poor ground conditions. Inspections should include detailed geotechnical assessment. Safe work procedures should be implemented when working in proximity to high walls. Audits should be conducted to ensure that procedures for working near highwalls are effectively implemented.

Mine operators are reminded of their obligations working in confined spaces, refer to http://www.safework.nsw.gov.au/health-and-safety/safety-topics-a-z/confined-spaces .Confined space work should comply with the NSW confined space code of practice, refer to http://www.safework.nsw.gov.au/__data/assets/pdf_file/0015/50073/confined-spaces-code-of-practice-3558.pdf

There have been several instances of vehicles skidding due to wet road conditions reported to Mine Safety recently. Mines should remind truck operator of:• driving to the road conditions and slowing down on wet roads• using the retarder when travelling down ramps.• Selecting the correct gear when descending.Mine operators should also consider road wetness as a potential hazard in their PMHP for roads and other operating areas

Mines need to consider:• the routing of pressurised hoses and other services, such as to minimise the potential of damage and/or entanglement. • locating lifting equipment such as to minimise potential of damage and/or entanglement with hoses and/or cables services.• locating, positioning and orientating isolation valves so as to minimises any potential of damage and/or entanglement

Mine operators should review the adequacy of their arrangements for delineating exclusion zones, particularly considering the visibility of the zones to the operators of mobile mining equipment in the vicinity

Mine operators should consider segregation of light and heavy vehicles as an effective control measure. Refer to investigation report into the fatal collision at Ravensworth open cut mine in 2013

Mine operators should consider the use of appropriate benches and bunding as an effective control measure to contain the potential risk to operators of rock falls from slopes and high walls.

Mine operators should ensure that only trained and competent people operate equipment associated with shaft winding systems including manually operated functions.Where manual controls of winder functions can bypass/override automatic controls or the functions that are controlled by a winder driver, the access to these controls should be restricted by hard barriers or interlocking.The mine should have clearly documented procedures for the operation of winding systems including manually operated functions that may be required for maintenance and repairs.

Mine operators should be aware of areas where gas has the potential to release from ground strata. The hazards associated with unintended release of gas must be assessed and appropriate controls must be implementedControls in a metalliferous mine may include but are not limited to:• establishing formal exclusion zones• regular gas monitoring of areas where gas may potentially accumulate• procedures for workers to access and work in areas where gas may be released or accumulateMine operators should consider the need to probe drill for gas accumulations using appropriate drilling techniques

Collision

Complaint

Electrical

Electrical Energy

Explosion Fire

Explosives

Dangerous Incident


Fall

Fatality

Fire

Gas

Hazardous Materials


Injury

Loss of Control

Mech Equipment

Investigation Report


Other

Serious Incident

Serious Injury

Mobile Equipment


Structural Failure

Vehicle collision

Vehicle impact


Unplanned Movement

Work Environment

Workshop injury

Published Event ID11/01/2017 SInNot-2016/01110

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SinNot-2018/00263

SummaryEight rocks fell from a high wall and landed on a drill working under that wall. The rear windscreen on the drill shattered and shards of glass have ended up inside the cab

At the end of night shift, an EH5000 dump truck parked-up in the designated parking area. Two dump trucks were already parked in the area. The driver of the dump truck entered the area and due to a blind spot mistook his position in relation to the other two trucks and reversed, striking the front of one of the trucks.The operator of the truck that was struck was standing outside the cab of the truck deck waiting to disembark at the time of the incident. No people were injured. The collision caused damage to the handrail and walkway of the truck

While cutting on the longwall face, a sudden rise of CO2 (over 5%) was detected at the TG monitor. Coal production was subsequently halted for several hours for unrelated reasons. Upon resumption it was noticed that there was a cavity between the coal seam and roof strata of about 150 mm height extending at least 4 m into the coal seam and about 4 m wide. It has been interpreted that it was caused by a low energy outburst event. There is very little evidence of ejected material on the goaf side of the spill plates. The location on the face has been previously identified as a geologically disturbed area.In a second incident, gas outburst on the longwall face resulted in the release of a large volume of carbon dioxide and obstruction of the passage across the face. No people were injured.


A complainant alleges that there have been numerous reportable incidents at a mine site that have not been reported to the regulator

A haul truck and a light vehicle were approaching the same intersection and the haul truck was required to give way. Both drivers were aware of each other and approached with caution but the haul truck failed to give way.

A private vehicle was leaving a mine site. Weather conditions at the time of the incident were poor. The driver of the private vehicle lost control while driving and collided head-on with the mine site security gate. The gate impaled the vehicle resulting in the gate passing through the engine bay and under the driver’s seat. The driver of the private vehicle suffered a fractured ankle and the passenger was unharmed

A stand-alone battery was being used to jump start a water pump. When an attempt was made to crank the pump the stand-alone battery exploded. The worker was approximately 4 m from the battery and was not injured or affected by the exploding battery

While dewatering the gas drainage line in a development panel, an operator isolated the gas riser. This resulted in the gas range pressurising. The resulting increase in pressure resulted in a 150 mm hose separating at a joint. This released a large volume of CO2 inbye.

After completing a task, an operator was docking the overhead crane in the coal handling and preparation plan. As he was docking the crane, a bracket fell from the crane to the deck beside him. The bracket was approximately 5 kg and possibly broke away due to fatigue.

A truck lost traction while travelling down a ramp from the crib hut. The operator was not injured, but the truck slid more than 100 metres on an over-watered ramp. The truck stopped when it hit the centre of the bund wall. The NSW Resources Regulator is currently investigating the incident

A section of rib fell onto a miner driver’s lower-leg. He continued to work for around two hours before his leg began to swell. The Deputy stopped production and had the worker transported to the surface. He was taken to hospital, where an X-ray revealed a fracture to his lower-leg.

Two tradespersons were removing broken bolts from a tertiary sizer roller. Worker A was using vice grips to hold a nut onto the broken bolt while Worker B attempted to tack weld it into position. Worker A moved and brushed his forearm against the sizer and felt a shock in his forearm. The site’s electric shock protocol was activated. After taking an ECG, ambulance officers cleared Worker A.

The operator of a Volvo stemming truck noticed a rock caught between the driver's side front drive duals. The operator then attempted to break up and dislodge the rock using a small hand-held chipping hammer. The inside tyre failed and the force of the air knocked the operator off his feet and forced him backwards approximately 1m

After loading the bucket, an electric face shovel was swung toward a parked truck when the crowd sticks extended and overran the electric limits and hit the mechanical stops. This caused significant damage to the mechanical stops. The operator brought the shovel to a stop before contact was made with the truck

A worker injured his leg while cleaning up scaffolding at a coal preparation plant.The operator of the forklift was moving a load of scaffold into position, close to storage pallets, when the scaffold on the pallet being moved into position, has made contact with the left leg of the worker on the ground. The worker was taken to first aid for treatment.

A person suffered an electric shock while removing a flexible extension lead from a 240 volt socket. The area was described as having a damp work environment. Water was found inside the 240 volt IP56 plug that was fitted to the lead

A shaft winder was in automatic mode bringing 12 people to the surface. It tripped out at 3.6 m below the surface due to the plat not being extended (i.e. not engaged into the cage plat guides). The winder was then placed in manual control to raise the cage out of the mine sufficiently to reset the winder position encoder. Once the position encoder was reset, it was then intended to then extend the plats and return the cage to the docking platform to enable the men to disembark. The cage subsequently hit the plat while being raised manually as the plat had in fact partially extended.

As a shaft cage was returning to the surface empty after dropping off a mine worker, the winder suddenly tripped and stopped the cage partway to the surface. When the cage was later brought to the surface, it was found that the cage sliding door had come open during transit causing the winder to trip.

The department has received a complaint relating to the reporting of several safety defects and practices on a NSW quarry site

On night shift, the driver of a DT771 dump truck was reversing into the work area of an excavator when it struck the D10 dozer that was cleaning up the areaNo workers were injured.

An operator suffered a crush injury to his foot while in the process of loading supplies onto a materials pod. The operator was hand-loading supplies onto the pod, which was located on the front of a forklift prior to being loaded onto the dollycar trailer. The pod slipped off the forklift tynes while the operator was positioned beside the supply pod

Thirty metres of drill steel string was released from a roof, where it fell and crushed the right hand of a contract driller’s off-sider. The incident resulted in the loss of two fingers on the right hand.An exploration drill rig was being used underground to drill an inter-seam borehole for an electric cable installation. After repairing a broken drill string, the operator raised the drill string to commence reaming operations. At this time the grippers were released, allowing the drill string to fall. The off-sider had hisright hand on the drill chuck area and the falling drill string struck his hand. This resulted in crush injuries and the amputation of two fingers.

A fire was reported underground in the loop take-up on a belt storage unit. The drive and LTU had been replaced and recommissioned around three months earlier. The investigation determined that mounting bolts on the larger of the two pulleys had loosened. This loosening allowed the pulley to move 12 mm out of alignment. It is notable that three of the four wander switches on the carriage were not correctly set.

A complainant has alleged that a child was attempting to look down an old and disused mine shaft at Lightning Ridge. While looking down the shaft, the child allegedly held on to a star picket to stabilise himself and the picket snapped off at ground level. Star pickets are used for securing the shaft by fencing it

A 400 tonne excavator was loading off the D parting Strip 13 in Pit 7 when the machine slipped down a 3 m bench. The operator exited the machine uninjured. He was assessed by emergency response personnel.

A CAT 789 rear dump truck tipped its load and was heading back to the loaderempty. There was a bend in the haul road but the truck continued to drive straight. It hit the windrow and turned over on its side. The driver said he was distracted.The driver was not injured. The driver had completed three to four loads previously on this road. It appears the driver may have had a micro-sleep.

There was a fire in the engine bay of a CAI AE55 truck. The trainee driver noticed flames coming from the engine bay. The driver stopped the truck and extinguished the fire with a hand held extinguisher. The driver then hosed the engine down in the area of the turbo to cool it. The on-board automatic fire system did not operate. The driver did not operate the on-board fire suppression system manually.It was later discovered that an o’ring failure allowed hydraulic oil to spray onto the hot turbo.

A mine deputy walking the underground conveyor belts noticed a collapsed roller emitting sparks and heating up. A quick response avoided further danger. During the investigation, it was found that many rollers had been tagged for action along the lengthy conveyor system

A worker was carrying out some welding at the wash plant. When the worker was changing an electrode in the welding hand piece, he reported receiving an electric shock. The worker was taken to Sutherland hospital for an ECG assessment and cleared of any injuries.

The brakes of a Manitou telehandler failed when an operator started it. The telehandler broke through a bund wall about 10 m from the pit edge. The operator jumped from the vehicle before it drove off the pit edge, where the vehicle fell 30 m to the pit floor. No people were at the bottom of the pit when the incident occurred.

An operator who was working on a sub-level cave was struck by an isolation valve at the end of a hose. While the drill jumbo was tramming into position, the hose did not unwind and tensioned the hose line. The tension broke off the fitting, subsequently hitting the operator on the left leg. He suffered a suspected fracture of the tibia and fibula.

A fall of roof has occurred in a development panel while the continuous miner was back-holing in a predicted fault zone. The collapse has extended to a height of 2.5 m above the normal roof horizon over a length of 13 m and width of 4 m. The normal roof support for the area consists of 1.8m roof bolts.No persons were injured or equipment damaged.It would appear that Trigger Action Response Plan (TARP) used to identify changes in strata conditions was presentt but may not have been acted upon.

An operator was cleaning under a conveyor with a backhoe using a T-attachment. The attachment is used to drag material out from under the conveyor. A strip of metal came into contact with the attachment and flicked up a golf ball-sized rock through the open rear cabin window. The rock smashed through the front window and came to rest on the front of the machine. The rock did not hit the operator, who was in the cabin.

While placing a pallet back on shelving, the back board frame of a forklift became caught in a pallet located about 4 m above the ground. The pallet had a heater attached to it. As the load was lowered, it caused the heater pallet to flip over. The load came into contact with the forklift on the way down, damaging its top-revolving light. The forklift was new on the site.

Two workers in the basket of a boom-type elevated work platform (EWP) were undoing pipework using an impact gun. The workers put the gun down on the platform controls. The basket began to rise without the foot-operated deadman being utilised.

An ejection of flyrock landed outside the exclusion zone and was seen by a sentry 100 metres away. Inspection by the shotfirer found that the hole was drilled too close to the edge. The hole was downloaded in response to the closeness to the edge. Despite this, the under- loaded face hole burst from the shot.

A continuous miner was being used under remoting mining procedures due to identified outburst indicators. As the continuous miner cut the floor an outburst was initiated resulting in the release of a large volume of methane and the ejection of coal from the face. Procedures in place at the time protected workers from the consequences of the outburst. It was noted that gas monitoring in the immediate area of the outburst were poisoned (CO2 maximum 5.5%)

A crane operator was placing a steel plate in position so that it could be cut with a plasma cutter. The two magnets holding the plate unexpectedly released and the steel plate fell 200 mm onto the gate and the plasma cutting bed. A second operator was programming the cutter in the vicinity, inside the gated plasma cutter working area.

A deputy had headed to a closed gate valve to re-energise a water range. When he opened the valve, a 2-inch gate valve adjacent to the closed valve expelled the spindle, grazing the deputy’s jaw. The deputy fell back, striking the back of his head. The deputy lost consciousness for a short period of time. Other people isolated the water and brought the deputy to the surface. The deputy was checked by paramedics and taken to hospital.

A rear dump truck was in normal operation while tipping a load at a tiphead, when the hoist cylinders failed, allowed the body to fully extend and then free fall uncontrolled back to the truck chassis rails.

An operator was using a hired pneumatic ratchet on a boat winch to tension recovery mesh in preparation for longwall change out, when the swivel fitting on the air hose detached from the ratchet tool striking him in the left.A similar incident occurred at the same mine on a previous longwall change out, and the incident investigation controls identified installing a swivel to prevent rotation of the air hose undoing the fitting into the ratchet tool

A fitter isolated a longwall powered roof support near the tailgate. In the process of preparing maintenance access the fitter pulled a hose bundle clear and the high set hose failed, spraying emulsion into the floor which ricocheted hitting the fitter in the face. The fitter was uninjured.The support isolation did not isolate the high set hose, which is normally isolated at the dump sled in the maingate.The hose failed as it was worn through from rubbing on mounting bolts for the base lift cylinder. This rubbing had been identified on previous failures

A rear dump truck was in normal operation while tipping a load at a tiphead, when the hoist cylinders failed allowing the body of the truck to fully extend and then free fall uncontrolled back to the truck chassis rails.

An operator was using a hired pneumatic ratchet on a boat winch to tension recovery mesh in preparation for a longwall change out, when the swivel fitting on the air hose detached from the ratchet tool striking him in the left forearm.A similar incident occurred at the same mine on a previous longwall change out, and the incident investigation controls identified installing a swivel to prevent rotation of the air hose undoing the fitting into the ratchet tool.

A fitter isolated a longwall powered roof support near the tailgate. In the process of preparing maintenance access the fitter pulled a hose bundle clear and the high set hose failed, spraying emulsion onto the floor that ricocheted hitting the fitter in the face. The fitter was uninjured.The support isolation did not isolate the high set hose, which is normally isolated at the dump sled in the maingate. The hose failed as it was worn through from rubbing on mounting bolts for the base lift cylinder. This rubbing had been identified on previous failures

A continuous miner was developing a roadway for a longwall block. The direction of the roadway was sub-parallel to the geological structures in the area. Whilst developing the roadway, the mine’s rib failed between the supported rib and the face and a large piece of rib coal was dislodged. The coal struck the roof bolter operator, who suffered a fractured jaw and several dislocated toes

A worker (deputy) was removing old 6-inch air and water pipes when one pipe flicked up and hit the worker on the cheek. The pipes were hanging from the roof on chains. The worker suffered a suspected fractured eye socket.

A contract truck driver was cleaning grain out of the back of his truck before picking up a load of stone. The truck driver exited the truck between the tailgate and the truck tub. While he did so, the prop and pole were dislodged. The tailgate fell to the ground, striking the truck driver on the top of his head. The tailgate weighed approximately 220 kg.

A worker was changing conveyor rollers on an elevated walkway when a floor plate collapsed under their foot. The hazard was identified prior to the incident and the walkway was barricaded. However, there was no information to explain why the barricade was in place. The potential fall from this location was approximately 9 m. The worker was uninjured

A worker was stowing a roof support during a longwall change out using a chock trailer. The support was reversed into a heading. It hit a 6 inch compressed air pipeline. This caused the end of the pipe to be ejected. The end of the pipe landed approximately 10 m away, beside the roof support and on the driver’s side of a LHD.Although the pipeline was isolated about 100 m upstream, residual pressure in the line provided the energy to eject the pipe

A rock fell backwards out of a loader bucket while material was being loaded in a quarry. As it fell, the rock struck the top of the loader’s cabin and rebounded onto the hydraulic lift rams. This damaged the front windscreen and dashboard of the loader. The operator reportedly suffered a sore knee and was taken for medical assessment

A fall of roof was reported in a mine. The fall resulted in the loss of the mine’s secondary emergency exit

A worker was operating a machine when the service brake failed and the machine did not stop. The operator then applied the park brake valve, which stopped the machine.The piston (spool) had failed, leading to the failure of the service brake valve. The broken valve prevented the loss of pressure to automatically trigger the posi-stop brake system.Prior to the incident, the original equipment manufacturer (OEM) had issued a safety bulletin and updates on this valve.

A worker was lifting material using a pendant crane. He placed his left hand on the material while holding the crane pendant. The worker believes he suffered an electric shock. He attendeda local hospital and was released after an examination and an ECG test.

A fire occurred in the front tyre of a load-haul dump loader. The loader was fitted with a solid fill tyre made of polyurethane. The fire was extinguished and no one was injured.It is likely that the locking ring behind the tyre came loose and caused a frictional ignition fire. The tyre may also have been under-filled, causing excessive deflection of the tyre. Both claims are yet to be confirmed.

A load-haul dump (LHD) made contact with an energised, high tension cable.There was no electric arcing reported. Damage was recorded to the outer sheave only. There was no damage to the cable armouring

An operator was using a crane to lift replacement legs for a skyline conveyor when one of the two slings being used broke. The leg then swung in an uncontrolled manner and landed next to an elevated work platform (EWP) where two operators were guiding the legs into position.The two operators exited via the skyline conveyor. The EWP was not damaged.The direct cause of the incident was the failure of a synthetic fibre sling that had been attached under a bolted flange.

The department has received a complaint regarding the maintenance and management of self-rescuers. The complainant alleges that self-rescuers were stored incorrectly

A truck driver was tipping a load at a tip head a couple of metres from the rill, when the edge of the tip head slumped, dropping about 2-3 m, bringing the truck to an angle of about 45 degrees. The operator was not hurt and the truck tray was down at the time. The slump was a couple of metres from the edge and the truck was stable. The tip edge was about 15-20 m high.It is suspected that the stabilising material at the base of the tip head may not have been sufficient. The mine reported it had been raining heavily in the days before the incident, which may have been a contributing factor.

Burial of mine roof supports by roof fall. An incident occurred while lifting off using three breaker-line supports The fall occurred over No 3 & No 2 supports. The fall was about 2.3 m high and 3 m in front of the two supports. The fall was in line with No. 1 support which was advanced at the time. Workers were behind the continuous miner at the time of the fall, as required by the operating procedures

Several workers were finishing working on a chute. The chute incorporated a solid structural door on hinges. When one of the workers opened the door, the hinges broke and the door fell off. The impact caused the worker to fall backwards.An investigation into the incident found that the door hinges were not built according to the original design. The investigation found the hinges were insufficient to hold the load of the door.

While cleaning a conveyor, a worker pushed a hole through one of the conveyor guards. This caused his finger to be amputated.The guarding had been modified on the site to assist with the process of cleaning the tail roller.

A maintenance worker was preparing to remove the lid from an A-frame reclaimer luff drive gearbox. As he undid the final bolts, the worker heard the gearing moving inside the box.The shaft had lifted and the gears had come out of their mesh. The rope drum attached to the output of the gearbox unspooled about 2 metres of rope. The bridle on the boom lowered about 1 metre to rest on the bucket. The worker was not injured.

A fire started on a grader while the engine bay was being refuelled. The fire was extinguished with a nearby water hose. It appears the filler cap became dislodged and fuel sprayed under pressure during the refuelling process.

Two operators were working off the Malibu (platform) extending monorail when a beam dropped from the roof. As it dropped, it hit one of the operators on the right side of his body. Injuries included a cut above the ear and numerous abrasions

Two transport vehicles collided while travelling in opposite directions at the bottom of the drift in an underground coal mine. There were no injuries reported.Traffic lights in the mine were functional, however, the two drivers failed to observe that other traffic was in the area.

A dump truck driver was approaching a crushing pad area while another truck was reversing into the tip off area. The dump truck operator stopped the truck to wait. When it was clear, the driver proceeded slowly until he was 10m away from the other truck. When he applied the brakes, they were unresponsive. The operator attempted to use the truck’s retarder but it also did not work. The truck rolled into the 2m high berm (artificial ridge). This activated the truck’s emergency stop.The operator found that a failure of the service brake chamber caused the incident.

A fitter was working on an automatic processing filter and called out to a colleague to lower a hydraulic cylinder on the filter. The cylinder dropped onto the fitter, crushing his foot. The mine identified that the filter was locked out during the maintenance procedure.However, the maintenance remote control was not locked out.At the time of giving the all clear to move the hydraulic cylinder, the worker did not believe he was located at a high-risk position.

An underground mine experienced what may have been a significant seismic event or earthquake. There were 60 people working underground at the time. All workers were evacuated. The mine suffered some damage.All mining operations have been stopped while detailed investigations are undertaken by the regulator. The investigations will determine the likelihood of another similar event and to assess the damage to the mine.

A grader driver was maintaining a haul road at a quarry. While he was changing direction, the grader made contact with a tipper truck.The mine determined that the driver of the tipper truck did not allow enough distance when travelling behind the grader. All haul road transport was stopped by the mine to investigate the incident. The mine engaged its workers in a tool box talk to reconfirm the safety issue of keeping minimum distances between vehicles.

A tyre fitter contractor was using a forklift to place a heavy machinery tyre vertically on top of a second tyre. The heavy machinery tyre weighed approximately 600kgs. The fitter placed his body between the tyres to insert a piece of wood. The forklift did not have its hand brake on and the forklift moved back and the tyre descended onto the fitter. The fitter was trapped for a few minutes until he was rescued.

An electrical apprentice suffered an electric shock while verifying the isolation of a 415 volt generator. The apprentice was about to fit an improvised lock out device when the incident occurred. The worker was working inside a motor control cubicle. The point of contact was his fourth finger on his left hand.The operator reported to the regulator that the isolation handle of the fusible switch had not been turned off before the apprentice entered the cubicle. A multimeter was on the ground in front of the drive module. We do not know if a non-contact tester was used before applying the leads of the multimeter.Ambulance paramedics attended to the apprentice, who was then transported to Singleton Hospital.

A worker suffered a crush injury to his fifth finger on his left hand. He also suffered a laceration and suspected fracture of his fourth finger on the same hand. His fingers were injured after becoming jammed between a PET canopy and the rib. Ambulance paramedics drove to the mine site and transported the worker to hospital.

A piece of flat bar steel fell from a shaft collar to the shaft bottom. The piece was 1.5 m long x 50 mm wide x 6 mm thick. A multi-level shaft stage was in the shaft when the flat bar fell. The stage contained three workers and was about 900 m below the shaft collar. The flat bar hit the stage and continued to the bottom of the shaft. No workers were injured.The flat bar had been tack-welded to a pipe trolley in what was described as a ‘trial’. The trolley was used until the flat bar broke off and fell down the shaft.

A loader operator was cleaning under a mobile power screen conveyor. The loader reversed and made contact with the conveyor

An underground mine reported a methane exceedance over 4% at the longwall maingate regulator monitor.The reason for the elevated gas level was a blockage in a methane gas drainage range.All underground personnel were withdrawn. The withdrawal was delayed because of a delay in responding to the initial alarm.

Work was being carried out in an area of an underground mine that was subject to a development application. The mine site had permission to install a boundary fence. A drill rig operated by one worker trammed under 11kV power lines and made contact with them. This led to the lines being snapped in half and ultimately tripping power to the site. The energy supply company attended the site and decommissioned all power back to the main incomer. The main incomer is located outside the mine site’s boundary. As a precaution, the rig operator was sent to hospital and cleared of any electric shock.

During the replacement of the bolting pod onto a continuous miner, a worker (the spotter) positioned himself in a strike zone of the racker. The operator assisted guiding the pod racker, which was connected to the long haul dumper, by stepping into the restricted area. After the racker was lined up, the worker signalled to the loader operator to eject the pod out of the racker to the continuous miner. Instead of ejecting, the racker moved to the left and hit the worker. This momentarily pinned the worker against the coal rib wall.

An operator was tramming a monorail outbye during a services retraction when a high pressure filter sled fell from height. The sled fell from about 1 metre. The retraction was from an 8 cut-through to 6 cut-throughThe original equipment manufacturer had released an industry-wide safety bulletin, however, the operator did not act on its recommendations. The bulletin, which was issued in 2008, recommended a bolt upgrade from M12 to M14 grade 10.9 socket head cap due to failures that have been witnessed throughout the industry.

A truck driver weighed his vehicle on a weighbridge. As he got out of the truck, the driver stood on a manhole cover and fell 1m into a void, which was located on the side of the weighbridge. An ambulance was called and the man was taken to hospital

A continuous miner was mining on the second cut in a longwall installation panel. The picks on the miner hit a mega bolt tail.This caused one of the carbide tips on the miner picks to forcefully dislodge from the pick shank. The carbide tip travelled about 4 m and hit the operator of the miner in the throat.

Two contractors were engaged by a contract company to carry out poly pipe welding and shaving. After completing the poly shaving, the two workers began packing up their tools. While dismantling a piece of portable electrical equipment, one contractor suffered an electric shock. The other contractor was demobilising the equipment at the time.

A worker was found deceased by his colleagues on the surface of an underground mine.

A rock fell from the back of an underground drive, hitting a worker’s hard hat. The rock weighed about 2 kg and appears to have fallen from an area where the strata mesh had been damaged by recent blasting. The worker attended a hospital and was cleared of any major head or neck injury.

A personnel transport vehicle hit a pothole in the road. As result of hitting the pothole a worker in the rear of the personnel transport has jarred their back resulting in the worker not being fit for normal duties

Two boats collided at low speed on a dredge pond. The collision occurred when one boat was leaving the jetty and the other was approaching the jetty. The incoming boat did not hear the radio communications from the outgoing boat.

A worker turned off a light switch and felt what she described as a 'sensation' in her hand.The light switch mechanism was in poor condition and was hard to open and close. The light switch cover plate also had cracks and the mechanism was not rated to switch fluoro light circuits.

An operator of a haul truck saw flames coming from the truck and manually activated the auto fire suppression system. The flames were suppressed but not extinguished. The emergency response team (ERT) was activated and hoses connected to two water carts were used by the team to extinguish the fire.

A dump truck driver lost the steering on his truck. The cause was reported by the mine operator to be a failed steering hose connected to the accumulator and resulting in a loss of oil.

A 66kV feed tripped during night shift at a mine, resulting in the loss of the gas drainage plant. As this was the only plant running at the time, the mine followed its procedures to withdraw people from the mine.The trip was re-set and the methane level did not exceed 2%.

A maintenance technician noticed smoke coming from the engine bay of a Volvo L120 (IT12). The Volvo had just arrived at an underground fuel bay. When the technician opened the engine bay cover, he noticed flames coming from the Volvo. The fire was extinguished by the on-board fire suppression system and a hand-held extinguisher

A worker stumbled while walking past the surface switch room and put his hand on an air conditioner unit (415v) to steady himself. He felt what he described as a 'tingle'. He did not report the incident at first, but was later sent for an electrocardiogram (ECG).The air conditioner, which was operating at the time, was isolated.

A contractor was struck in the jaw by the handle of a Hi-Lift Wallaby jack. The jack was being used to lift a roof support post in a gravity tank.The contractor suffered a suspected fractured jaw and may have a serious head injury.

A shearer operator was hit in the face by flyrock that was ejected from the shearer’s maingate cutter drum

The ventilation was being extended in the485FWN when the bag became caughton the roof of an IT machine. The operator put his foot on the step above the rear mudguard to unhook the bag. The step gave way and he fell through. The operator lost balance and put his hand out to steady himself. His hand made contact with the ground support on the wall of the drive. The operator suffered a broken finger.

During the removal of shields on a longwall 30 faceline, the goaf caved behind the buttress supports for a distance of around 30 shields. This caused gas from the goaf area to be pushed into the return outbye of the longwall face, causing the gas level to rise above 2%. The level was above 2% for about 26 minutes, reaching a maximum of 2.69%.

A haul truck collided with a light vehicle while passing in a decline. The light vehicle was dragged a short distance before the haul truck driver was notified of the incident by radio from the driver of the light vehicle. No injuries were reported

Methane was detected above the limit of 2%. The methane level instantaneous peaked at 2.6% and was above 2% for a period of approximately 1.5 minutes.

When longwall operators were in the process of removing a longwall support leg cylinder using a winch, the roof bolt broke and the snatch block fell to the groundAt the time the operators were slowly starting to put tension on the winch. The winch was at the maingate drive, and the first snatch block was attached to a roof bolt adjacent to the #1 support. The snatch block fell to the ground in a diagonal direction back towards the winch. No-go zones had been identified and were in place.

The regulator received a notification that non-compliant self-contained self-rescuers (SCSR) may have been in use at two underground coal operations.

A surface drill operator on an exploration lease raised a drill rod. As he did so, his hand became caught between the drill rod spanner and a hand-held spanner. This resulted in a severe laceration across his palm and fourth finger.The rod spinner was partially rotated out of the way but the spanner and rod spinner were aligned. This created a pinch point.

A processing plant conveyor stopped when a product bin filled with sand partially collapsed onto the plant.

Methane levels greater than 2% were detected in the general body of an underground mine. Power to the panel and an auxiliary fan was tripped when an electrician was calibrating a methane monitor. The loss of power led to the methane build-up. An incorrect methane monitor was placed in bypass, tripping power to the panel. A subsequent issue arose following the power trip in which restoration of power to the panel was delayed for approximately 45 minutes due to a communications fault. This contributed to the gas build-up.

A truck was driving down a decline when it collided with an agitator. The agitator was driving up the decline. The truck driver was not injured but the agitator driver’s arm was cut. The truck was slightly damaged and there was considerable damage to the front of the agitator.

A contractor was helping to install flexible conveyor train modules.While he did so, his left finger was crushed and amputated.

A gas plant lost power due to an earth leakage trip on an incoming transformer. This resulted in the mine’s trigger action response plan (TARP) being activated and a withdrawal of workers from underground. The gas level peaked at 1.96%.

A contract worker was using a magnetic-based electric drill in a workshop. While using the drill, he suffered an electric shock

While hoisting ore, a broken drill steel fell from the skip onto the main cage. This caused significant damage. The hoisting winder is also the mine’s second means of exit (egress).

A gas drainage plant failed at an underground mine. The mine withdrew all workers from the underground part of the mine in accordance with their trigger action response plan (TARP).

A fitter was undertaking maintenance activity in an underground mine. During maintenance, he noticed that there was foaming fluid releasing from roof support ‘RS0047’. The dump valve was activated. The shift maintenance supervisor was contacted and the supervisor gave his permission to investigate the root cause of the fluid release. The investigation identified that the hi-set inter-leg hose fail

An articulated dump truck operator was tipping a load on a stockpile. Halfway through tipping this load, the body of the truck rolled onto its side. The cabin remained upright and no people were injured. The back wheel of the truck had moved too far up onto the stockpile.The mine operator conducted a risk assessment and later, made a decision to reposition the truck using an excavator.

While driving inbye, there was a catastrophic failure of an engine on a FBL10 LHD vehicle. This resulted in internal components exiting the engine block. The LHD vehicle was travelling unloaded at the time of the incident. The incident occurred in the main intake airway.

An electrician was carrying out scheduled light switch inspections. When he went to turn off a switch, he suffered an electric shock.

A flatbed truck was travelling down to the 9800 level. The operator attempted to brake but the brakes did not pull the truck up. The operator tried to change the truck’s gears from second to first gear when the truck started ‘over revving’ and speeding up. The operator attempted to steer the truck onto the decline and get it back under-control. He took evasive action and steered the truck into the wall, making impact four times before the machine came to rest. The truck was loaded with an estimated 8 tonnes of fuel and mesh at the time of the incident.The mine operator has ordered an independent mechanical assessment of the truck.

An excavator was operating at a bench within a mine. The excavator was a Hitachi brand ‘EX3600’ model. During operation, the excavator slid off the operating bench, reportedly falling four or five metres. At the time, the excavator was digging the toe of the bench towards the highwall. It came to rest at a 45 degree angle. The operator of the excavator was not injured.

A load haul dump truck was coming out of a cut-through bucket. As it exited, it collided with a truck travelling on the main transport road. This resulted in damage to the front driver’s side pillar. No people were injured.

The syntron feeder of a surface bin broke away from its restraints. The bin weighed approximately 2000 tonnes. As it broke away from its restraints, it fell onto the conveyor gate. The knife gate buckled and material dropped out.An exclusion zone was in force at the time of the incident as there was wet product in the bin. The bin was being run out with a sucker truck on standby.The excess wet material in the bin resulted in damage to the knife gate, syntron anchors, chute side wall and the receiving conveyor

A dump truck operator was operating a truck at a mine. He slipped from the truck ladder and fell to the ground. Medical personnel assessed the operator and he was sent home. At a later time, the operator sought further medical treatment. Medical personnel found that he had suffered two broken ribs and a fractured eye socket.

A handrail at a coal handling and preparation plant shifted when a worker leaned against it. The handrail was 3.5 metres above ground level. It was located at the breaker feeder. The worker fell onto a scrap metal chute but was not injured.The handrail was designed to facilitate servicing of motors and drives. The locking bolt used to secure the handrail was not reinserted after recent maintenance activities.

While cutting out of the maingate, the shearer trailing drum lifted 400mm off the floor level while it was changing states. An operator saw the trailing drum lift and stopped the operation to investigate. The mine site has reinstated the original parameters with a full 360 audit (maingate to tailgate/tailgate to maingate)conducted which has proven that the system is now suitable for continued cutting with no further issues.

A battery failure in the back-up system for the controls within the surface substation caused the power to the main fans to trip. This resulted in a loss of power to the underground and surface areas of the mine. The mine manager immediately enacted the withdrawal trigger action response plan (TARPs) and withdrew persons from the mine. Once all personnel were confirmed as being withdrawn from the mine, the main fans were restarted in a controlled manner under direction of the ventilation officer but the methane level in the return leading from the longwall rose above 2%, reaching a maximum level of 4.7%.

The methane level in the longwall return rose above 2% for 45 minutes, with a peak level of 2.17%. The background level was 0.7% before the incident.

A small fire occurred on a truck near the muffler while driving up a decline. The driver noticed smoke and operated the fire suppression system, which extinguished the fire.A piece of combustible waste material (cardboard) that was being loaded onto a truck lodged between the exhaust and the purifier igniting during transportation.

An empty haul truck was travelling south-west on a haul road. As the truck neared an intersection, it was travelling about 35kmh when the operator misjudged the distance between the truck and a light vehicle that was giving way to a water truck that was turning into their path. The operator activated the dynamic retard pedal, slowed the speed off the truck and brought it to a stop with a tyre in the road windrow. The distance between the front of the haul truck and the back of the light vehicle was about 15 metres. The condition of the road was normal, the weather was fine and dry and there were no known defects on the truck.

A load haul dump vehicle failed to shut down when the on/off switch was activated.

Two LHDs collided on the surface of a mine. One LHD was parked up with a worker nearby when the other machine transporting stowage material collided with the parked machine. The impact moved the parked LHD about 400mm.

A loaded truck was descending a ramp when the operator noticed that the retarder was not holding the truck back. The truck was approaching an intersection and the operator had committed to turn the corner. The driver decided not to brake because he was concerned the truck would roll over. The truck turned wide and hit a noise bund on the left side of road then came to a stop, leaving the truck leaning at a precarious angle

Methane greater than 2% was found at the back of the continuous miner.Power had tripped to the section at the start of the shift, causing loss of auxiliary fan ventilation to the face.The section transformer had tripped on earth continuity.

Three haul trucks were tipping their final loads at the end of the shift. Other mobile equipment was in the area to gain access to parking. Due to a high volume of radio communication between mobile equipment operators, a mix-up occurred and a haul truck that was reversing hit a light vehicle.

An articulated dump truck ran off the road and rolled over. The trailer rolled completely over and the cabin went onto its side. The operator was able to exit from the machine and was uninjured.

A rear dump truck was returning from the tip head when the operator slowed to make a turn, at this time the ‘A-frame’ has failed, with the tray of the truck coming to rest on the rear tyres. The operator was rescued from the cab using an elevated work platform and taken to hospital

A light vehicle, carrying five people, was stationary at a stop sign at an intersection. A second light vehicle, with a single occupant, collided with the rear of the stationary vehicle.A passenger in the stationary vehicle was reported to have a serious hip injury. The driver of the other car was reported to have suffered a knee injury.Police and ambulance were called to the scene when equipment was needed to rescue one of the passengers.

A rock the size of a hard hat ejected from under a service truck wheel as the truck moved off. The rock landed 15m to 20m from a worker.

A miner cable was hanging too low during breakaway. The cable was caught on the trapping shoe of a shuttle car and when the shuttle car was returning to boot, cable was pulled from a receptacle on the miner. Background gas levels were 0.52 (carbon dioxide) and 0.34 (methane). The area was isolated and made safe.

A panel electrician manning the main gate smelled something unusual. He inspected and found a collapsed idler with sparks coming from it about 5m outbye of boot end. He immediately isolated the conveyor.He went to remove the idler set and saw a flame at the bearing seal of the idler. He immediately placed the idler in ground water then hosed down the area.

A dump truck was travelling down a hill from the tip. A light vehicle was travelling uphill to the pit at the same time - the light vehicle driver noticed the dump truck did not slow down at the give way sign and so he stopped and rolled back downhill out of the way. The truck and light vehicle missed each other by one metre.

There was a longwall face intercom unit temporarily wired in to the permanent longwall 901 face system because of polyurethane activities. The temporary wiring voided the ingress protection (IP) integrity of the unit and, as such, the mine reporting a failure of explosion-protected apparatus.

A near miss occurred at an intersection because the operator of a haul truck failed to stop at a stop sign. On approaching the intersection, the operator of a light vehicle saw the haul truck coming from the right and braked. The light vehicle stopped within approximately 18 m of the haul truck.

Workers made a complaint of bullying and harassment to the regulator. The bullying and harassment is allegedly spread across shotfiring, mining and maintenance departments

The methane gas level was reported to have risen above 2% in the longwall return roadway. The highest reading was 3.04%.

An articulated dump truck lost control after the operator braked in wet road conditions. The tray rolled onto its side. The cabin remained upright. The driver was uninjured.

The park brake on a front end loader was reported as having failed during refuelling. The operator applied the park brake and walked away from the machine. When he was about 40 m from the loader he heard a scraping sound. He turned around and saw that the loader was moving. He returned and stopped the machine using the service brake.

Production had only recently commenced in a newly formed longwall panel. As the goaf formed, falls resulted, pushing out a plug of methane gas (2.2%).

A rear dump truck tipped its load and was driving away from the crusher with the tray elevated. The tray made contact with an energised power line, causing a support ‘cross arm’ on the pole to break. The operator was unaware of incident.

A piece of stone fell from the roof and bounced off the rib striking a miner driver in the leg. An ambulance was called and the injured worker was taken to hospital for assessment.

An operator suffered a crush injury to his toes. The operator was cleaning out his boot when he placed his left foot on the top of the stabilising ram on the shotcrete pump while the stabilising jack was being operated in preparation for moving the shotcrete pump.

A mine reported the failure of a soapy water test from injectors on three machines. This incident is under investigation, however, with one machine, the mine mechanical trades identified that a build-up of contaminants on the injector and the sealing face contributed to the failure of the closed

A haul truck and a service truck collided at an open cut mine site. The haul truck steps hit the corner of the service truck, breaking them off.

A fire was reported on the maingate corner around shields 1-2 of Longwall 107 (described as smoke and glowing embers). The incident occurred as the shearer was cutting into the maingate (shearer stopped with drum opposite #4 shield).The fire was extinguished - hoses were run out and the area was wet down. The cause and exact location of the fire was unknown at the time of reporting.Several blunt picks were observed on the maingate drum, and that drum sprays automatically turned off when entering the maingate.

A worker suffered a suspected electric shock from a conveyor. There were multiple power sources. The worker was taken to hospital for tests.

Two workers each suffered an electric shock while using an electric hand tool during poly pipe welding preparation. Investigation has shown the electrical sensation experienced by the operators was due to static build-up in the high density polyethelye (HDPE) pipe flange caused by the cutting bit of the router rotating at up to 22,000rpm.

While driving a 25 tonne Franna crane underground, the operator smelled the brakes. He parked the machine in an off ramp and inspected the wheels. At wheel number two he saw a flickering glow. He used the hand-held fire extinguisher to extinguish the ‘fire’. No one was injured. The emergency response team inspected the machine and reported the fire was extinguished. An investigation found that the brake booster had an air leak.

A deputy parked an underground personal transport vehicle to enable him to inspect an area of slumped rib. While he was investigating the rib, a piece of roof approximately 1 m x 0.5 m x 0.1 m fell out between the existing roof support on to passenger side canopy of the vehicle

An operator went to move an LHD and noticed that the machine would propel itself backwards when in the neutral gear.No personnel were within the restricted or no go zones at the time of the incident and as such were not placed at risk.

An industry safety and health representative identified that a coal mine was operating with an expired exemption. The exemption expired after two years.

An incoming power supply issue caused one fan on a ventilation shaft and a gas plant to shut down. A fan at another ventilation shaft was automatically dropped off when the fan on the first ventilation shaft stopped. Workers were withdrawn to the surface.

During the inspection of a conveyor belt it was found that rib had come out and fallen against the belt structure, impeding passageway on the walkway side of the conveyor

A dozer was pushing material at a dumping operation when a large rock (approximately 1.5m x 1.5m) came off the side of the dozer and ran down the face of the dump to the set up operation below (approximately 40 m). It breached a 10 m containment barrier (windrow) and hit and significantly damaged a lighting plant.

A loader arm failed at the pivot point (catastrophic failure) causing the arm and bucket to fall to the ground.The incident occurred at a stockpile area while loading 40 mm aggregate. T e operator suffered a significant jolt.

The tub of a 40 tonne articulated dump truck rolled onto its side. The truck was carting scalps material at the primary fixed plant and had travelled about 200 m. As it tried to negotiate a right hand corner it appears that a mechanical failure (spring) has caused the tub to roll over. The road surface was described as being in good condition

Detection of methane exceeding 2% in the general body of air

An electric shovel lost power. Site electrical personal were dispatched to find the cause and discovered that a haul truck had made contact with a cable sled junction box, resulting in the cable and plug being damaged. There were no injuries reported from the operator of the truck and no other damage identified to any other mining HME associated with the loss of power.

A fire occurred on a turbo charger of an excavator. This was caused by the turbo oil feed hose being compromised by heat from a previous turbo fire incident two days earlier, allowing weeping oil onto the turbo housing. The fire was extinguished by the operator using a hand held extinguisher

A worker was replacing a drill stem. The top of the drill pipe swung and struck him above right eye, knocking him off his feet. The worker suffered a cut above his right eye. The mine’s first aid personnel treated the injury. Ambulance attended the site and transported the worker to hospital.

A worker was operating a tilt tray truck for delivering shotcrete materials to site. When the driver was alighting from the vehicle the truck moved forward hitting a rock wall. The driver suffered an injury to his left knee.

A worker was fuelling a tyre handler from the cap on the top of the tank from the main fuel farm delivery point. The fuel ignited and resulted in a fire covering an area from the tyre handler to the fuel distribution point. The worker suffered serious burns.

When an articulated dump truck reversed to the topsoil dump, the left hand side of the trailer mounted some previously dumped material and rolled over.

A series of methane exceedances have been notified to the regulator at a number of underground coal mines. The exceedances were related to development operations where methane has accumulated due to changes in face ventilation.In all instances, the Deputy withdrew workers from the area, degassed the face by restoring adequate ventilation and purged electrical equipment before restoring power

A series of methane exceedances have been notified to the regulator at a number of underground coal mines. The exceedances were related to longwall operations associated with production activities.

The regulator was notified of a methane gas exceedance due to a major barometric fall. The falling barometer has resulted in an increase in methane being liberated into the accessible roadways of the mine.

Approximately 2 tonne of rock fell from a berm about 10 m onto a 120 tonne excavator, damaging the walkway on the excavator

A drill rig was drilling on the surface and trammed over a light vehicle parked on the drill pattern.The vehicle was parked approximately 50 metres away from the drill by another operator. The drill trammed forward, hitting the light vehicle and running over its rear tray.

An operator was adjusting the cable reel anti-whip valve on a shuttle car with a spanner when he suspected that his right hand was injected with pressurised fluid.The operator was assisting with a belt move and was adjusting the amount of cable on the shuttle car reel

A mine worker had a metal shard lodge in his lower lip after hitting a drill steel with a 2 kg hammer.The worker was drilling through floor concrete with a panther bolting machine when the drill steel jammed. The mine worker then attempted to lift the panther off the drill still but found the drill steel was also jammed in the panther. He has then ‘tapped’ the drill steel with the hammer in an attempt to release the drill steel.

Detection of methane exceeding 2% in the general body of air. Maximum level CH4 was 2.5% in bleeder road because of a drop in barometric pressure

A small fire was reported in the engine bay of a truck in an underground metal mine. The automatic fire fighting system deployed and immediately extinguished the fire.Component failure of upper drive shaft universal joint causing excessive lateral movement and vibration to output yoke. This has in turn caused failure of the output seal of the torque converter. The high turning speed of the drive shaft has caused the oil to splash up onto the heat shields beneath the exhaust piping. The oil has caught fire from the high temperature exhaust

A number of longwall tailgate methane levels were detected at greater than 2%. Falling barometric pressure along with the longwall shearer in the tailgate zone for extended period caused goaf flushing


While conducting a pre-shift inspection, an undermanager detected methane levels greater than 2%. The maximum level found was believed to be 2.7%. The workforce was withdrawn from the area

While in the process of starting a forklift on the surface, an operator could not get the forklift to respond to the accelerator pedal despite going through the correct start-up sequence. The operator repeatedly removed and reconnected the seatbelt in an attempt to get the forklift to respond. On about the seventh attempt the operator noted that with the seatbelt disconnected in his hand the forklift propelled itself forward about 2 m without operator input. The forklift was bought to rest through the application of the foot brake.No personnel were placed at immediate risk at the time of the incident as no-go zones were in place.

While in the process of returning to a clay pit, a dump truck veered off the road and onto a safety bund.

Two fitters were fault finding on a tilt bucket issue on a 45 tonne excavator.While attempting to remove a counter balance valve, the cartridge ejected at velocity over the heads of the fitters and sprayed one of the fitters with oil.

The operator of a roof bolting rig on a continuous miner was sprayed on the back of the knee with hydraulic oil when a hydraulic hose burst. The hose was covered by DAS sleaving. The bend radius of the hose may have been too tight.

While drilling polyurethane holes into the longwall face, a 5 m drill steel became bogged horizontally. In attempting to pull the steels free from the face, a sling was connected to the bolt and a pull lift was used to try and pull the stuck bolt out.The pull lift was attached to the sling and the pull lift hook was attached to the armoured face conveyor pan spill plate (a vertical steel plate). When the pull lift was tensioned, the chain block hook slipped off the spill plant and struck a worker in the face.The worker received five stitches and dental treatment.

An operator was unable to make the accelerator pedal on a forklift respond despite going through the correct start-up sequence. On about the seventh attempt, the operator noticed that with the seatbelt disconnected in his hand the forklift propelled forward approximately 2 m by itself. The forklift was stopped through the application of the foot brake.

A cyanide chemical leak was reported at the leaching tank in the process plant. This was contained in a bunded area that is accessed by few people

While changing the quick detach system (QDS) attachment on a load haul dump, an operator’s hand was sprayed with oil from the quick release connectors. When connecting the QDS fitting, the operator misjudged the position and depressed the male QDS fitting sealing device allowing pressurised fluid to be released.

A driver stopped a truck up at a tip head and applied the park brake. He started to raise to tip and realised the ground was starting to slump. The driver tried unsuccessfully to reverse, then called for help. The truck was later pulled clear.In a separate incident, an articulated tipper rolled over while tipping its load. The prime mover has remained uprig


A bubble was identified in the sidewall of a tyre on a 500 tonne truck. The tyre fitter instructed the truck operator to relocate the truck to the tyre bay. When the truck was parked at the tyre bay, the tyre fitter and operator left the immediate area of the tyre. After they left, the tyre failed resulting in a rapid release of air and one piece of sidewall rubber being thrown about 5 m away from the tyre.

A light vehicle was travelling on a haul road when the driver lost control and the vehicle rolled onto the passenger side. No injuries were reported.

An LHD hit and damaged a methane drainage line resulting in methane being discharged in to the general body roadway of an underground coal mine.At the time of the incident the mine was undertaking maintenance activities on the methane drainage plant, resulting in the methane range being pressurised.As a result of the damage to the methane range, general body methane levels exceeded 2.0% with a peak reading being identified by a mining official of 3.5% at a workplace inbye of the incident scene while in the process of withdrawing workers from the area.As the incident progressed, there was then a failure to apply the mine’s withdrawal trigger action response plans, resulting in people remaining underground as methane levels increased.

A truck dumped coal on the run-of-mine pan close to a bulldozer. The dozer reversed after pushing the load and clipped the truck mirror. The truck and dozer were stopped and the workers’ supervisors were informed

High winds brought down tree branches on to 66KV power lines. This resulted in a power dip that caused fan motors to trip off at the fan shaft which resulted in workers being evacuated from the mine. Settings on protection relays for the fan motors were found to be set incorrectly

An underground coal mine identified an increasing trend in methane levels in the return roadways of the mine associated with old workings. The mine responded to the increasing trend by implementing a ventilation change to increase ventilation quantity to the affected roadways, however the ventilation change was not timely and methane levels in the roadways peaked at 2.17%.

A fitter was driving a light vehicle to a workshop on a recently watered haul road. The driver lost control and skidded for some distance before rolling the vehicle onto its side. The driver was uninjured

A gas exceedance was reported at an underground coal mine. Planned works were being undertaken that involved removing power from underground booster fans and a tailgate real-time gas monitoring point. A separate task was also being undertaken on the gas drainage plant. A tube bundle sample point in the tailgate detected the exceedance. The source of the methane appears to be seals around the longwall 30 recovery area, two of which were incomplete. Methane peaked at 4.04%. Withdrawal of underground workers was delayed but completed. Upon restart of gas drainage plant and booster fans, gas levels fell to normal levels.

A truck driver was cleaning the draw bar of a dog trailer with the body of the truck raised and the hoist control in the down position. The truck body stayed up and the tailgate rested on the material he had just tipped. As the driver reached in to flick a rock off the draw bar, the truck body suddenly dropped causing the tailgate to come free and strike the driver on the head. The driver fell and hit his head again. He suffered cuts to his head and was taken to hospital for treatment.

An operator in the area of a fuel farm was sprayed with a fine mist of diesel fuel when the seal on the main delivery line failed. The pump was not running at the time of failure, however there was residual pressure in the line. The operator was not injured.

A coaltram was reversing down a roadway with a quick detach system water cart attachment. The diversion valve was operated, lifting the water cart, which hit a high voltage cable. Power dropped to the circuit breaker. No one was injured

A shaft winder at an underground mine tripped. It was initially attributed to a communications fault as a result of a flat battery. In the process of arranging a battery change out, it was identified that 37m of hoist rope was damaged and became knotted and looped on itself. The shaft depth was more than 1000m.An initial investigation found that the cage may have become stuck near the bottom of the shaft and continued to pay out rope.

While running in drill rods on a drill rig in an underground metal mine, a driller saw a flame appear, then disappear out of the drill rod. The flame was about 30cm, bright orange and lasted for about 30 seconds. The gas monitor was not alarming. The incident was not reported until a few days after the event because the drillers and supervisor were not aware of the reporting requirements of clause 179(b) regarding a fire in the underground parts of a mine.During re-entry in a cross cut in an underground metal mine, a shift boss found a burned ventilation bag. This was reported to the foreman. The mine has not been able to identify the cause of the fire and the regulator directed the mine operator to complete further investigation and assessment.The incident was not notified to the regulator until several days after the incident occurred.


An operator of a dump truck noticed smoke coming from an engine compartment. The operator stopped the truck and activated the fire suppression system. The operator used a hand-held extinguisher to extinguish the fire.An underground truck was on the surface pit ramp when there was a fire in the engine bay


An articulated water cart tanker was reported as having rolled over. The truck cab remained upright

A fully loaded dump truck lost control on a haul road with the truck’s front wheels going through a windrow. The windrow stopped the truck from going over a 10m drop-off to a small berm and a further 30m to the pit floor.The truck operator said he lost control while avoiding a kangaroo. The incident occurred at night with roadway conditions reported as good.

Falling rocks damaged the cabin of a loader while the operator was cleaning up the working face. The operator was uninjured.

The operator of a 75 tonne excavator requested an articulated water cart to wash down the front windscreen of his excavator. The water cart started the wash down. The excavator had its boom and stick in the air. The excavator operator lowered the bucket to assist the wash down, but in the process of lowering the bucket hit the cab of the articulated water cart.

A heavy vehicle interaction near-miss was reported to the regulator. Two large mining haul trucks avoided a low speed collision at a T-intersection when the haul truck coming from the right failed to give away to the haul truck on the left (as per the site transport rules). The speed limit at the intersection is 20km/h and the haul trucks stopped without making contact (about 8m between them). The incident occurred at night, the weather conditions were fine and the intersection was not lit

An electric shock was reported by an operator who made contact with an external storage hot water system at a crib hut. The hot water system was supplied from a 240V AC source. The water heater was within a mobile crib hut fed by a generator.

A dump truck pulled out from a stop sign into the path of a light vehicle. The light vehicle driver took evasive action, avoiding a collision.The operator of the dump truck indicated he had stopped, looked in both directions, but did not see the light vehicle

A dump truck reversed through the dump windrow while tipping, causing the rear wheels of the truck to slump on the rill and raise the front tyre.

During the installation of monorail services at a longwall installation face, a spotter was positioned at the maingate corner to communicate with a loader operator. The loader was being used to tow monorail services and the longwall distribution control box up a slight grade and into position with the assistance of two air mules on the monorail. During the task, the 24 mm rope failed near the connection to the monorail and retracted making contact with the spotter that was positioned at the maingate (63 metres away). The spotter was taken to hospital for assessment with abrasion, bruising and swelling above the right ankle.

A contractor was refuelling a petrol-driven water pump. The pump caught fire and the person suffered burns to his hand. There was a strong wind blowing and this may have blown fuel onto hot engine parts during the refuelling. The incident was not immediately reported to the regulator

An operator was in the process of establishing the edge of bench bund prior to carrying out push over to an excavator on the bottom level. The operator had to rip a hard rock area prior to pushing up the bund. In dropping the drive down, the operator slipped the dozer into neutral and the dozer rolled backwards over the edge onto bottom level. The operator suffered a bump to his head as a result of the incident.

While an excavator was in the process of moving a 3 m log from sand in a pit, the log slipped and went through the excavator windscreen. It landed on the cabin travel controls. The operator suffered minor lacerations to his fingers

A truck was driving under a coal handling preparation plant bypass coal bin while the tray was up. The track hit the beam on the coal bin

An operator of a dump truck fell asleep on a haul road. There was no other traffic at the time and no injuries were reported. The truck ran over some poly pipe in a culvert. The driver passed fitness-to-work testing

The operator of a haul truck was lowering his tray after dumping a load when the tray suddenly slammed down to the bump stops. The lower retaining bolts of the left hand cylinder retainer may have failed, causing the cylinder to fall off when lowering. An on-site audit of other haul trucks revealed more loose bolts on the cylinder retainers

An operator using a shotcrete rig was preparing the machine for a maintenance task to repair a fault on the nozzle on the boom. While operating the remote control, a spring return to centre control overshot resulting in the boom moving unexpectedly and the boom / nozzle hit the side of the operator’s head. The operator received treatment in hospital for head injuries

An operator of an underground haul truck noticed sparks coming from the engine bay area of a concrete agitator. The truck operator immediately notified the agitator operator, who stopped. The fire was extinguished using a hand-held extinguisher.

When hoisting, a skip trip in the head frame occurred. The skip tipped and the cylinder pushed the skip back into bridle, then the skip descended to the guides. The skip became caught and the winder tripped out. The winder driver heard a bang and stopped to look at what happened. Upon inspection, the cylinder didn’t finish pushing the skip into bridle before the bridle descended.The skip wear plates (herring bone liners) allowed rocks and material to build up to the point where rocks jammed the skip door. The push plate became caught on the lip of the chute, jamming the conveyance.The site modified the liners and repositioned the retract cylinder and proximity switch to ensure the skip was pushed and monitored into the bridle once tipped.

Ten 3300V phase condition indicators were sent to a licensed repairer for an overhaul. The licensed repairer advised that all of the phase condition indicators did not meet the requirements of approval MDA Ex.d 1319 in that one of the minimum flamepath dimensions specified on the drawing was not met.

A run of mine (ROM) coal stockpile was showing signs of spontaneous combustion. A dozer was being used to push coal. The operator drove the dozer to the top of the stockpile. The dozer then slid down the stockpile sideways approximately 2.5 m. The operator suffered some bruising from the seat belt. The operator was experienced with dozers, however he was not experienced with ROM coal stockpiles. The incident was reported as a high potential, however it should have been reported as a dangerous incident.

A supervisor was driving a light vehicle from a pit office area to the stores. While driving up hill and turning a corner, the driver went to apply the brake but accidently applied the accelerator. The vehicle hit a bund between the car park and store access road and rolled the vehicle on to its side.

A fitter jump-started a light vehicle that had a flat battery. The vehicle was parked outside a workshop. The fitter walked back to the workshop to return the jumper leads. While he was away from the vehicle, it rolled about 30 m and collided with an articulated water truck.When the fitter came back from the workshop and noticed the vehicle had rolled away and hit the water truck, he ran to it and stopped the engine, put it in gear and applied the handbrake.

The operator of a fully loaded truck saw flames coming from a resistor grid box.The operator stopped the truck and activated the e-stop and fire suppressionsystem. The fire suppression system didn’t adequately reach the resistor grid box tofully extinguish the fire so a water truck was called to apply water, which ultimately extinguished the fire

A driller and offsider were preparing to move a drill rig to a new hole, however the jump-up stand and rod rack were interacting. The drill rods were moved from the rod rack up against a wall to allow the rod rack to move. While thedriller was positioning the rod rack, the offsider was using timber to level the rig.During this process the leg of the rod rack made contact with the drill rods positionedon the wall behind. As a result, the 13 drill rods where knocked over and fell onto thejump-up stand and onto the ground. The offsider was also hit by the rods. Theoffsider suffered bumps and contusions to his wrist and leg.

A mining truck was tipping competent material (stone) at the tip head when theoperator thought the rear wheels dropped down. The operator asked the dozeroperator who confirmed the rear wheels had dropped approximately 0.5 m.

A coal burst occurred in a development unit. The unit stopped and workers wereremoved from the area. The area was secured and the workers were uninjured.A large scale ‘pressure bump’ resulted in the displacement of coal from the rib overa distance of approximately 3m. Workers at the face observed the ejection of coal,however did not immediately recognise it as a coal burst.An independent geotechnical engineer and the mine’s geotechnical engineerinspected the area and determined the incident to be a coal burst.Normal mining production was taking place at the time. The area is headingtowards the swamp fault zone and had reduced the spacing's between the cuttingtest as per the mine’s plan. A cutting test was taken 1 m before and was deemed tobe okay.

An IT (integrated tool) carrier was travelling down the bank of a tailings dam.The machine lost brakes at the top section and the operator continued to steer themachine with increasing speed. The operator jumped from the machinewhich continued out of control through a windrow and dropped a further 10 to 12vertical metres where the it rolled over, coming to rest on its side.

An articulated dump truck trailer (body) of the truck rolled onto its side.

A loaded mining truck had completed loading and was leaving the loading areawhen it collided with another unloaded mining truck that had just travelled downthe ramp. The collision occurred at the base of a ramp.

A mining haul truck operator reportedly lost steering. After trying to turn both ways he applied the brake. The truck ran into a windrow.

A mulching machine and water cart were clearing scrub and timber. As the water cart returned from refilling and re-entered the work area, a piece of wood about the size of a softball ejected from the mulcher and travelled about 30 m before hitting the water cart’s windscreen at the operator's head height. The result was a smashed windscreen, with no glass entering the cabin.

A mining haul truck entered the mine’s fuel farm via the wrong entrance. The roof height of the fuel farm was insufficient for the truck and the truck made contact with the building structure. The contact also caused electric cable damage.

On a shift change, a light vehicle carrying five people was travelling along a haul road towards an intersection near a crib hut. Travelling in the opposite direction was a mine haul truck. The haul truck turned into the crib hut, which was across the path of the vehicle. The light vehicle driver did not identify the haul truck was intending to turn. The light vehicle driver braked and skidded, resulting in a near miss. The haul truck operator also braked, coming to a stop.

A mining dump truck was spotting to a dozer and reversed into the rear right hand side of the dozer damaging a light bracket.

In an underground metal mine, a diamond drill rig was coring a new hole that was right on top of a resin bolt. While drilling, the drill offsider saw a flash which was thought to be a gas fire. He yelled out to the drill operator, the operator stopped drilling and the offsider pointed the water hoses to the hole. The driller then contacted the supervisor. The supervisor came and looked at the hole. At no point did the gas alarm go off with the gas monitor about 1 m from the hole.

An empty mining haul truck was descending a ramp after rain, and the operator lost control of the truck. The truck skidded into the potential path of a loaded haul truck. The two trucks stopped approximately 12 m apart.

An operator was driving a light vehicle with the window down and his arm resting on the window sill. While passing another vehicle, his vehicle hit the gutter and in doing so the operator jammed his left arm between the mine wall and the vehicle door (left hand drive vehicle). The operator then drove the vehicle to where he was given first aid. Initially it looked like the injuries were confined to lacerations and swelling. The operator drove himself to hospital for X-rays where it was found that he had two fractures to his left arm. Hazard1 : Kinetic energy - Velocity vehicles. Risk: Harm to people from being crushedWhile a loader was picking up oversize waste from a reject bin and loading it into a 5 tonne tipper, a 1.5 metre fibreglass roof bolt fell out of the bucket, passed through the mesh aperture protecting the truck rear window and lodged under the window sealing rubber. As the loader emptied its bucket and lifted the bucket up, the fibreglass bolt flexed and struck up, shattering the window. The truck driver was observed on camera looking at the rear window as it shattered (in response to a hearing a tapping noise generated by the bolt).

A surface drill was drilling on a pattern in the pit on a slope of approximately 10 degrees. As the operator began tramming, the drill travelled forward down the slope in an uncontrolled movement for approximately 10 metres. The operator parked the drill and put the jacks down to secure the machine. The wiring harness was found to have been rubbing, and was damaged, underneath the operator’s seat. Hazard1 : Kinetic energy – Velocity/inertiaof vehicle. Risk: Harm to people from unexpected movement of mobile plant

A deputy has stepped into a pumping auger hole while hanging a pump line along the rib. The auger hole was below the surface of the water and was not visible. The hole was about 300 mm in diameter. The deputy's entire leg went into the hole. Hazard1 : Gravity. Risk: Harm to people from slips trips and falls

As a worker was attempting to lift a pump that was fitted with a wire safety cage surrounding it, the pump moved sidewards and cut through the worker’s glove resulting in a laceration to his right hand. A grinder had damaged the pump cage two days before, leaving sharp edges, which caused the laceration. Hazard1: Gravity. Risk: Harm to people from sharp edges.

A mining rear dump truck hit the centre bund of a haul road. Hazard1 : Kinetic energy – velocity/inertia vehicles. Risk: Harm to people from collision.

An operator detected a fire on a hydraulic shovel. The operator manually initiated the on-board suppression system when the infrared detection cameras identified a heat source. The on-board suppression systems successfully extinguished the fire. A failed engine turbo oil supply line allowed oil to spray onto adjacent turbo. Hazard1 : Chemical reaction – fire (fuel, heat, oxygen). Risk: Harm to people from fire on mobile plant.

A tyre on a road-registered truck blew out while reversing. This caused debris to be ejected from the area around the tyre blowout towards another road-registered truck that was parked alongside the area where the truck was reversing. The operator was sitting in the parked truck with the window down. Hazard1: Pressurised fluids – compressed airRisk: • Harm to people from the uncontrolled release of compressed air.• Harm to people from flying debris.

Repairs were being carried out on a product conveyor. A hot splice was completed earlier in the day with the belt technician finalising the splice using a 180 mm polisher with a tungsten carbide buffing disc. While operating the polisher, the belt technician made contact with the table supporting the conveyor in the area of splice. As the polisher wheel made contact with the table it has changed direction and hit the technician’s face, moving across his safety glasses and causing a laceration to his nose. The technician received five stitches to his nose and bruising to his forehead. Hazard1: Kinetic energy – moving parts.Risk: Harm to people from friction of abrasion.

An articulated dump truck rear body rolled onto its side. The operator began tipping a load of rock and saw in his mirror that the second row right hand wheel was coming off the ground. The operator released the hoisting lever and the rear body of the truck rolled over. The cross grade was measured at 1:5. The truck was involved in building an access road.

An operator drove a truck out of the pit and in the process of turning the truck around, the truck rolled over. No injuries were reported.

Two fitters were changing a strut on a mining truck. After completing the work, they began replacing the hub. It was unsecured during this process and came loose. The hub struck one fitter, fracturing his arm and dislocating his knee cap.

A haul truck reversed into a dozer when the truck was backing up. Tyre positions 5 and 6 of the haul truck hit the dozer on the ripper box causing minimal damage. The haul truck operator did not see the dozer.

A small fire was reported on an excavator left hand engine. The operator noticed the fire on IR camera screen, shut down the engine and put the fire out with a handheld extinguisher. There was residual oil in the turbo lagging, which was soaked in oil and the fire reignited. The operator put it out again with the fire extinguisher.There was a loose fitting on the poly-steel braided turbo feed line to the o-ring connection. This was the oil that soaked the turbo lagging. There was mid-life maintenance carried out on the engine about three days previously.

A fire occurred on a collapsed conveyor return idler on the main truck belt in an underground coal mine. The outbye deputy smelled smoke and went with another deputy to identify the source. They found fines burning under the collapsed return idler. They put stone dust on the fire, which flared it up. The deputy then went and got a water hose to extinguish the fire.

A professional wildlife catcher was engaged by the mine to cull pigeons with a 22 calibre air rifle. The shooter shot a pigeon which fell to the ground. The shooter realised the pigeons wing was only clipped. As he walked toward the pigeon to shoot it again, the rifle dropped and rubbed his leg and a slug fired into the concrete floor. The slug ricocheted off the concrete, past a supervisor and then through a glass door panel then into the CHPP control room that had an operator inside.

A load hall dump (LHD) vehicle, was preparing to dump a load of shot-fired roof material at a nominated surface dump. The LHD travelled up a ramp and turned into the dump site, placing the LHD across the grade of the ramp. Approaching the dump site, the operator began raising the bucket. He brought the LHD to a stop and continued raising the bucket to full height to allow him to tip the load. The operator felt the front offside (down dip) of the machine subside then the machine tipped over/rolled until the bucket and boom of the machine stabilised on the muck-pile. The operator assessed his position and determined a safe exit from the cab. He climbed over the door and down the top of the machine on the low side then reported the incident.

While driving a shuttle car down a steep grade the operator tried to slow the machine by applying the foot brake. This didn't work, so after trying several other things he pushed the emergency stop button that stopped the machine.

A dozer was trammed up a rill between two benches with a height difference of approximately 4 m. Upon reaching the crest of the rill, the operator steered the dozer to the left as it drove over the windrow on the edge of the bench. The right hand track sank into the loose material, causing the dozer to roll onto its right hand side. The operator was uninjured and was able to safely exit himself from the cab and raise the alarm. He was wearing a seat belt at the time of the incident.

An operator of an underground LHD was pushing an auxiliary fan around a corner when it rode up on a cable boat frame. This put the fan up on one wheel. The operator stopped pushing and tried to pull the fan back off the cable boat. During this, the fan rolled onto its side

A fitter was doing some fault finding on an integrated tool carrier that could not be started. He had moved some cables when he thought he heard some electrical activity and called out to the operator in the cabin to start the engine. The operator cranked the engine and the machine suddenly lurched forward catching the fitter's hand between the rear tyre and themud guard. The integrated tool carrier was moved before it was realised the scene had to bepreserved. The machine was left on the main decline.

While carrying out a breakdown maintenance task with the fitter on a continuous miner roof drill rig solenoid, an electrician was dowsed in hydraulic oil. A hydraulic hose was disconnected by the fitter before the incident, however the hose was not capped. During testing, the hose was flipped around releasing a large amount of oil, some of which went into the electrician’s eyes.

The operator of an excavator saw a fire system fault light in the cab. The operator shut down the machine and inspected the engine bay but he could not find anything wrong. The operator called for a maintenance electrician to investigate the fire system. An electrician inspected the right-hand engine and saw a small fire on the turbo. He used a fire extinguisher to extinguish the fire. A water cart was placed on standby, but not used.

A small bushfire resulted when overhead powerlines came close together and arced. Movement in the powerlines was attributed to suspected blast overpressure. About 4m3 of area was burnt o

During monorail services retraction, a monorail beam separated from a monorail trolley and subsequently two more trolleys fell to the ground. An operator was about 3 m away operating the traction drive using a pendant control.

A 3.3kV back-to-back coupler failed in service on a monorail in B heading. It ejected one of the plugs and there was a visible light and a loud bang. A worker was within 5 m of the failure, another 10 m away and another 25 m away. All three reported ringing in their ears. The two workers closest to the coupler were sent to hospital for treatment.

An underground low speed collision between a grader and a LHD was reported. A grader was travelling about 20 km/h in an outbye direction while an LHD sounding its horn began entering the intersection. The bucket of the LHD hit the grader. The bucket of the LHD was bent. No injuries were reported.

An OCE step-up supervisor had positioned a lighting plant using a Toyota Hilux ute. After disconnecting the lighting plant, as the vehicle drove away the left front wheel was half dislodged off the axle. A number of wheel nuts were loose and a stud was broken.

An electrician involved in the installation of a water treatment plant was rolling cable off a drum and wedged his left arm between the rear of the ute tray and the drum. His arm was broken and he was taken to hospital for treatment

An operator was using a front end loader to clean up around a haul truck when he reversed into a truck. A cover was damaged on the loader, which then moved forward and cracked the back window.

An operator stopped at a diesel tag board and smelled something unusual and discovered flames coming from under a steel cover at a conveyor boot end. The operator hosed the area with water and removed the cover to make an inspection to ensure the fire was fully extinguished.

A drill rig off-sider was hit in the face by a haul plug resulting in a fractured cheek bone and broken nose. He was taken to hospital for medical attention.

A shaft winder tripped a limit, stopping it approximately 5 m below the No 9 level plat. One worker was in the man cage at the time. He was not injured. The site’s mines rescue team was activated. A ladder was used to extricate the worker from the man cage.

A trained worker doing routine clean-up of plant on a stable, concrete surface misjudged the corner of the concrete edge when backing up. In the process of turning the bobcat, the back right wheel rode up onto the concrete curb putting him at an imbalance point. As he tried to correct and drive off he overbalanced and the bobcat and rolled onto its side. Other workers righted the bobcat to stop and contain further oil spills.

The operator of a water truck was operating the truck when she smelled something unusual. The operator pulled the truck over on the go line, applied the park brake and turned the machine off. At this time she heard a 'pop/bang' sound, as did a plant mechanic who was in the vicinity of the area at the time. The hold-down cover was not an original equipment manufacturer-supplied part and did not have provision to prevent the movement of the battery under the plate. This has resulted in the battery terminals shorting to the cover plate and overheating two of the batteries.

An operator detected smoke while he was using a dozer on a waste dump. He parked the machine and saw a fire. He activated the fire suppression system and called emergency.

While drilling an underground exploration hole, a gas flame occurred, which was self-extinguished. The hole was placed onto gas diversion to make it safe. A gas detector located about half a metre above the drill hole did not detect any gas. A second incident occurred that had to be extinguished by the operator. There were no indications from the drillingreturn water or from gas meters that gas had been hit and the rig was operating as normal at the time. It is believed that the friction from the spinning rods against the jaws .

During a routine conveyor inspection a deputy identified glowing embers and a small amount of smoke under a trunk conveyor. No naked flames were seen and a collapsed return roller was found to be the source of the heat. There was a small amount of fines below the collapsed roller, which had 500 mm clearance from the floor.

The operator of a bulldozer saw flames coming from the left hand side walkway and manually activated the on-board fire suppression system. The fire was extinguished and a water cart was also used to cool the walkway area. There is no visible evidence of equipment damage but all guards and covers were removed. The machine hydraulic tank was reported as empty, which indicated a failed internal hydraulic line as the likely source of the fire.

While in the process of changing a half filled medical oxygen cylinder gas bottle from the back of a truck, it slipped from a person’s grasp. The bottle hit the holding crate and broke off the isolation valve. There was a release of gas under pressure that created a lot of dust, but the bottle didn’t move. Two workers in the area remained still until the dust cleared.

Two fitters were removing the main drive shaft from a loader with the bearing attached. While lifting the shaft, the mount and bearing came loose falling one metre and hitting one of the fitters on the leg. The fitter was taken to hospital.

A longwall fitter had the top of his left index finger amputated when a maintenance access cover on the top of the longwall crusher fell on his finger.

A worker was operating a front end loader on a cross grade with a full bucket that was lifted in the air. This resulted in the front end loader rolling onto its side. The operator was not injured.

A dozer was parked up and the operator was standing on the deck preparing to lower the ladder so he could retrieve earplugs from an approaching grader driver. The approaching grader driver inadvertently accelerated instead of braking and the blade of the grader struck the lower section of the ladder and tore it from the dozer. The dozer driver lost balance and fell from the deck to the ground (about 3 m) and injured his knee.

A haul truck was taking waste to the dump when the driver of the following truck saw fluid coming from truck. He advised the driver via two-way radio and then saw what appeared to be a small flame. The flame grew in size to about 40 cm. After more discussions with the truck driver, the onboard fire suppression system was activated to extinguish the flame.

An operator was driving an articulated water cart across a windrow as part of the construction process. As he attempted to straddle the windrow he realised his approach was potentially unstable and he tried to reverse out to improve his position. However, the trailer section of the truck rolled over but the cabin remained upright.

During dayshift, workers on the drift conveyor noticed a smell coming from outbye. They investigated and found the source to be hot coal under a roller. When raked out, there was evidence of glowing embers. They did not report this until the end of shift.

The operator of a dozer was alerted to a fire on the left hand side of the engine bay by the dragline operator. The dozer operator activated the onboard fire suppression system, which extinguished the fire and he left the dozer without incident.

During a longwall pump station relocation. a 100 mm diameter flexible water hose with a crimped Victaulic fitting has come apart at the feral. The water hose swung down and hit a worker on the head. He was taken to hospital for treatment.

A bearing failed in the troughing set at the front of the longwall mobile boot end resulting in a small grease fire. The fire was quickly extinguished by water.

A rock weighing about 2 kg fell from a wall. No one was in the area at the time.

An articulated haul truck was leaving the pit floor loaded with material and as it turned onto the main ramp, one of the rear tyres blew out. The shift in load caused the body of the truck to overturn. The cabin of the haul truck remained upright and the driver was not injured.

A contractor was carrying out painting and sand blasting activities in a coal handling and preparation plant. While sand blasting, the jet nozzle and hose entered his protective clothing (apron) and into his airstream helmet. This resulted in it striking him on the right side of his temple and causing a laceration. He was taken to hospital for assessment

A roof fall occurred at a four-way intersection just behind the main north conveyor LTU. It went up about 4 m high and was about 10 m in diameter.

A worker was hit by the ramp of a low loader when the chain retaining the ramp broke. The worker was hit on the head (he was wearing a hard hat) but suffered a compound fracture of the right tibia. The truck and low loader had just been delivering a dozer to the mine and was being prepared to leave the mine. The first ramp had been raised and secured with the chain. The second ramp was not lifting. While attempting to get the ramp to lift, the chain on the first ramp broke and allowed the first ramp to drop. The worker was walking past the ramp at the time that the chain broke.

Recent rain caused stone to fall from a bench above a roadway, with a small piece hitting the roof of a light vehicle. The operator stopped the vehicle and saw more stone landing on the roadway. No one was injured.

A fire occurred on a dozer while working on the underground return of mine (ROM) stockpile. The dozer operator noticed the hydraulics failing on the machine. He drove the dozer off the stockpile to enable a fitter to inspect the machine. After parking the machine, the operator noticed smoke coming from the left-hand side of the engine bay. He called in an emergency on the two-way radio and then initiated the onboard fire suppression system. The operator then used a hand-held extinguisher to extinguish the fire. The fire was in the vicinity of the left-hand turbo.

A fitter was hit on the forehead by a radiator shroud (piece of steel) that fell about 1 to 1.5 metres. The fitter was working underneath a haul truck at the time the section fell. The shroud was being refitted following the replacement of the engine in a CAT 793 haul truck.

At an underground location, a flat top truck was delivering materials. A telehandler was being used to unload a cage of dry goods. On the opposite side of the truck was a cage with sixgas cylinders in it. When the telehandler lifted the dry goods, the cage with the gas cylinderslifted as well, toppled over and fell off the opposite side of the truck flat bed. One of thecylinders had its valve broken and the gas was released. All workers stood back andremained away from the venting cylinder. The way the cylinders were laying necessitated them being moved to make the scene safe.

A driller's index fingertip was crushed and amputated when the door of a blast hole drill rig was closed onto his finger. The operator had his hand resting on the door frame of the non-hinged side when another worker closed it. He was taken to hospital for treatment.

A small fire was reported on a contractor’s shotcrete machine. The fire occurred in the electrical (24 volt) componentry on the lefthand side of the machine and was extinguished using the aqueous film forming foam (AFFF). There was minimal damage to the machine and nobody was injured.

A hire drill rig had completed drilling a hole as part of a shot pattern and was in the process of removing the steels from the hole and racking them in the carrousel. The operator lifted the lead steel to the top of the mast and the steel disconnected at the saver sub causing the steel to fall about 2 metres, penetrating the drill deck adjacent to the operator’s cab. The operator was not injured and reported the incident.

The operator of a bobcat was picking up overflow spillage (mud, coal, magnetite) that was spread around the collection sump. The operator had picked up and loaded about 15 to 20 loads of wet muddy material into the collection sump before the incident. On the bucket load of the incident, the operator drove towards the collection sump and raised the bucket in the air (with material in the bucket), when he went to stop the bobcat rear wheels came off the ground and the windscreen made contact with the guard rail surrounding the collection sump causing the windscreen to smash.

A haul truck was reversing into the pit dump behind a dozer that was positioned and working perpendicular to the haul truck. The dozer reversed into the haul truck making contact between the ripper frame on the dozer and a tyre on the haul truck. The wheel rim was scored and scuffed. No escape of air occurred from the tyre,

A charge-up rig was driving in the decline when the operator noticed flames possibly coming from the central articulation area. The fire was immediately extinguished and the plant isolated. It appears the fire may have been caused by a burst hydraulic hose spraying oil on the engine exhaust.

An underground mono pump stopped operating and upon inspection the electrician noticed smoke and a possible fire coming from the pulley belts that drive the pump. The electrician used an extinguisher to eliminate any fire, isolated the pump andnotified the shift supervisor.

A haul truck operator lost traction on an over-watered haul road ramp (no dry line). The driver stayed in his lane despite spinning the truck 180 degrees after hitting the retard pedal.An electrician was driving a ute (light vehicle) around a righthand bend when he lost control. The ute spun around and rolled onto the driver's side. The driver was not injured. He was drug and alcohol tested and checked for dehydration. All results were negative.

While welding a cleat to the port side of the dredge approximately 100mm above the water, the wind created waves that splashed up onto the work area. This resulted in the person welding suffering an electric shock.

A worker was welding a pipe to the outside of a sump. A fire occurred inside the sump with flames passing up through floor grating above the sump to within1 m of the second floor. A fire watchman quickly extinguished the fire using a water hose from the first floor.

The operator of a loader noticed flames from the rear of the loader when in the decline. He activated the fire suppression and parked the loader safely. The fire was extinguished with the onboard fire suppression. Initial investigation identified the ignition source was electrical as the fire originated around the battery area.

An articulated dump truck park brake failed to hold a truck when it was stopped, about to tip a load. The loaded truck rolled forward about 50 m before striking an earth berm. The cab of the truck remained upright but the body overturned. The operator reported that the truck lost all steering and braking while rolling forward. No one was injured.

After parking a utility vehicle in the lower quarry bench, an operator of a 40 tonne articulated haul truck parked about 1.5 metres from the back of the utility. The operator exited the haul truck and walked to another area of the quarry. When a leading-hand worker was obtaining something from the front of the utility vehicle, the haul truck rolled forward and rested against the rear tailgate of the utility causing minor damage to the tailgate. No injuries occurred.

A fire occurred on a dozer. The operator saw smoke coming from in front of the radiator. The operator stopped the machine, called emergency, initiated thefire suppression system and exited the machine. The fire was extinguished about an hour later with help from a water cart

A contract worker was driving an articulated dump truck when control was lost and the truck ran off the road into a drain. The worker was found unresponsiveand died despite efforts of his coworkers and ambulance officers to resuscitate him.

A dump truck exited a dump and was proceeding down a 10% grade when the truck started to slide. It slid for about 80 m before it started to turn. The driverbraked and the truck slid over the centre line of the road. The speed at the start of the slide was 24kph and reached up to 29 kph during the incident. The truck wasempty. The road had been watered and had a 4 m dry line.

A worker was greasing a frontend loader from a mobile service truck when the hose failed. The worker was not injured but was about 0.5 m from the point of hose failure at the time it failed. The hose was rated to 5000psi and the working pressure supplyfrom the pump was about 2500psi.

A fitter working on a 25 tonne excavator fell off the stairs when exiting the machine. The operator fell about 2 m, landing heavily on ground.

A worker was hit in the face by a return hose when it whipped around (unrestrained) after roof consolidation product (mineseal) was returned to the re-circulation tank.

An excavator was deck loading overburden in the pit. The operator saw oil on both tracks and communicated to the trucks and dozer in the area that he had an oil leak. The operator positioned the machine for better access and then noticed smokeand fire in the engine bay of the machine. The operator shut down the machine, initiated the fire suppression and called an emergency. The fire was extinguished. Further inspection identified that a bolt was missing from the hydraulic fitting attached to the fan drive motor on power pack 1, allowing the release ofhydraulic oil to be blown over the motor resulting in the initiation of a fire. There was no visible damage to the machine.

A worker was weed spraying near and old underground sealed entrance. As he walked towards the entrance he noticed an unusual smell and felt lightheaded.He walk out of the area and contacted the supervisor. The operator continued work.

A dump truck was reversing up a stockpile when the truck's trailer rolled over. The cab remained upright. The driver was not injured.

A maintenance contractor was fault finding on a mobile crusher while it was running. The crusher was empty at the time and a jaw plate had become loose. The plate was thrown about 15 m into the air. It then hit the control panel hatch that the contractorwas standing under. This resulted in the hatch and plate hitting the contractor on the head. He was knocked down and suffered a laceration required five stitches.

While joining rods in the process of diamond drilling in an underground metalliferous mine, a flame came out of the hole. The flame was immediatelyextinguished using a diverter and fire extinguisher.

A water truck was descending a haul road when the truck travelled from a wet section of the road to a dry section. The truck hit a bump in the road and the driver braked. The truck began to skid then rolled onto its side. The section of road was straight and the road was not over watered.An ignition of methane occurred at the coal face during production in a development panel. A continuous miner intersected a known strata fault when the ignition occurred. No injuries were reported.

A fitter was servicing a dozer. While using the grease gun, the fitting became stuck on the grease nipple. When the fitting became free the fitter was splattered with grease. The incident was treated as a potential fluid injection.

A 25-tonne crane was parked four metres from a materials chute above a material feeder onto a conveyor belt. A worker was in the chute, about to carry out a welding job. The crane did not have the park brake applied and rolled towards the opening.The chute lip prevented the crane from entering the chute. The crane driver had left for a shift change and had not put wheel chocks in place as per site procedure.

An alarm was activated on the dashboard of a new truck on a mine site. A worker parked the truck and proceeded to notify the supervisor. A fitter of an oncoming shift went to check out the reported alarm. When the fitter arrived with the truck operator, they saw smoke coming out of the truck window. They isolated the power at the front of the vehicle. The smoke subsided and stopped. No flameswere observed. No fire extinguish

An empty truck (previously containing ammonium nitrate) leaving a site had a raised rear trailer while travelling on an exit road. The trailer made contact with a tunnel on the access road, which resulted in the trailer decoupling from the truck.

During roadworks, an excavator was shaping windrows on a haul road ramp. The worker requested additional material to fill a gap. A haul truck reversed to about three metres from the excavator. While dumping the load, a rock fell over the side of the truck and hit the excavator. There were no injuriesA steel prop used to help support a steel cross beam in a belt roadway fell. The steel prop had been set into the floor but the floor was brushed about a week previously. There were mine workers about one and a half metres from where the prop landed.

A fire was reported on a water cart. The water cart was under a water fill point when the operator noticed the fire. The operator initiated the onboard suppression system to put out the fire and then used a hand-held extinguisher on a section that was giving off smoke.A worker suffered a fluid injection injury when a hose fitting on a high pressure wash down wand failed. The hose whipped around and the person was hit on the chest and the left forearm with the highpressure water.

A light vehicle made contact with an integrated tool carrier and the wall of a mine. As the vehicle approached the accident scene, the driver applied the brake but the vehicle did not respond. On applying more force to the brake, the motor speed increased. Consequently, the vehicles collided. No-one was injured.

The handrail of a dozer was damaged when hit by an excavator bucket. The dozer was cleaning up on the off side of the excavator and moved within the swing radius of the excavator without making positive communications with the excavator operator. Note: This dozer was a hired machine and was not fitted with the proximity detection systems as fitted to mine-owned machines.

A Cat 777 service cart skidded while travelling down the main pit access ramp. It veered to the right across the grade and then rolled over. A watercart operator had previously watered the ramp using the centre spray only. The service cart was travelling on the wet line with full tanks. This portion of the ramp was on the roof of the coal seam. The coal is hard and slippery when wet. There was a bump in the road at about the point where the rollover occurred. The truck operator stated that the retard was used further up on the ramp and was travelling at about 12 kph. The driver initiated the retard as the vehicle approached the bump in the road and this was when the rear of the service truck slid out to the left.

An operator was in a man basket recovering ventilation tubes. As the operator was breaking the tubes for a new auxiliary fan location the operator removed the chain and pulled the tubes apart with the handle. The tubes suddenly released jamming the operator’s right ring finger between the ventilation tube and the man basket resulting in a laceration to the operator’s finger

A truck-mounted crane was to be used to assist with a repair to a shroud on the bucket of an excavator. While preparing the crane, the procedure was not followed correctly. This, in turn, put extra pressure on the crane’s hook. The boom extended into the operator’s standing area causing the operator to take a step back to avoid being struck.

During the unloading of a trailer at the processing site the trailer has rolled onto its side when the 3rd stage of the hoist ram has been reached. The truck's cabin has lent to the passenger's side but didn't rollover. The dump is on the crest. There were no injuries.

A haul truck road train that was taking coal from a washery bin to a rail-loop stockpile was driven into a bund wall at low speed. The bund was protecting a drainage channel. A review of video data obtained from the truck's DSS safety system indicated the driver may have had a micro-sleep.

A contractor was regassing a light vehicle when he felt an electric shock from a 240-volt re-gassing machine. The contractor did not report the incident until the end of his shift, so the site was not preserved at the time of the incident and the exact time is unknown. On initial investigation, the regas machine tested correctly however, the extension lead was found to have damaged earth.

Police informed the mine a child had an accident on the mountain behind the administration area on site. The area, which was locked, was opened to allow the ambulance and police to find the child. The injured child was found at 9.30 am and a rescue helicopter flew the child to a hospital in Sydney.

While trying to clear a blocked diaphragm pump, a worker isolated the compressed air line. The worker then opened the bleed valve in the delivery line while putting their face in the line of fire. Dirt and grit hit the worker in the face and eyes. The worker was wearing safety glasses that were blown off. The worker was transported by ambulance to hospital for treatment.

Three workers were 15 m away from where a a 30 kg piece of steel landed after it fell from the underside of the floor above in the concentrator pump floor in a surface mill.

A crew was operating a new belt maintenance station to retract belt from the maingate conveyor. After 30 m was retracted, a clip became caught on the pinch roller. When the crew reattempted to get the clip through 14 of the 24 x 3/8" mounting bolts sheared sending several bolts in the direction of two of the crew who were standing 5 m from the belt maintenance station. From initial site investigations, there may have been a hydraulic issue with a blocked drain case port.

A worker was using a water pressure cleaner at up to 5Kpsi pressure to scale salt from the top of a service. The worker stopped to change out the lance before depressurising. The worker had a hand on the end of lance and a co-worker hit the trigger, injuring the worker's hand.

A contract operator suffered a deep cut to his finger during the installation of 6 m high tension roof bolts using a load haul dump hydraulic bolter. The hole had been drilled and the operator was installing the bolt in to the hole when the plate slid back down the bolt, cutting his finger. The operator was wearing gloves at the time of the incident.

A dump truck lost control while travelling down a ramp. The dump truck was empty with the road conditions wet from recent water cart activity and a passing storm. The dump truck slid out at 90 degrees and crossed the centre line before stopping. No injuries were reported and there were no other vehicles on the ramp at the time of the incident

While travelling through a traffic light area a person transport vehicle made contact with a high voltage plug.

While a contract driller was drilling a pit pattern in an open cut coal mine, a flammable gas ignited within the drill hole. The fire propagated from the hole to the front hydraulic system and partially burnt and damaged the cab. The operator activated the automatic fire suppression system, which was ineffective because of the flammable gas burning in the hole. An emergency was initiated and two water carts extinguished the fire.

A coalburst was reported on a longwall between shields 92- 107. About 50 tonnes of coal was ejected. The shearer was cutting from the maingate to the tailgate. The majority of the ejected material occurred where the shearer was positioned, over onto the shield pontoons. One operator was injured and taken to hospital. The operator was given three stitches to the left hand.

An operator was sprayed with hydraulic oil on the left forearm from a bolter inner rig. The oil release originated from an Oring that failed with no apparent mechanical damage to the fitting or components.

A new worker operating a loader was cleaning up under a conveyor belt after receiving verbal instructions from a trainer. While cleaning up, the loader made contact with the conveyor structure causing damage to the loader’s windscreen.

A front-end loader was building a ramp on a surface ROM pad. While reversing, the loader’s front wheels lost traction and it slid off the ramp. The loader came to rest at an angle of approximately 35 degrees. There were no injuries and the scene was preserved.

The operator of a dump truck detected a hot tyre-like smell. After the tyre fitter checked all tyres with a heat gun the smell remained. The mobile plant fitter was about to check the machine when flames rose approximately one metre from the engine bay. The operator shut down the machine and activated the fire suppression. When the operator exited the dump truck a water cart extinguised the rest of the fire.

A worker was taking a sample from a cyclone unit on an exploration drill rig when a noise was heard. The unit cap struck the worker after it was ejected from a small air receiver mounted at the rear of the drill rig.

While undertaking the process of removing water, the operator of a load haul dump loader (LHD) suffered a laceration to their nose after the reservoir cap was ejected under pressure.

The night shift operator of a haul truck identified a number of alarms sounding in the driver’s cabin during the commencement of their shift. To reset the truck the operator went to the main isolator located on the bumper, adjacent to the position of the number one wheel. As the operator de-energised the truck it rolled approximately one metre away from the operator’s position before comingto rest. No one was injured.

During the process of changing a drill bit, a drill rig operator stepped out of the cab and noticed the dust collector was full. The operator stepped back into the cab and switched from drill mode to raise mask mode. After switching modes the drill rods have spun and a rod has become dislodged, allowing the drill rod to hit and slightly penetrate the cab windscreen. The operator wasn't injured and no other person was in the area.

A telehandler operated by a sub-contractor was transporting a skip bin containing scrap timber in the coal handling and preparation plant (CHPP) construction area. The telehandler made contact with two concrete footings causing the front left wheel to ride up and over the concrete footings. The contact damaged the bolts and dislodged the skip bin off the forks. No injuries were sustained.

A Jumbo drill rig was drilling a cable bolt hole when the pivot of the roll over boom collapsed and fell to the floor. No persons were injured.

A contract fitter was using a high-torque wrench to remove bolts from the final drive on an excavator. He had a remote control in his hand and was using his right leg to steady the wrench in place when a failure occurred at the fitting/coupling at the manifold block on the high torque wrench. The fitter was sprayed with oil. The fitter was taken to first aid and checked but no entry point of fluid was located.

A dump truck reversed to a dump windrow on an active tip head to tip a load of waste. The windrow collapsed behind the rear tyres with the truck’s tyres going through the windrow.

While inspecting a dewatering pump in a sump, a mine deputy removed a 2” air hose from the 6” pipe range manifold to which it was connected to identify the cause of a blockage. After opening the valve, the deputy felt for an air flow with the back of his left hand and felt only a small movement of air. There was a sudden release of a pressurised substance and as a result, the back of the deputy’s left hand was hit by coal particles and compressed air.

The bearing on a water cart’s front left tyre failed during operation. This allowed the brake calliper to make contact with the brake disc, causing a rubber dust cover to catch fire.

Comment to IndustryMine operators are reminded of the need to assess the particular risks associated with work in close proximity to high walls and benches. Control of such hazards can be achieved through the use of bunding and appropriate stand off zones

Heavy vehicles such as large dump trucks are known to have blind spots. Mine operators should consider this when designing park-up areas for these vehicles. Such consideration may include road design that provides a single entry to park-up areas that allows the drivers to observe other vehicles parked-up in the area.

The hazards associated with gas outburst are well understood in underground coal mining operations, however, the incidence of gas outbursts on longwall faces are rare. Mine operators using the longwall method of extraction should make a determination of the gas outburst potential for the longwall. Such an assessment should include:• the geological assessment of the longwall block• taking core samples to determine the insitu gas content of the seam being mined• the assessment of the appropriate and effective methods required to reduce insitu gas content to below outburst threshold limits• the methods of testing required to ensure that gas drainage has been effective, particularly in and around geological structures.Where the gas outburst risk cannot be eliminated mine operators should isolate workers from the hazard, that is, remove workers from the area of risk


The Mine Safety regulator takes the reporting of incidents very seriously. The regulator must be notified of certain work-related incidents that occur at mine and petroleum sites.For all incidents that must be notified, call 1300 814 609 (24 hours a day, 7 days a week).A notification of incident and injury guide can be downloaded on the website.This matter is being investigated.

Mine operators are reminded that the interaction of light and heavy vehicles has resulted in fatalities (see Investigation into fatal collision on the website). Mine operators should be aware of the human and organisational factors that may result in an incident. As such the option of segregation of light and heavy vehicles should be considered as a control measure

A fatality occurred in very similar circumstances in 1998. Mine operators should consider the potential for such an incident and consider the placement of appropriate barriers to ensure a vehicle that loses control cannot collide with any gate.

This incident is still under investigation, but initial observation highlights the risks associated with the use of lead acid batteries. The battery involved in this incident appears to have been removed from service in its original application. When a battery is removed from service due to inability to perform its intended function, it should be considered unserviceable and disposed of, in accordance with original equipment manufacturer recommendations It should not be reassigned to alternative usesReference should be made to following safety alerts for further information relating to battery explosions• NSW Department of Industry – Mine Safety, safety bulletin: SB16-02 Exploding lead acid batteries• QLD Dept of Natural Resources and Mines: Safety Bulletin no.150 Exploding lead acid batteries• Worksafe Victoria: Safety Alert Preventing battery explosions

Mine operators should ensure that:• their gas drainage system is designed to accommodate the anticipated peak pressures • all hose fittings are design-rated for the anticipated peak pressures• isolation procedures are in place that minimise the potential for the gas drainage line to pressurise

Mine operators are reminded that regular inspection and, where appropriate, non-destructive testing should be carried out as part of the maintenance and certification cycle for plant. Where any modification is made to the plant, change management procedures should be used to ensure that the modification is captured in the maintenance and inspection scheduleMine operators should also consider the environment in which the plant is to be operated and adjust those timeframes accordingly

Mine operators should consider how a loss of traction can present a variety of risks to health and safety. This is particularly relevant to heavy vehicles when watering roads. Procedures around road watering should include: • the provision of dry lines to assist heavy vehicle traction• signage and communication of the areas where road watering has taken place. It is also important to consider the expected volume of traffic on roads after watering has been undertaken

Mine operators and workers must be aware of the potential for strata failure resulting in serious injury or death.Mine operators should ensure that their safe systems of work can manage the risk of strata failure. The systems should be able to identify poor strata conditions and appropriately position workers to minimise their exposure to strata failure

Work return clamps should be attached directly to the welding job. They should not be dependent on bolted joints for effective return paths. People involved with welding activities should remain insulated from the welding job. Welding gloves are not electrical insulators and if they are damp, can enhance the effects of an electric shockRefer to the following publications for guidance• AS/NZS 1674.2 Safety in welding and allied processes - Electrical • WTIA Technical Note 22 Welding Electrical Safety• NSW Resources Regulator Safety Bulletin: Safe use of electric welders• NSW Resources Regulator Information Sheet No.2: Basic welding practicesQLD Department of Natural Resources and Mines Safety Alert no. 253: Electric shocks from welding equipment

Tyres contain a significant amount of stored energy in the form of compressed gas, which if released suddenly may cause fatal injuries. The integrity of tyres (and rims) is a critical control in preventing the uncontrolled blast of compressed gas from within the tyreOperators of mobile plant should be reminded of the hazards associated with tyres. Any work on tyres should only be carried out by competent people using appropriate equipment and safe work proceduresRefer to:• SA15-06 Sudden burst of truck tyre• SA04-01 Queensland Tyre Fitting Fatality• QLD safety alert No. 334 Earthmover tyre and rims

Mine operators must ensure that when machines are commissioned they include operator message and alarm displays, ensuring they accurately report fault conditions. Machines should only be operated in the manner in which they were intended and designed to be operated. Changes in operating methods require reassessment of machine control systems (change management) prior to the changed procedures being implemented.Where faults occur with machinery, operators must report the defects to ensure they are corrected to prevent incidents occurring

Mines should have systems of work for the operation of fork lifts which includes no standing zones by spotters and bystanders.Refer to:• IU report Serious injuries sustained by a delivery truck driver - Tasman mine• SA04-05 Crane Dogger Killed Unloading Trailer

Battery powered or compressed air portable tools and equipment should be used in wet or damp environments in preference to 240 volt portable tools and equipment. Unless specifically designed for use in wet areas, 240 volt portable tools and equipment should not be used if the equipment, leads or plugs are likely to get wet during use of the equipment. Equipment designed for wet environments will deteriorate with age and use and will expose people to electric shock risks if not maintained appropriately for the environment in which it is to be used. Pre-use inspections should look for evidence of damage and moisture and, if found, the equipment must be removed from service.

Winder controls should not enable movement of the cage while the plat is either not fully engaged, or not fully retracted for the appropriate mode/stage of the operation.

Maintenance of the winding system, including the cage, must be undertaken in accordance with the manufacturer’s recommendations, or if no manufacturer recommendations, as required by a competent person familiar with the winding system (refer to WHS clause 213).

It is the quarry operator’s responsibility as the person conducting a business or undertaking (PCBU) under the WHS Act to ensure the protection of workers and others against harm. A PCBU must ensure, in so far as is reasonably practicable, that persons are not put at risk as a result of the conduct of their operations

Investigation of this incident should highlight to mine operators that traffic management plans should include:• Positive communications process at the mine for all vehicle interactions• Lighting requirements for night shift operations• Allocation of who controls the loading/work area• Fatigue management • Adequate supervision arrangements to verify controls are being maintained

Forklift operators should place loads onto the ground when they are not being transported. No person should place themselves or any part of their body under any suspended load.Where equipment, such as materials pods, are to be moved, they should be designed with dedicated lift points, such as forklift tyne slots, or otherwise slung by a competent rigger, before being lifted

Horizontal exploration drills should not be used in vertical drilling applications, unless a risk assessment has reviewed the adequacy of risk controls for the proposed change in use at the drilling plant. • Both drilling operators and driller’s assistants must be trained and competent in the proposed drilling task and risk controls. • No-go zones for driller’s assistants need to be maintained during the drilling process at all times. • Mine operators should periodically check the work procedures of contractors

The functionality of all safety-related equipment,such as a belt wander trip, should be confirmed and documented during commissioning checks on conveyor belts.Operators are reminded of the design, commissioning, operation and maintenance requirements in: • AS/NZS 4024.3610:2015 Conveyors – General requirements• AS/NZS 4024.3611:2015 Conveyors – Belt conveyors for bulk materials handlingThese documents are incorporated in the Mechanical engineering control plan code of practice

The department is investigating the allegation. People have been fatally injured falling down mine shafts. Old mine shafts can be dangerous. The rock or soil around the shaft may be unstable and the shaft timbers may be rotten. People must not walk anywhere near a shaft opening. For further information regarding the Lightning Ridge mine fields, contact the mine safety office at Lot 60, Morilla Street, Lightning Ridge or by calling (02) 6829 9200

Mine operators should review operational procedures for excavators (“diggers”) loading from a bench. The review should include criteria such as bench height, the nature and stability of the bench material, dimensions of the loader and the operating criteria for the loader as defined by the original equipment manufacturer

Operations should review the adequacy of controls associated with worker fatigue.Guidance on fatigue can be found on our website. When designing systems of work, consider the risk of fatigue including the use of engineering aids to monitor operator fatigue.

Good maintenance practices are essential in preventing the ignition of combustible fluidsfrom hose or pipe failures. Consider guidance in Australian Standard 5062:2016 – Ire protection for mobile and transportable equipment.Truck operators should be trained to respond to a fire event (refer to MDG 15):1. stop the machine safely2. shut down all power and the apply park brake3. activate the fire suppression system4. initiate the mine emergency response.

AS/NZS 4024.3611 Safety of machinery,Conveyors – Belt conveyors for bulk material handing is incorporated into the mechanical engineering control plan code.Clause 5.2 states:5.2 Idler ManagementA system shall be implemented to minimize hazards created by idler failure in accordance with the following:(a) The system shall allow the position of idlers to be identified for maintenance purposes.(b) The system shall identify defective idlers.(c) The system shall determine when defective idlers should be replaced through an appropriate trigger action response plan (TARP). Where failure of the idler creates a risk to people in the event of a fire (E.g. in confined environments), the TARP shallbe escalated accordingly.The system shall provide for the safe replacement of idlers with consideration to:(i) location and accessibility;(ii) weight, size, shape;(iii) tools/systems required for change out (E.g. lifting gear); and(iv) required personnel and skills

Prior to commencing welding, the work area should be assessed for the risk of electric shock. You should consider hazards such as contact with conductive parts, welding in confined spaces, and welding in damp environments and rain.All welding equipment should be inspected prior to use and properly maintained. Personal protective equipment (PPE) should be dry and in good order. Site welding procedures and hot work permits should be understood and followed.Guidance material can be found in: AS1674.2 “Safety in welding and allied processes Part 2: Electrical”, MDG 25, and the Safe Work Australia Welding Process Code of Practice.

Mines must ensure safety critical systems on mobile plant remains functional. Mines should review the recommendations in:•SA06-12 Maintenance of Safety CriticalSystems - Braking, Steering & Warningsystems•SB10-03 Mobile plant - safety criticalsystems•SB09-05 Failure of mobile equipmentbraking systems and procedures•SA09-01 Driver injured in dump truckrolloverFit-for-purpose barriers, such as bunding or windrows, should be in place to prevent uncontrolled mobile plant going over embankments.

It is a known hazard that there is potential for trailing cables and water hoses to not reel out freely while drill rigs are running out these services. Exclusion zones should be established and effectively enforced to ensure workers are not exposed to unexpected failures of anchor points and associated equipment when running out water hoses and trailing cables.Good maintenance practices must be in place to ensure that cable or hose reels are operating correctly. Pre-start inspections should check that cables and hoses are correctly wound onto their reels.Refer to SA13-04 Jumbo Trailing Cable Incident

Mine operators should review the critical controls in their strata failure management plan to identify and quickly respond to any area of concern. Some mines have implemented a strata defect system including TARPs, which specify a timely response. This system is considered good practice and has reduced the incidence of roof falls at these operations.It is important that all personnel are familiar with the TARPs. They should understand the actio that need to be taken if a change is detected.

Mine operators must ensure risk assessments identify and assess potential risks so that adequate controls are implemented.Plant needs to be fit-for-purpose. In this case, consider guards and/or purpose-built attachments, such as those with little or no flex in the rake attachment.

Mine operators should note: they should have a robust change management process that identifies operational differences between the new and old plant heavy, unbalanced loads should be stored at lower heights on pallet racking pallets should be stored within the pallet racking system falling object protection must be provided on forklifts forklift operators must hold the appropriate licence (see SafeWork NSW: Forklift licences for more details).

Unplanned movements of EWPs are a serious risk to the health and safety of workers, particularly when in close proximity to fixed objects and at heights. EWP safety devices such as guards, interlocks, emergency stops and deadman controls must be regularly tested. EWPs must be regularly maintained and inspected by competent persons. Further information and recommendations can be found in SB15-04 Collisions of mobile elevated work platforms increase.

Mine operators should review quality assurance systems in relation to all aspects of the drill and blast process. If any anomalies are found, additional controls should be implemented, such as moving sentries further out and modifying exclusion zones to ensure the safety of personnel until the shot has been fired.

Operators of mines in coal seams prone to the outburst hazard should review systems that address the identification of zones where remote mining should be undertaken. Operators should also review the implementation and audit of controls for remote mining. Mine operators should also review gas monitoring requirements taking into consideration the range of gas that the sensor may be exposed to.

Chain spreader bars should be used when lifting a heavy plate using multiple magnets and chains to a single lifting hook. This allows the magnets to maintain vertical contact during the lift.We do not recommend using triangular chains on multiple magnets as the will tend to peel off the magnetic contact area.

The gate valve had been highlighted as being faulty but no action had been taken. This is because the defect failed to reach the defect management system (refer to section 4.5.6 of the Mechanical engineering control plan code of practice). This system should be documented and should incorporate: a way to document how the defect was found and its defect a way to prevent the use of mechanical plant or structures until a defect has been assessed by a competent person recording action taken to remedy or controlthe defect a competent person reviewing the plant or structure and verifying it is safe to use eliminate, if possible, the defect fromoccurring again.

Mines should consider:• fatigue/endurance life of hoisting cylinder and where possible carry out periodic non-destructive testing of structural areas • means hoisting cylinders may be overloaded or subject to shock loads, such as body top out, body kick out settings, reversing collisions with tray up• replacement, repair and/or testing of hoisting cylinders in accordance with original equipment manufacturer recommendations• communication good dumping practices to truck drivers and reporting/stand down requirements such as when the body top is out.

Mines hiring powered tools should ensure:• they are fit for purpose• that any controls identified have been effectively implemented• automated hose rupture detection air shut off valves are fitted when required

Mines should:• identify wear points for high pressure hydraulic hoses and implement effective controls, refer Section 7 Inspection, maintenance and repair of MDG 41 Fluid power system safety• ensure that pressurised fluid power systems can be effectively isolated and energy dissipated , refer SB12-03 Fluid power isolation failures• ensure workers are aware of, and trained in effective isolation and energy dissipation.

Mines should consider:• fatigue/endurance life of hoisting cylinders and where possible carry out periodic non-destructive testing of structural areas • hoisting cylinders can be overloaded or subject to shock loads, such as body top out, body kick out settings, reversing collisions with tray up• replacement, repair and/or testing of hoisting cylinders in accordance with original equipment manufacturer recommendations• communicating good dumping practices to truck drivers and reporting/stand down requirements such as when the body top is out.

Mines hiring powered tools should ensure:• they are fit for purpose• that any controls identified have been effectively implemented• automated hose rupture detection air shut off valves are fitted when required.

Mines should:• identify wear points for high pressure hydraulic hoses and implement effective controls, refer to Section 7 Inspection, maintenance and repair of MDG 41 Fluid power system safety• ensure that pressurised fluid power systems can be effectively isolated and energy dissipated , refer to SB12-03 Fluid power isolation failures• ensure workers are aware of, and trained in effective isolation and energy dissipation.

Mine operators should review the effectiveness of all rib and roof support and protection devices, particularly in changing geological conditions. All operators should be trained in the effective use and the operating parameters of these devices to maximise protection.

Mine operators should review their pipe installation and removal plans. Operators must ensure that there is sufficient labour to complete tasks. Only equipment that is fit for purpose should be used to safely complete these tasks

Falling plant and equipment (loads) pose a serious risk to health and safety. Appropriate control measures are required to prevent the risk of falling objects.• Mine operators should be aware of the observations in IIR16-08 Fatality after being struck by truck tailgate. Operators should communicate these to all workers and contractors that use trucks at their mines.• Workers should not undertake any work underneath suspended or unsecured loads. • Trucks should be cleaned at fit-for-purpose washing facilities. This eliminates the need for people to work underneath unsecured, suspended loads. • Trailers and truck trays should have safe access points.

Mine operators should review safety barrier practices to ensure that the reason for barricading is communicated to everyone working in that area. When hazards are identified, the operator needs to effectively control and manage the hazard

This incident demonstrates the importance of dissipating all stored energy after energy isolation. Mine operators should remind workers of how to make sure energy is effectively isolated. Key steps are• isolate the energy source• lock the isolation method• dissipate any stored energy• verify effective isolation is achieved.Refer to SB12-03 Fluid power isolation failures and the Mechanical engineering control plan code of practice

Mine operators must ensure buckets are not overloaded with materials or unbalanced, and material is of an appropriate size. Mobile plant must be fit for purpose. Mine operator should ensure they comply with Clause 214 and 215 of the Work Health and Safety Regulation 2011. The mine operator must manage the risk of things falling on the operator of the plant and ensure a suitable combination of operator protective devices for the plant is being used

Mine operators are reminded of the importance of monitoring changes in strata conditions and reviewing reported changes in the strata, particularly in older parts of mines. Refer to the NSW code of practice: strata control in underground coal mines

Mine operators should review information on safety critical components from OEMs and take their recommendations into consideration.Safety critical components that are essential to the operation of braking systems should be replaced and overhauled at intervals• recommended by the manufacturer, or• if there are no recommendations, as recommended by a competent person

Water that enters an electrical enclosure can cause insulation failure and lead to electric shocks. It has been reported by workers that push buttons installed in plastic enclosures may be vulnerable to this issue. This is the case whether the buttons are run on low voltage or extra-low voltage circuits. All electrical equipment should be located in non-hostile environments, where possible. Equipment that is exposed to hostile environments should be regularly opened and inspected for evidence of water or dust. If water has entered, remedial action should be taken to restore the equipment to its original state. Installing push button operators in well-earthed, metal-clad enclosures provides another layer of protection against this shock mechanis

Mines that use solid fill type tyres should review the recommendations in SA08-08 Overheated tyres require miners to use self-rescuers

Transport rules must identify the maximum profiles of loads that can be safely transported in roadways. They must also identify any special procedures that are required where loads are different from the specified profilesAll cables should be installed in locations where the possibility of damage is minimised. They should be installed either:• in roadways that are not used for material transportation• at heights above those required for material and transport movements, or• by installing guards over the cables.Mine operators must consider the specific locations where cables must pass through, including obstructions, such as air and water pipes.Protection relay settings should be set to achieve the quickest operating times at the lowest values that would allow for reliable operation

Synthetic fibre slings are susceptible to damage and can tear if exposed to sharp edges or corners. Chain or wire rope slings should be used where the load to be lifted has sharp edges or attached components such as cleats or bolts at the point where the sling is to be attached.The potential for slings to rotate around the anchor point as a load is lifted from ground should be assessed.Lift plans should identify all hazards, assess risks to workers and include the specification of all lifting components to be used and when certain types should not be used.

Mine operators should follow manufacturer’s recommendations for how a breathing apparatus is used and stored.MDG 3609 - Escape breathing apparatus for underground mining applications sets out standards for the design and ongoing performance of breathing apparatus. It includes the requirement for mine operators, in consultation with the supplier and an appropriate employee representative, to draw up a risk-based scheme for regular maintenance and checks on the apparatus.

Slumping due to rain events is foreseeable and mine operators should address this hazard in risk assessments. The effect(s) of heavy rainfall should also be considered in geotechnical assessments of dump design.

The relative positioning and sequencing of supports is critical in maintaining effective control of the roof.Operators must ensure when carrying out pillar extraction, the roof support system(s) are operated in sequence and maintained in accordance with safe working procedures.

Structures need to be installed according to the designer’s specifications, unless a qualified structural engineer has signed off on an alternative design.

Operators are reminded of the minimum standards for conveyor guards, contained in: AS/NZS 4024.3610 Safety of machinery- Conveyors - General requirements AS/NZS 4024.3611 Safety of machinery- Conveyors - Belt conveyors for bulk materials handling AS/NZS 4024.3612 Safety of machinery- Conveyors - Chain conveyors and unit handling conveyors.These documents set the requirements for guard maintainability. They are incorporated in the Mechanical engineering control plan code of practice.Only a competent person should carry outchanges to conveyor guards, taking these standards into consideration.

Mine operators need to develop isolation procedures that identify all stored energies. The procedure must be developed using hierarchy of control methods to mitigate these risks.Plant should be maintained according to the original equipment manufacturer’s specifications.Guidance on stored energy in conveyor systems (including stacker/reclaimers) is provided in appendix B of AS/NZS 4024.3610 Safety of machinery - Conveyors - General requirements.

Mine operators should review their engineering control plans with regard to risks associated with fuel management. This review should consider the recommendations in SB15-03 Fires ignite while refuelling mobile plant with quick-fill fuel system. Operators should also refer to SA15-05 Fire destroys water truck.

Mines should develop detailed commissioning and decommissioning procedures for the installation of monorail, including pre-use checks, before installation. These procedures should be developed through a risk assessment process with reference to the original equipment manufacturer’s standards

Mine operators should: remind all vehicle drivers of the site traffic rules and that they must be followed periodically monitor traffic rule compliance at the site through unplanned task observation.When site traffic rules have not been followed,vestigate why and review those rules as appropriate.

Operators of mobile plant must be trained in emergency braking procedures, including how to apply the emergency (or secondary) brakes.Braking systems should be inspected, tested and maintained in accordance with the original equipment manufacturer’s information. Braking systems on mobile plant must be maintained by competent people. These people must have a thorough understanding of the braking systems on the mobile plant that they are maintaining.For information on braking systems’ integrity, refer to:• SA11-10 Park-brake malfunction leads to crush injuries• SA11-07 Transport service brake failure• SB10-03 Mobile plant - safety critical systems• SB09-05 Failure of mobile equipment braking systems and procedures•SA06-12 Maintenance of safety criticalsystems - braking, steering & warningsystems•SA05-10 Fatal truck accident at quarry.

This incident raises two safety issues. These are failure to:•lock out the remote control, and•identify that the fitter’s foot was in ahazardous position.Mine operators should communicate to workers that:•they must not put any part of their bodyunderneath unsecured suspended loads•effective isolation means:1.isolate the energy source2.lock the isolation method3.dissipate any stored energy4.verify effective isolation is achieved.Refer SB12-03 Fluid power isolation failures and the mechanical engineering control plan code of practice. Mine operators should provide appropriate maintenance access systems.

The investigation has not yet determined if the event was caused by natural means or by mining. Until the regulator has completed the investigation, mine operators are reminded of the following:•operators have obligations under clause44B of the Work Health and Safety (Minesand Petroleum Sites) Regulation, inparticular sub-clause (2)(c):“Mine operators must ensure that, as far asis reasonably possible, the design of themine mitigates the damage arising from thesudden release of energy from the build-upof mining induced stress.”•in general, mine operators are remindedthat the process of identifying potentialemergencies must be comprehensive. Theprocess should consider low frequency andhigh consequence events. These eventsmay arise from factors external to themining activities (for example, naturaldisaster-type events). The effects of theseevents should form part of theconsiderations within the mine’s principalmining hazard and emergency managementplans. Refer to the NSW code of practice foremergency planning at mines for more information.

All mines should review signage and visual indicators on any vehicle that frequently stops or changes direction on haul roads. The risks related to frequently stopping vehicles should be assessed and controls implemented through the principal hazard management plan (PHMP) for roads or other vehicle operating areas.

Workers should not undertake any work underneath unsecured suspended loads.All energy that has potential to move a suspended load needs to be isolated and locked out.Mines should reinforce the need to complete pre-task hazard assessments when tasks or environments change.

This incident highlights that operators should ensure that:• the level of supervision for all apprentices is relative to the risks associated with the task• before starting electrical work, hazards have been assessed and the risks are controlled• accurate, well-documented isolation procedures and permit systems are in-place• processes for testing to prove electrical equipment is de-energised are documented. The processes should also include the use of non-contact testers, where possible, before the use of contact test equipment. The test equipment must be fit for purpose.• training and assessments are adequate to ensure people are competent to carry out tasks safely• fit-for-purpose facilities are provided for verifying and securing energy isolation points• surface electrical installations are compliant to the requirements set out in AS/NZS 3000.

Mine operators should speak with their workers and reinforce how important it is to remain totally within the confines of mobile plant while it is being operated.

Whenever equipment is introduced to a mine site or is modified, proper change management procedures should be followed. Plant should not be used unless it has been fully commissioned. Temporary repairs or modifications must have sufficient strength to withstand in-service loadsMaterial falling down a shaft poses a serious risk to the health and safety of any person in the shaft. Appropriate control measures are required to prevent the risk of material falling down a shaft. Mine operators must ensure they comply with clause 49 (6) of the Work Health and Safety (Mines and Petroleum Sites) Regulation 2014.

Mine operators should: remind loader operators to be careful when operating in close proximity to other small plant. Job-specific risk assessments should be carried out. consider using proximity sensors or reversing camerasStructural damage to plant needs to be checked by a qualified structural or mechanical engineer or the original equipment manufacturer (OEM) to determine the design adequacy of any structural repairs.

Mines should use risk assessments to review what alarms are critical to their operations and how they are: monitored alarmed responded to escalated and re-alarmed.This will help ensure the mine’s response is appropriate and that no alarms are missed. If no alarms are missed, the response is less likely to be delayed.Training and ongoing refresher training, together with the competency of control room operators (CROs), should form part of the review. First responders should also be involved in the review process.

Drill rigs should not be driven around the mine sites with masts raised. The machines should be fitted with interlocking systems designed to prevent the machines from being driven while the mast is raised. The rig’s interlocking systems need to be maintained and operationalWhere overhead power lines are present, vehicles should only be operated on predefined traffic routes unless a specific risk assessment has been undertaken. The risk assessment should take into account safe clearance distances and the equipment being moved.Operators should refer to the following documents for additional information: SB15-05 Plant contacting overhead powerlines and structures AS/ZS 3007:2013 Electrical equipment in mines and quarries – surface installations and processing plants Safe Work Australia General guide for working in the vicinity of overhead and underground electric lines

Mines should review their cassette changeout procedures where they use pod rackers. This review should consider continuous miner set up, for example, head down and stab jacks up. Additionally, the review should encompass the angle of approach of the pod racker, bolting during the pod removal and positioning, and setting up appropriate no-go zones.All load haul dumpers and pod rackers should be set up so that the slew/eject functions operate the same way on each machine and for every possible combination. The pressures and flows on the pod racker should be reviewed to ensure a safe level of control of the operation.

Mines should: review safety bulletins issued by the original equipment manufacturer. When a manufacturer’s recommendation is delayed or not implemented, a risk assessment should be carried out. The assessment should document how the hazard is being alternatively controlled. audit plant for compliance with the original equipment manufacturer’s bulletins, information or instructions and/or with a risk assessment. have a systems-based approach to how they review and assess industry safety information. This information includes documents such as original equipment manufacturer bulletins and department-issued safety bulletins and safety alerts. The system and how it is reviewed should also be documented.

The integrity of guarding, covers and their locking mechanisms must form part of the mine inspection and maintenance system. This is particularly important when they are constantly exposed to vibrations.Mine operators are advised of their obligations under sub-section 19 (3) the Work Health and Safety Act 2011:“A person conducting a business or undertaking must ensure, so far as is reasonable practicable:a) the provision and maintenance of a work environment without risks to health and safetyb) the provision and maintenance of safe plant and structures, andc) the provision and maintenance of safe systems of work.”We recommend operators consider the recommendations in Safety alert: Fall from height risk and Safety alert: Truck driver fatally injured in weighbridge incident.

When undertaking a risk assessment for a high risk activities notification, for example, widening an existing roadway, mines should consider all hazards associated with the activity. Such hazards may include cutting while in the vicinity of existing roof control measures. When identifying controls, the mine operator should also consider:• maintaining safe standing zones• removing picks that are not required for cutting or could interfere with existing support• further reducing cutting height at the second pass to limit exposure to any potential interactions with existing supports.

Mine operators must ensure that all electrical hazards are identified and that risks to health and safety are adequately controlled. This event highlights the need to effectively manage:• contractor induction and training, including incident identification, notification and scene preservation• contractors’ work authority and permits, for example, authorisation to perform hot work• inspections of contractors’ equipment and introduction to the site by the mine• inspection and testing regimes that are appropriate for the working environment• supervision of contractors and their supervisors• job-specific hazard analysis, SLAM, TAKE 5 or JSA assessment tools• the use of generator set earthing and bonding, truck bonding, welders, electric cables and leads, use of appropriate ingress protection (IP) rated equipment, use of residual current devices (safety switches)• the work environment at the mine• the use of appropriately rated personal protective equipment that could include gloves, face shield, full length clothing, footwear and rubber mats.We recommend operators to consider the advice in AS/NZS 3760: In-service safety inspection and testing of electrical equipment and the department’s technical reference EES-014: Technical principles for the use of ‘stand-alone’ generators at NSW mines (coal and metals) and extractives operations.

Investigations are continuing. The cause of death will be determined by the NSW Coroner.

Underground operators should ensure workplace inspections are undertaken before starting work in an area. This must include checking: installed ground support systems for correct installation and any damage to the support systems strata mesh for damage, even minor damage, especially where loose rocks can be observed in and around the damaged mesh.Procedures should be implemented to ensure any damaged or incorrectly installed ground support are isolated and repaired to mine design standards before people work or travel under the affected area.

Mines and original equipment manufacturers should consider the recommendations in safety bulletin SB15-06 - Analysis aims to reduce injuries while travelling in vehicles undergroundWhen a person is injured the mine investigation needs to include those items in the safety bulletin SB15-06, Appendix B Fillable questionnaire in their investigation

Masters of boats should make sure vessels are safe before embarking on a journey, including ensuring that fully functioning communications and safety equipment is on board.Masters should have knowledge of all local conditions and hazards. Where a risk assessment requires workers to use life jackets while on the water, the master must ensure all workers on board vessels have jackets fitted.Maintaining a proper lookout and safe manageable speeds is essential, particularly in restricted visibility, darkness and restricted zones, in order to avoid collisions.Fire risks should be identified and controlled, and boat masters should fully prepare for emergencies, including understanding and maintaining emergency procedures.

Where lighting loads are fluorescent, the switching mechanisms should be appropriately rated to the load.

Mines should conduct a thorough investigation of every mobile plant fire. The investigation should be completed before submitting an ancillary form and should include:1. identification of the cause of the fire2. identification of additional contributing factors3. implementation of effective risk control measures to prevent recurrence of the fire4. consultation with an expert fire investigator.Fire suppression systems should be designed, installed and maintained in accordance with AS 5602: Refined petroleum products – vehicle bottom loading and vapour recovery.Plant operators should be competent to safely operate plant, use automatic and manual fire control systems, and to implement emergency response procedures in the event of a fire.

Safety critical systems are fundamental to the safe operation of mobile plant. These systems include:braking systemssteering systemswarning systemsoperator restraintoperator protectionMines should assess the risks associated with operating mobile plant by taking into consideration the failure modes of all critical systems. Daily pre-start safety checks should be rigorously carried out. Mobile plant operators should be familiar with warning systems that may indicate a failure of a safety critical system.Refer to:Safety bulletin: Mobile plant - safety criticalsystemsSafety alert: Maintenance of safety criticalsystems - braking, steering and warningsystems

Effective gas drainage and main ventilation systems are essential for the control of gas and the safe operation of coal mines.Where these systems are compromised by electrical power supply faults, the cause must be investigated thoroughly. Trigger action response plans (TARPs) must be enacted immediately after alarms have been activatedStrategies to improve reliability include: assessing and managing failure modes a protection study to ensure supply and protection adequacy a protection grading review appropriate maintenance strategies frequencies and production windows to ensure scheduled maintenance is performed on-time.

The fuel for the fire was identified as residual coolant in exhaust lagging. The heat of the exhaust evaporated the water. This left residual glycol in a crystallised state. The glycol reached its flash point, causing the fire to ignite.Effective maintenance practices are essential in preventing the ignition of combustible fluids from hose or pipe failures. Where practicable, hoses should be segregated from hot surfaces using hard barriers. Non-flammable coolants should be used. Mine operators should consider the guidance in Australian Standard 5062:2016 Fire protection for mobile and transportable equipment.

Investigations have identified that the air conditioner unit had a high earth resistance to the external frame and an internal anti-condensation heater coil with failed insulation. Other similar air conditioners were also inspected. The inspections revealed that other air conditioners had similar defects with the low voltage anti-condensation heater coil.Routine air conditioner maintenance should include schedules for internal electrical inspections as well as the testing of insulation resistance and earth continuity to exposed conductive materials. Mine sites should also consider the adequacy of induction packages to cover notifiable incidents, including the requirements for scene preservation.

Selecting the correct lifting equipment is important to keep workers safe. Equipment must be fit-for-purpose, have pre-use inspections and staff members need to be trained in how to use the equipment. Hazards should be assessed at the worksite before any work begins.

Mines that are cutting ‘hard coal’ that has the potential to throw flyrock from the face should:• ensure that adequate no-go zones are developed and enforced• review the pick choice as the pick may alter the cut-ability and direction, which could influence the positioning of no-go zones• review cutting sequences• exploit longwall automation to minimise worker exposure.

There should be recognition of increased risk of failure of plant that is increasing in age and is in an environment that may contribute to corrosion and structural failure. Structural components, such as handrails, guardrails, ladders and steps should have an appropriate inspection, maintenance and audit schedule to ensure those structural components are safe.Fixed access ladders, steps and guardrail installations should be periodically inspected for rust, corrosion and structural integrity and kept in good condition to ensure the safety of workers.

Mines should consider this risk and implement appropriate controls including trigger action response plans (TARPs) that respond to goaf level stand up distances. Ventilation quantities should be maximised and adequate exclusion no-go zones developed and enforced.Mines should review their windblast management plans to include longwall take-offs.

A number of contributing factors have been identified with this incident, including:• poor radio communications• some pass bays in poor condition for vehicle entry• lack of blind side camera• lack of co-operation between vehicle operatorsMines should not rely on procedural controls without appropriate consideration of the impact and effect of human factors. They should consider among other things:• road design, including intersection design• control measures for separating heavy from light vehicles• night driving conditions and visibility• traffic control systems and intersection speeds• communication systems,collision avoidance and proximity detection systems for both heavy and light vehicles• daily inspections of roads and intersections are carried out by a competent person.Refer to:IIR15-03 Haul truck and light vehicle collideIIR13-06 Collision between haul truck and light vehicle

Mines should review their procedures for degassing of development panels using auxiliary fans with respect to:• a pre-degassing inspection where possible. This procedure must include an inspection to determine the gas levels, the position of gas fringe and any possibility of gas layering• notification to the control room to ensure all people are removed from the return side of degassing in the event of an unplanned gas plug• considering having a settling time for each setting when closing the degassing box.

When using winches, ropes and snatch blocks on their own or in combination to pull loads horizontally underground, the lifting, pulling and anchoring equipment needs to be suitably rated to match the potential load combinationsMechanical engineering assessments may be required to verify the intended system is within the lifting and pulling equipment capabilities.Refer to:SB09-03 Broken pull chain results in fatalitySA04-09 Broken chain connector results in serious injuries

Self-contained self rescuers are a critical piece of emergency escape equipment for underground mines. Because of this, units are tested in accordance with specified standards. Rescuers should be performance tested with a 2% tolerance. This is a requirement under the department’s mining design guideline on escape breathing apparatus for underground mining applications.If rescuers fail testing at 2% tolerance, all units in that batch are considered non-compliant and must be removed from service immediately.Mine operators are reminded to ensure that all rescuers in use at their mines are tested during the required intervals. Where units have failed, operators must order their removal.Information on testing and compliance is available from the SCSR supplier or from an approved testing facility.For more information, refer to the department’s design guideline.

This incident is a reminder to:• review the design and operational risk assessments associated with exploration drill rigs• ensure that no workers are exposed to hazards associated with the operation of rotating drilling equipment. Numerous entanglement injuries have been reported in recent years.• eliminate or where this is not possible, control the hazards that could result in hand injuries. This may require operators to install effective guarding• ensure safe operating procedures are available and clearly documented• ensure drill rig operators are trained and assessed for competency• use formal systems of pre-operational checks and hazard identification, along with assessing the risk before use.

Mine operators have several obligations in relation to plant in mines:• Any structure in a mine that may affect the health and safety of people should be periodically inspected by a competent structural engineer. Inspections should be undertaken at intervals recommended by the structural engineer. Refer to clause 4.5.5 ‘Inspection and testing of plant’ in the department’s code of practice: Mechanical engineering control plan. If a structural engineer has not specified a period, inspections should be carried out at two-year intervals.• Steel structures should be designed, fabricated and erected in accordance with Australian Standard 4100 Steel structures or AS 3990 – Mechanical equipment – Steelwork as well as other relevant Australian Standards where appropriate.For more information, refer to:• Safety Alert: Sudden failure of feed hopper• Safety Alert: Structural bin failure

This incident was preventable. Mines should assess their calibration procedures associated with real-time gas sensors. They should consider:• how gas sensors are selected and verified for calibration• the system of placing gas monitors in bypass. There appears to be risks associated with control room officers doing this remotely.• the use of a two-step verification process to ensure the correct sensor is bypassed and not the operational sensor (where dual systems are configured).• using improved engineering controls that ‘automatically’ confirms (audible or visual) when a sensor is placed in bypass/defeat.• changes to supervisory control and data acquisitions (SCADA) or data logging systems that sound an alarm when a sensor is left in bypass/defeat and re-triggers after a pre-defined time.• how to ensure that trip circuits are periodically checked to test and maintain their level of functional safety.

Mine operators should consider:• a review of communication protocols. In this incident radio congestion played a significant part• reviewing the practice of turning off lights in declines• updating and communicating written traffic management procedures• ensuring drivers are trained and assessed as competent in the site’s rules and procedures• the role of engineering in assessing risk and, where necessary, standardising the positioning of lights on vehicles• using collision avoidance and proximity detection systems for both heavy and light vehicles• periodic monitoring of traffic rule compliance on site through unplanned task observations.

Human factors played a role in this incident. The injured contractor’s hand was resting on the top rail joint. This was a pinch point. Clearly, hazard awareness was not adequately assessed and the root cause appears to be human error.

Where an electrical supply is feeding critical mine infrastructure, mine operators should consider the active monitoring and recording of leakage to earth at various locations across the network. This can help electrical staff make priority decisions around maintenance activities and the location of system degradation before tripping.Change management should be followed before altering electrical protection devices, settings, tripping ratios, maintenance test frequencies, alarms and trip levelsMines need to ensure that when performing insulation testing on electrical networks that they have given due consideration to the voltages used, the duration and what the acceptable minimal levels are.For more information, refer to AS/NZS 4871.1 Electrical equipment for coal mines

The electric shock was caused by a faulty drill that was in service for five months. A contributing cause was an incorrect test procedureWe recommend that mine operators routinely test portable tools and extension leads. An inspection tag should be attached. Mine operators should ensure electrical tests are performed by competent staff members who have been trained in the procedures and use of all test instruments. For more information, refer to clauses 148-151 of the Work Health and Safety Regulation 2011.Mine operators should consider using battery powered tools instead of low voltage (240 volt) tools. They should also consider using permanent magnet drill bases instead of 240+ volt electro-magnetic bases. Operators should refer to Safety alert: Severe electric shock from power tool.Non-coal mines are reminded that their nominated electrical engineer is required to attend their site to fulfil the nominated duties under the requirements of clause 33 (1), schedule 10 of the Work Health and Safety (Mines and Petroleum Sites) Regulation. This duty cannot be delegated to other persons.

Material falling down a shaft poses a serious risk to the health and safety of any person in the shaft. Appropriate control measures are required to prevent the risk of material falling down a shaft. Mine operators must ensure they comply with clause 49 (6) of the Work Health and Safety (Mines and Petroleum Sites) Regulation 2014

Mine operators must review the procedures and conditions in relation to failed plant before allowing people to re-enter an underground mine. Mine operators must also revise and implement changes to ensure that the trigger event does not reoccur.

The investigation determined that the hi-set inter-leg hose was too long for the application and the loop was rubbing on the tailgate roof support leg. The hose failed due to abrasive wear. Hose integrity is the single control measure for the prevention of an escape of pressurised fluid into the work area.Mines should have effective hose management systems to ensure hose integrity. This should include considering the recommendations in section 7 of the department’s guideline for fluid power system safety at mines.Routine hose maintenance inspections should include a condition assessment of hoses with particular focus on wear, impact and squashing between the equipment

Mine operators should identify all work activities on the mine site where trucks are used and review control measures for truck rollovers. This should consider the following risk controls to prevent a truck roll: tipping areas should be level without cross grades tipping areas should be stable, and capable of withstanding the truck wheel pressures and not prone to subsideRefer to the department’s Safety bulletin: industry reports more truck rollover incidents.

The regulator will launch an investigation to determine the causal factors of the incident. Until the outcome of the investigation is available, people with management and control of plant are reminded that: maintenance, inspection and testing should be carried out in accordance with the manufacturer’s recommendations maintenance activities should consider the duty cycle and the operating environment explosion-protected diesel engine systems should be maintained in accordance with the conditions of item and design registration.

A soap dispenser was installed directly above a light switch. Soap ingress was evident after an investigation.Mine operators are reminded of their obligations to manage risks under the WHS (M&PS) Regulation 2014. In managing risks to health and safety associated with electricity at the mine or petroleum site, the operator must ensure: installation work at the surface is carried out in accordance with the wiring rules (AS/NZS 3000), in particular refer to clause 32 (2), and modifications to buildings and plant do not reduce the safety of existing electrical installations that are generated by complying with the wiring rules.

Mine operators are reminded that mobile plant must be maintained to a good standard and in accordance with original equipment manufacturer’s recommendations. The operating tolerances of mobile plant must be adhered to within road design parameters.The mine operator should consider: maintenance, inspection and testing of braking systems of mobile plant that the frequency of maintenance and inspections is appropriate for the mine operating environment and the type of plant both vehicles owned by the mine and any contractor vehicles should be included in the review.Operators of trucks should ensure that they drive according to the conditions.

There were several factors that contributed to this incident. These include: digging outside the limits of the machine lack of supervision, and failure to identify the hazard, that is, an excessively high bench in proportion to the machine uncompacted ground working too close to the edge of benches or ramps, and inadequate hazard identification.The regulator recommends operators ensure that the following are actioned to reduce risk: working pads are adequately compacted and constructed tasks are supervised and potential hazards are identified when working on benches, excavator tracks are parallel to the face and positioned an adequate distance from the edge. This includes taking into account the stability of the edge in terms of geological structure, blast damage and undercutting operator training and assessment takes into account specific conditions and activities at the site operators understand original equipment manufacturer’s operating instructions, including load limits at various boom extension distances, stability parameters, and safe operating procedures.

Underground operations must review their controls when vehicles are operating in and around main travel roads. The review must consider traffic control and making others aware of the operating vehicle. The review must also consider the frequency of work in the area and other factors that may affect visibility. This could include, for example, seam grades

We recommend mine operators consider: the importance of no-go zones when running out this type of material engineering design review and making changes to the chute at the bottom of the bin a review of the design of the bin to minimise fluid into the surface bin the importance of annual structural audits of surface bins and having a clear scope

Mine operators should reinforce the safety risks inherent in accessing mobile equipment. Ways to manage these risks include ensuring that:• people have three points ofcontact when entering and exiting vehicles• boot laces are tied and soles are in good condition• access steps are clear of debris• items carried by operators do not prevent secure contact with hand rails.

Where this type of hazard exists, consideration as to the suitability of controls for the risk is required.Critical controls may require more than one action or activity to manage the risk.

System software parameters, their access and change must be controlled. The loading of the software and parameters, especially at times of longwall change-out in readiness for wet commissioning, should be undertaken by one person and then verified by another person.Any changes to parameters must be signed off by the appropriate mine personnel before installation and then correct operation of the modified parameters verified before normal operations recommence.Commissioning procedures should ensure all scenarios are considered where the equipment may fail to operate as intended (both in automation and manual).For longwalls, the procedures should also include a full cutting cycle (360 degree) before releasing the shearer back into normal operations. The mine operator should ensure all no-go zones are identified and enforced before the start of commissioning

Electrical protection systems form part of the safety network associated with the safe use of electricity and should have appropriate levels of functional safety.Mine operators should identify all mine critical infrastructure, risk assess it and ensure the electrical power supplies provide a suitable level of reliability.

Sites are reminded to review their TARPS that are in-place to control these events such that methane does not exceed 2% in areas where persons travel or work as per clause 72 WHS (Mines and Petroleum Sites) Regulation 2014.

Mine operators should:• maintain housekeeping standards toremove combustible materials so far as is reasonably practicable• verify that fire extinguishers and fire suppression systems are inspected and maintained in accordance with manufacturers’ recommendations• review and revise (as necessary) vehicle fire risk assessments with consideration to AS5062.Review control measures for high surface temperatures of engine exhaust components for the prevention of controlled fires.

The incident highlights the importance of having an effective risk management program in relation to the interaction of light and heavy vehicles at surface mine sites. It is also a timely reminder to ensure that workers are adequately trained and that the requirements of the roads or other vehicle operating areas principal hazard management plan are followed.Review the report and associated recommendations within:Ravensworth open cut investigation report of a fatality that occurred in November 2013 – Heavy and light vehicle interaction.

Underground operations should review their surface transport controls to ensure the risk of vehicle / pedestrian interaction is removed as far as is reasonably practicable.Competent workers and operators should inspect surface transport areas and should be trained in the safe operation and park- up requirements of mobile plant.

Speed may have been a factor, with the operation of braking / retard systems not effectively engaged or operated.It is recommended that mine operators review the training of their operators to ensure that mobile plant is operated within its specifications.

The cause of the power failure was identified as a harmonics filter on the VSD of the traction system of a shuttle car, placing excessive noise on the earth continuity system.Mine operators are reminded to ensure de-gassing procedures are in place and that they should include methods to purge electrical enclosures from potential explosive concentrations of gas.

Mine sites should establish safe park-up areas and develop specific controls for the management of vehicle interactions.Take consideration to separating light and heavy vehicles as far as is reasonably practicable, and verify control implementation.Sites are reminded to review their principal hazard management plans.

This type of incident has occurred on numerous occasions across mine sites within NSW. Mine operators are reminded to adopt the hierarchy of control for the management of hazards with reference to this type of incident and confirm the suitability of mobile plant for task. Mine operators are reminded of the Safety Bulletin 17-01, in reference to truck rollovers

People with management or control of large haul trucks should review the adequacy and effectiveness of periodic inspections of axle or wheel location components noting the following:components need to be properlycleaned before visual inspections forthe presence of cracks or developingfaultssafe access should be provided tomake a complete inspection ofidentified componentsThe use and frequency of non-destructive testing techniques should also be considered. Sites are reminded to review their mechanical engineering control plan.

Pneumatic cylinders are often single line components in the automatic safety shutdown system of an ExDES making the maintenance, inspection and proof testing of such components critical to the reliability of the safety function.Mine operators with management and control of ExDES that have singular fuel shutdown cylinders should review maintenance practices. Maintenance, inspection and testing should be carried out in accordance with manufacturers’ recommendations and with regard to site environmental conditions and experience.

Mine operators should consider enforcing the use of seat belts, assessing the suitability of intersections and the lighting of these intersections on sites.Mine operators are also reminded that in fulfilling their duties to notify emergency services, the agencies may activate defined response arrangements including a ‘standard response’ as outlined in the NSW State Rescue Policy. Mine emergency procedures and site management practices should integrate these arrangements to enable agencies to perform their duties as required.

Roads must be maintained to a high standard. Remove rocks and debris that could pose a hazard. Vehicle location should be carefully considered with respect to parking while performing maintenance activities on-site outside of a workshop.

Sites must maintain cables consistently with their cable management plans. Face workers and mining supervisors should all be trained and familiar with the requirements of the plan.Regular audits by mining supervisors and electrical staff will assist in compliance and maintenance of heights avoiding contact with shuttle cars and other mobile machines.

The failure mode of the idler needs to be determined and the risk of collapse and failure considered in risk assessments.Operators should review control measures for the prevention, detection and suppression of fires on conveyors including consideration given to: minimising external loads applied to conveyor rollers from the conveyor belt alignment and set up lifecycle management of conveyor rollers (operational hours used) and consideration of mean time between failure regular inspections general housekeeping accessibility to firefighting equipment in the event of a fire occurring.

Mine operators should review the vehicle and traffic management system and check intersection design and signs are consistent with mine plans height of windrows foreground and background lighting along with machine and vehicle lighting limited vision of operators due to blind spots fatigue distractions.See Investigation report – Fatal collision at Ravensworth mine.

The IP rating on enclosures of intrinsically safe equipment must be maintained to ensure its integrity and that it complies with its certification.This incident highlights the need for sites to: plan works that involve the interconnection of temporary additions to critical control and monitoring systems follow and complete site change management processes ensure electrical tradespeople who install, repair and maintain intrinsically safe equipment are trained and competent in the intrinsically safe explosion-protected technique and are aware of the importance of maintaining IP ratings.

The incident highlights the importance of having effective controls in relation to the interaction of light vehicles and heavy vehicles at surface mine sites. Roads or other vehicle operating areas are identified as a principal hazard within the Work Health and Safety (Mines and Petroleum Sites) Regulation 2014Refer to the recommendations in the fatal incident.• IIR13-06 Collision between haul truck and light vehicle• Investigation into a fatal collision at Ravensworth open cut mine on 30 November 2013

The complaint is being investigated by the department. Information on bullying and harassment is available on our website at: www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/topics/bullying-in-the-workplace SafeWork Australia also publishes guides to preventing and responding to workplace bullying and a worker’s guide to dealing with bullying. See their website for more details: www.safeworkaustralia.gov.au

All underground operators are reminded that they have a responsibility to review their ventilation management plans after any exceedance. Attention should be drawn to the relationship to the conformance with the standards of the VCDs and the location of gas monitoring sensors and alarm settings.

This type of incident has occurred on numerous occasions across mine sites within NSW. Mine operators are reminded to adopt the hierarchy of controls for the management of hazards with reference to this type of incident and confirm the suitability of mobile plant for task. Mine operators are reminded of the Safety Bulletin 17-01, in reference to truck rollovers.

Risks must be eliminated, so far as reasonably practicable, so due consideration is required when considering mobile plant refuelling locations and ensuring plant is parked in a fundamentally stable position.Refuelling arrangements for mobile plant should be risk assessed and managed for all mine sites. The potential risk of plant/worker interaction and fire should be controlled.Mobile plant braking systems should be maintained and checked.• SB09-05 Failure of mobile equipment braking systems and procedures

Operators should review their windblast management plans and withdrawal trigger action response plans (TARPs) in relation to the formation of the first goaf before the start of any new longwall extraction.

Mine operators are reminded to review their sites for this risk and ensure site procedures and worker training for travelling near or under powerlines is established and appropriate. Mine operators should identify and delineate access corridors and transport routes under overhead power lines and establish warning systems or ‘goal posts’ to indicate physical clearance limits and to alert operators. Consideration should be given to installation of underground cables to manage this risk.Confirm that emergency procedures for accidental contact with energised power lines are established and understood by workers.Reference should be made to the Safework NSW Code of Practice for Work Near Overhead Power LinesMine operators should also refer to SB15-05 Plant contacting overhead powerlines and structuresSA 99-23 Truck driver raises tray under powerlines

This incident highlights the need for the mine operators to review and revise the strata control measures for the formation of right hand breakaways and the subsequent straight cut (in accordance with WHS Regulation clause 38). The review should encompass the support required before starting the breakaway and the subsequent straight cut, and personnel positioning during those activities. The aim is to ensure there is sufficient distance between the operator and unsupported roof so as that any failure of the unsupported roof does not impact on the operator.

Mines should remind workers of:• the need for effective communication between workers• standing well clear of stabilising rams when these rams are being operated to stabilise mobile plant.If it is essential for the short term removal of personal protective equipment, move to a safe place and ensure there is no risk of harm while it is removed.

Mines and licenced registered service facilities should review their maintenance strategies around the sealing and checking of injectors, using OEM recommended maintenance.

Mine operators are asked to consider: collision avoidance and proximity detection systems fields of vision and use of cameras on large mobile plant positive communication between vehicles procedures on parking and isolation of vehicles.Reference should be made to MDG 2007 for guidance on proximity awareness and collision avoidance technologies

One possible cause is heating friction between the shearer picks and changing geological conditions. To mitigate the potential of frictional heating ensure that: picks are not worn and carbide tips are intact and conduct more regular checks when conditions change water sprays are functional without blockage there is adequate ventilation.

Mine operators should ensure that safe work method statements and task risk assessments identify the risks associated with using portable electrical equipment in relation to the particular work activities.Where portable electric tools have been modified by the replacement of a supply cord and three-pin plug, the risks associated with this practice including the maintenance of ingress protection rating (IP rating) and mechanical integrity (cord grips) of the equipment should be considered. This is of particular concern where IP56 plugs are fitted to light duty cords.‘Introduction to site’ processes for portable electrical equipment should be routinely audited to ensure compliance to site standards.Supervisors should review work site activities against mine site requirements associated with the use of portable electrical equipment, including: routing of extension leads suitability of equipment for task and environment compliance to site installation standards

Where workers are performing work on HDPE pipe including cutting, routing, grinding and welding, mine operators should ensure that: procedures address the risks associated with static generation on HDPE pipes and tools being used workers are trained in and familiar with the site procedures, particularly those for control of static electricity site introduction of electrical equipment intended for use with HDPE pipe work and the associated pre-start checks are performed correctly to ensure the integrity of tools and associated equipment.Refer to AS/NZS 1020:1995 The control of undesirable static electricity

There have been several incidents associated with brake boosters on mobile plant over the past six months.Brake boosters on mobile plant need to be overhauled or replaced at intervals recommended by the original equipment manufacturer.Mines with brake boosters on mobile plant should review their maintenance practices to ensure this occurs.

Mine operators should identify areas where the potential of unsupported rib coal and poorly supported roof may exist, whether in roadways, pillar extraction workings or longwall faces. For identified areas: review the support rules assess risks and implement controls to avoid danger to the safety of workers from unconfined rib and roof strata.

Consideration for preventing this hazard from occurring include:control system design integrity and validation by OEMs maintenance is performed in accordance with OEM specifications compliance with site functional safety management plan to ensure ongoing integrity.

It is the mine operator’s responsibility to ensure that where exemptions are granted, there is compliance with all conditions, including expiration dates.

Electrical power supply is critical to the operation of essential infrastructure such as ventilation fans. The effect of this loss of supply should be risk assessed to ensure that suitable controls are identified and provided.Safety management systems and the electrical engineering control plan may require review where critical mine infrastructure is affected by a loss of power supply.Consideration should be given to the provision of back-up (generators) or alternative drive systems (e.g. diesel engines) where the loss of power supply may adversely affect critical infrastructure.

Mine operators should identify areas where the potential rib spall may exist, whether in roadways, pillar extraction workings or longwall faces. For identified areas:• review the support rules• assess risks and implement additional controls to avoid danger to the safety of workers from unconfined rib to ensure continued safe passage• review and, if necessary, update mine strata management plans.Refer to the NSW code of practice: strata control in underground coal mines.

Dumping above any active working area is poor practice and should not be permitted.Work activities should be planned and coordinated to manage risks caused by the work activities of different work groups on each other. It is essential that work instructions are effectively communicated and are understood by all people that may impact, or be impacted by, others. As a minimum, the controls should include more rigorous inspection regimes, increased supervision and improved barriers.Mines should review inspection plans and ensure workers and statutory officials are trained in hazard identification and rectification

Structural components on loaders need to be periodically inspected as well as being maintained to OEM recommendations.Loaders must only be operated within their designed load-rating chart.The use and frequency of non-destructive testing techniques should also be considered. Sites are reminded to review their mechanical engineering control plan.

Suspension failures affect the stability of articulated trucks by shifting the truck’s centre of gravity.A competent person must carry out periodic maintenance and inspection of suspension components. Components need to be replaced, overhauled and maintained to OEM recommendations.The recommendations in SB17-01, Industry reports more truck rollover incidents should be considered

The electrical engineering control plan should contain requirements for the management of cables, in particular trailing and reeling cables.The cable management systems should include requirements for the adequate separation of cables and associated infrastructure, such as plug sleds, from mobile mining equipment. This includes the placement of demarcation markers and barriers that provide clear indication of the location of the cables.Sites must set up and maintain cable installations in accordance with the mine’s cable management standards.All operational personnel and statutory officials should be trained and familiar with the requirements of the cable management standards.Regular audits by statutory officials, supervisors and electrical staff will assist with compliance for cable installations, including the positioning and demarcation of cables and sleds to avoid contact by haul trucks and other mobile machines.Guidance is provided in Section 6 of AS/NZS 3007:2013 Electrical equipment in mines and quarries—Surface installations and associated processing plant.

Sites are reminded to review their ventilation control plans and TARPS that are in place to control these events so that methane does not exceed 2% in areas where people travel or work (clause 72 WHS (Mines and Petroleum Sites) Regulation 2014).

Fires on mobile plant require thorough investigation by a competent person to determine:• fuel source and heat sources • the cause of the fire• controls to prevent re-occurrence such as reducing engine component surface temperatures and segregating fuel sources from areas of high temperature and fire safety inspections.Ancillary forms must be submitted for fires on mobile plant.All repairs must be carried out by a competent person and appropriate checks to ensure the mobile plant is fit for use

This incident is a reminder to ensure: • operational risk assessments include documented safe work procedures for the replacement of a drill stem which are readily available • workers are not exposed to hazards of rotating drilling equipment. Numerous entanglement injuries have been reported in recent years• effective guarding to protect from entanglement is installed, where reasonably practicable• drill rig operators are trained • pre-operational checks and hazard identification systems are used.

Lessons that should be communicated through took box talks include:• compliance with correct parking procedures at all times • being situationally aware of hazards.Mine operators should consider:• audible warning systems audible and/or visual alarms that warn of the lack of park brake application• interlocking that automatically applies the park brake when the operator leaves the operator’s positon (ie door interlock). functional testing of park brake application warning systems• the recommendations in SB13-02 Unplanned movements of vehicles - too many near misses

The regulator’s Major Investigation and Emergency Response team is investigating the incident. High flow refuelling systems should not be used on mobile plant, which is not designed to accept high flow fueling systems. Refer to the Investigation Information Release Mt Arthur serious injury fire and the recommendations in safety bulletin SB15-03 Fires ignite while refuelling mobile plant with quick-fill fuel systems

Mine operators should identify all work activities on the mine site where trucks are used and review control measures for truck rollovers. This should consider the following risk controls to prevent a truck roll:• tipping areas should be level without cross grades• tipping areas should be stable, and capable of withstanding the truck wheel pressures and not prone to subside.The recommendations in safety bulletin SB17-01 Industry reports more truck rollover incidents should be considered

Mine operators are reminded that where background methane levels are high, caution needs to be exercised during all ventilation changes and ventilation work. This should include procedures for establishing ventilation to faces when auxiliary ventilation is stopped.Mine operators are reminded to ensure de-gassing procedures are in place and that they should include methods to purge electrical enclosures from potential explosive concentrations of gas

Mine operators are reminded of the obligation under WHS (MPS) Regulation clause 72 to ensure methane levels in the general body are as low as reasonably practicable and not greater than 2% by volume.Production activities should to be appropriately monitored to so that production activity can be modified where increasing methane trends are detected.This can be achieved through the application of appropriate trigger action response plans and implementation of documented cutting sequences into the tailgate roadway

Major barometric falls are a reasonably foreseeable event due to the availability of short-term monitoring and prediction available from the Bureau of Meteorology. A significant barometric fall can result in the ventilation system of the mine not being able to deal with the additional gas make.Mine operators are reminded of the effects a falling barometer can have on sealed goaf areas and methane levels. Mine operators should prepare appropriate trigger action response plans supported by both real-time and predictive services to understand barometric trend and magnitude and so provide adequate time to allow the implementation of mitigating controls to minimise a potential increase in methane gas levels more than 2%.Such mitigating controls may include:• ventilation changes• halting production• increasing gas capture• a combination of mitigating controls

‘Catch trenches’ or other controls should be in place and properly maintained to protect people from the risk of falling face material when mobile plant are operating near high-risk areas. Supervisor daily pit inspections should ensure that the catch trench is in place and maintainedBlasting techniques should be designed (in consultation with blasting contractors and supply engineers) to reduce excessive back break so as to control excessive ‘hung up’ material. Operators and supervisors should be trained in geological hazard awareness

Mobile plant, including light vehicles, must be parked in accordance with site proceduresWorkers should be trained in site park-up procedures. Regular site safety observations should be performed by supervisors to ensure compliance with site procedures.Collision avoidance technologies should be considered.

Adjustment of hydraulic pressures should be performed by people trained and assessed as competent for the task. This is normally a mechanical tradesperson (fitter).Mine operators should have a protocol in- place with how to deal with and manage a suspected fluid injection. These protocols need to be communicated and followed whenever an injection is suspected

All mine workers should be reminded of the dangers associated with the use of hard metal tools, including contact with hard metal surfaces. Stuck drill steels in drill chucks are reasonably foreseeable. Fit-for-purpose tools and equipment, work procedures and training should be provided to workers, including overcoming stuck drill steels

Ventilation officers are reminded that major barometric falls are a reasonably foreseeable event that should be addressed in the ventilation control plan.Barometric trending should include both the effects of diurnal barometric change as well as major barometric events. To assist in determining barometric trend, barometric monitoring should be installedMine operators are reminded of the effects a falling barometer can have on sealed goaf areas, and hence methane levels in accessible roadways.Mine operators should prepare appropriate trigger action response plans supported by both real-time and predictive services to understand barometric trend and magnitude and so provide adequate time to allow the implementation of mitigating controls to minimise a potential increase in methane gas levels more than 2%.

The hazard identification and control of fires on mobile plant should be carried out in accordance with AS 5062:2016 Fire protection for mobile and transportable equipmentFires on mobile plant require a thorough investigation by a competent person to determine:• the fuel source and heat sources • the cause of the fire • controls to prevent re-occurrence, such as reducing engine component surface temperatures and segregating fuel sources from areas of high temperature and fire safety inspections

Production activities should be appropriately monitored and modified where increasing methane trends are detected. This can be achieved through the application of appropriate trigger action response plans and implementation of documented cutting sequences into the tailgate roadway


Decommissioning booster fans coupled with a falling barometer and the distribution of ventilation in roadways in the vicinity of affected seals was inappropriate to adequately dilute gas from some of the seals resulted in the reported gas exceedancesPersonnel must be withdrawn consistent with trigger action response plan

Forklifts used on mine sites must be maintained and serviced at regular intervals and should be subjected to operator pre-start checks.Issues identified with control systems, over-revving and unintended activations and unplanned movements must be fully investigated and the root cause identified. The forklift should be repaired to maintain safety.People operating forklifts must hold high-risk work licence.

Some factors that may affect operator vision and / or ability to control a vehicle include:• fog, sunlight, storms, dust or environmental factors• fatigue• slippery road condition after being watered• obstructions that affect lines of sight.Mine operators should consider these items in their principal hazard management plans for roads and other vehicle operating areas, along with fit-for-purpose barriers such as bunding or windrows to prevent uncontrolled vehicles going over embankments.Drivers should be reminded to correct speeds, and select and use appropriate equipment and retarders when descending

Mine operators must identify the risks associated with working on hydraulic systems, hoses, rams and associated components. This should include the risk of people being struck by projectiles or pressurised fluid as a result of residual stored (or locked) hydraulic pressurePeople should be competent to work on hydraulic systems (including troubleshooting).Hydraulic schematics and original equipment manufacturer OEM maintenance information needs to be available and followed when maintenance is being carried out.Maintenance tasks should have comprehensive procedures for replacing or repairing hydraulic components. Particular attention should be given to effective means to dissipate stored pressure in hydraulic cylinders where valving may hold or lock in pressure for cylinder control. Release of this energy may require specific procedures. Effects of gravity should also be considered.Further information can be found in MDG41 Fluid power system safety

Fluid power systems should be designed, installed and maintained while taking into consideration the recommendations in MDG41 Fluid power system safetySection 7.6 deals with hose management.Preventative measures include:• hose rating and design• suitability of hydraulic fittings used to connect hoses to fixed components (such as valve banks and manifolds)• hose bend radius and rubbing• regular hose inspections and training of people doing those inspections.Mitigating measures include:• use of guards where possible • hose protection sleeves• ultraviolet sensor dye in oil

The unintended failure of lifting equipment such as slings, chains, hooks, connectors and chain blocks have caused fatal injuries in the past. Refer toThe unintended failure of lifting equipment such as slings, chains, hooks, connectors and chain blocks have caused fatal injuries in the past. Refer toSB09-03 Broken pull chain results in fatalitySA04-09 Broken chain connector results in serious injuriesSA04-05 Crane dogger killed unloading trailerMine operators should remind workers on the use of lifting equipment. The following generally applies:• lifting hooks are always put through purpose-made lifting points. Hooking onto a flat steel plate should not be done.• workers using the gear are trained and are competent in its use• equipment is fit for purpose and within current certification• equipment is used in accordance with the relevant Australian Standards and the OEM recommendations• in lifting applications, workers must hold the relevant dogging / rigging licence• lifting equipment that is used for towing should not be used for lifting.Personnel should be trained in the correct use of lifting equipment and correct anchorage.Mine operators should have safe work procedures for unusual tasks, such as freeing stuck drills. Procedures should be followed and specific risk assessments should be performed before starting work.Sites that have this risk should have established management and operating practices for the use of cyanide in their mining activities. These must extend to spillage management protocols.Mines should regularly audit their cyanide environmental monitoring and emergency response programs. Adequate containment facilities and bunding of liquid and solid cyanide containers are necessary to minimise the effects of accidental spillage (consideration must be given to local weather conditions in providing such containments).

Mobile plant being introduced to a mine should have controls and safety functions checked before the mobile plant is used. The site introduction process should include the recommendations in section 4.5.3 of the mechanical control plan code of practiceWhere faults are found, the mobile plant should be tagged out of service with the mobile plant owner notified.The mobile plant should not be used at the mine until a competent person has checked the repairs and verified the plant is safe to use

Sites that have this risk should have established management and operating practices for the use of cyanide in their mining activities. These must extend to spillage management protocols.Mines should regularly audit their cyanide environmental monitoring and emergency response programs. Adequate containment facilities and bunding of liquid and solid cyanide containers are necessary to minimise the effects of accidental spillage (consideration must be given to local weather conditions in providing such containments).

Quick release connections should be fit-for-purpose and have regular maintenance inspections. Maintenance personnel and operators should be competent in their use and inspection.Quick release connections should not be used when the hydraulic system is pressurised. Refer to MDG41 Fluid power system safety

Mine operators should identify all work activities on mine sites where trucks are used. Consideration should be given to the following risk controls to ensure ground stability and suitability for vehicle operations and to prevent a truck roll• Tipping areas should be level without cross grades• Tipping areas should be stable and capable of withstanding the truck wheel pressures and not prone to subside• Edge boundaries must be well identified• The recommendations in safety bulletin SB17-01 Industry reports more truck rollover incidents should be considered


An investigation identified a structural wire cord from the shoulder area penetrated the internal wall of the tyre. This caused a bubble between the outside wall of the tyre and the delaminated area, which continued to expand until it failed. Tyres should be checked and repaired in accordance with AS 4457.2-2008 Earth-moving machinery - Off-the-road wheels, rims and tyres - Maintenance and repair – Tyres.Mines should:• communicate actions required when a tyre bubble is identified for operators and maintainers• include management of sidewall bubbles in tyre handling procedures• establish safe method for the deflation of damaged tyres.

Some factors that may affect operator vision and/or ability to control a vehicle include:• fog, sunlight, storms or dust• fatigue • slippery road conditions • obstructions that affect lines of sight.Mine operators should consider these items in their principal hazard management plans for roads and other vehicle operating areas, along with fit-for-purpose barriers such as bunding or windrows to prevent uncontrolled vehicles going over embankments. Drivers should be reminded to travel at speeds suitable for conditions and select and use appropriate equipment and retarders when descending

Mine operators should consider: • change management processes being applied to work that may have a flow-on impact to other activities at the mine. • engineering controls for the automatic shutdown of diesel plant should general body methane be greater than 1.25%.• withdrawal conditions being defined in trigger action response plans with key persons such as control room operators being accountable for initiating action(s)• effective controls to prevent damage to methane drainage water trap installations from passing traffic• methods to detect and effectively control leakages along segments of the methane range.Mine operators must review the procedures and conditions in relation to failed plant or trigger events before allowing people to re-enter an underground mine particularly when elevated levels of methane have resulted in the withdrawal of workers from the mine.

When mobile plant is operating in close proximity, operators should remain in continual communication with each other and maintain an awareness of the other’s position.Mobile plant, including light vehicles, should be operated and parked in accordance with site procedures. Workers should be trained in site-specific procedures. Regular site safety observations should be performed by supervisors to ensure compliance with site procedures.Collision avoidance and proximity technologies should be considered – MDG 2007 Selection and implementation of collision management systems along with the use of cameras to assist operators by alarming encroachments.

Electrical power supply is critical to the operation of essential infrastructure such as ventilation fans. The effect of this loss of supply should be risk assessed to ensure that suitable controls are identified and provided.Motor protection relays should be selected, set up and commissioned correctly and maintained by competent personnel to ensure the protection functions correctly when required and is reliable and not subjected to nuisance trips.

Ventilation officers are reminded that major barometric falls are a reasonably foreseeable event that should be addressed in the ventilation control plan.Trending should include both the effects of diurnal barometric change as well as major barometric events. To assist in determining barometric trend, barometric monitoring should be installed.Mine operators are reminded of the effects a falling barometer can have on sealed goaf areas, and hence methane levels in accessible roadways.Mine operators should prepare appropriate trigger action response plans supported by both real-time and predictive services to understand barometric trend and magnitude and so provide adequate time to allow the implementation of mitigating controls to minimise a potential increase in methane gas levels more than 2%.

There have been a number of recent incidents that have resulted in light vehicles rolling over.Mine operators should consider if a road rule/control ‘drive to conditions’ is sufficient for wet and/or slippery roads or sections of roads.

Mine operators should consider if a planned task being undertaken may have any effect on other non-related planned tasks. This is especially so when one or more of the tasks may affect the ventilation in the mine.Mine operators should review their gas monitoring alarm response, control room operator training and withdrawal trigger action response plans to ensure that appropriate responses are implemented as quickly as possible following a gas alarms

This incident could have easily resulted in serious injuries or death (refer to IIR16-08 Fatality after being struck by truck tailgate)Mine operators should:• remind all truck operators (including contractors) of the hazards associatedwith putting body parts between the tailgate and truck trays• reinforce and communicate to workers the recommendations in IIR16-08• ensure workers are trained in recognising the hazards associated with gravity and the controls that should be used.

Mines are reminded that during maintenance, the original equipment manufacturer’s recommendations should be followed.In this case, a sealant incompatible with the hydrocarbon was used. The sealant reacted with the hydrocarbon allowing the gasket to be ejected under pressure.When tightening a series of flange bolts it is essential that all bolts are torqued equally to the required tension in the appropriate order. Good practice is to mark bolts to confirm they are tight.

All cables should be installed in locations where the possibility of damage is minimised. They should be installed either:in roadways that are not used for material transportation• at heights above those required for material and transport movements, or• by installing guards over the cables.Mine operators should ensure that where cables pass under, over or through, obstructions, such as air and water pipes they are positioned in a way that they are not likely to be damaged. Protection relay settings should be set to achieve the quickest operating times at the lowest values that would allow for reliable operation

Mines with winders must have a principal hazard management plan for mine shafts and winding systems. The plan must address control measures for risks associated with mine shafts and winding systems (clause 3, schedule 1 WHS (MPS) Regulation)In developing principal hazard management plans, mines should consider:• the type and adequacy of shaft and winder inspections, including, ropes and attachments, guides to identify damage or areas where a conveyance may bind or become stuck• maintenance requirements in accordance with the original equipment manufacturer’s recommendations• testing of safety-related functions in a manner and frequency as required by the designer

Both of these incidents required immediate notification to the regulator.Late reporting of incidents inhibits adequate assessment of potential causal factors and failed or absent control measures.Mine operators should have a documented process for notifiable incident responses and investigations.Mine operators should ensure all supervisors and workers are trained to identify and notify incidents when a notifiable incident occurs. Mines and petroleum sites must promptly notify the regulator when an incident occurs. For guidance on reporting refer to the Notification of incident and injury guide


Fire risks assessment should be carried out for mobile plant that is operated at the mine. The fire risk assessment should consider guidance in AS 5062:2016, Fire protection for mobile and transportable equipment.Good maintenance practices are essential in preventing the ignition of combustible fluids from hose or pipe failures.Hoses should be segregated from hot surfaces with the surface being protected. Surface heat must be minimised and fire resistant fluids should be used, where possible.


A number of articulated dump truck roll overs have occurred at mines recently. Mine operators should refer to the recommendations in safety bulletin SB17-01 Industry reports more truck rollover incidents

Mines should ensure windrows are installed and are of sufficient height to arrest mobile plant if it becomes uncontrollable. Factors that may affect operator vision and/or ability to control a vehicle include:• fog, sunlight, storms or dust• fatigue• slippery road conditions• obstructions that affect lines of sight.• wildlife. Mine operators should consider theseMatters in their principal hazard management plans for roads and other vehicle operating areas, along with fit-for purpose barriers such as bunding and windrows to prevent vehicles going over embankments.Vehicle operators should be reminded to travel at speeds suitable for conditions

Machine operators should inspect their work area to identify hazards that have the potential to fall or roll onto equipment, in this case falling rocks.MDG 15 Mobile and transportable equipment recommends all cabin windows be fitted with safety glass.MDG 15 guidelines should be consulted with respect to the use of roll-over protective structures and falling object protective structures.

Positive communication is essential.Mines should consider human and organisational factors when developing their principal hazard management plans for roads and other vehicle operating areas.

The incident highlights the importance of having an effective risk management program in relation to the interaction of light and heavy vehicles at surface mine sites. It is also a timely reminder to ensure that workers are adequately trained and that the requirements of the roads or other vehicle operating areas principal hazard management plan is followed.Mine should review the report and associated recommendations in Ravensworth open cut investigation report of a fatality that occurred in November 2013 – Heavy and light vehicle interaction.

Engineering risk controls for the prevention of electric shocks are well known and if properly implemented should prevent the likelihood of these incidents.Mines should review electric shock protocols to ensure they are consistent with actual assessment options, noting that ambulances are equipped with electrocardiograph capability so that victims may be cleared without attending hospital

Principal hazard management plans for roads or other vehicle operating areas (WHS(MPS) Regulation schedule 1 clause 4) should ensure that adequate consideration is given to:• which vehicle should have the right of way• the separation of heavy and light vehicles, where possible• the use of proximity detection• restricted / limited fields of vision from the operator’s position of heavy vehicles. Refer to MDG 15 Mobile and transportable equipment

Mine operators should review their tipping procedures to ensure that dump trucks do not tip close to edges. Mines should have systems in place to ensure windrow standards are regularly verified and maintainedConsideration should be given to:• retraining dump truck operators in tipping procedures• periodic workplace assessment of truck operators to ensure they are following tipping procedures

The procedure for this task required a winch attached to the loader. There was a fault with the rope on this winch, so the workers used a different rope with a direct pull from another loader. The tractive effort of the loader was much higher than the rope break strength.When using slings, the pull force should not be capable of breaking the slight unless a designed weak link or point is installed. Mine operators should:• identify that changes in work practices need to be appropriately managed through a change management process• use appropriately rated equipment• use engineering support as necessary to ensure equipment selected is suitably rated for the task to be performed• use lifting or pulling equipment in accordance with manufacturer’s instructions and for the intended purpose• develop JSAs for unfamiliar tasks.

Petrol engines should not be used in mines unless there is no reasonable alternative. Petrol engines have additional hazards and risks compared to diesel engines.Mine operators are reminded that hot engine exhausts can be a fuel ignition source, especially during hot weather. This incident required scene preservation and immediate notification to the regulator. For guidance on reporting refer to Notification of incident and injury guide

Mine operators should ensure that:• supervisors and workers comply with mine procedures • workers who operate equipment have sufficient experience• incident scenes are correctly preserved and site emergency procedures are followed.Operators of dozers and other heavy machinery must be adequately trained and assessed for competence

Mine operators are reminded to use the hierarchy of controls when considering risks associated with repetitive tasksMine operators are also reminded to reassess the risks when circumstances change and consider whether equipment is fit for purpose.

Operators should consider the recommendations in Safety Alert SA 05-04 Injury to excavator operator.

Mine operators should review the procedure for response to truck tray-up alarms and ensure that this is included in their truck operator training packagesMine operators should ensure, through pre-start and other periodic inspections, that engineering controls, alarms and warning devices are operating correctly before operating plant. Refer to section 4.2 of MDG 15 Guideline for mobile and transportable equipment for use in mines.

Mine operators should review their fitness-for-work and fatigue procedures.A review of compliance with road design rules, especially windrows, should be considered. Mines should ensure windrows are installed and are of sufficient height to stop mobile plant if it becomes uncontrolled

Mine operators should review the maintenance programs associated with haul trucks according to the original equipment manufacturer (OEM) recommendations. Maintenance and inspection frequency may need to be increased depending on the site’s environmental or operating conditions. Relevant OEM information for torque settings, lubrication or thread locking compounds and lock washers should be provided to maintenance personnel. Torque wrenches used for servicing should be calibrated.

All mine operators should review procedures for operating and moving machinery to ensure that no-go zones are identified and appropriate for the activities that may be required to be undertaken, including maintenance activities. The risk of injury to an operator from being in the line of fire as a result of an unplanned movement must be considered. The hierarchy of controls must be used to control the hazard.

Dangerous

Fire risk assessments should be carried out for mobile plant that is operated at mines. The fire risk assessment should consider guidance in AS 5062:2016 Fire protection for mobile and transportable equipment.Good maintenance practices are essential in preventing the ignition of combustible fluids from hose or pipe failures.Hoses should be segregated from hot surfaces with the surface being protected. Surface heat must be minimised and fire resistant fluids should be used, where possible.

Mines with winders should consider the type and adequacy of shaft and winder inspections, including:• ropes and attachments• guides to identify damage or areas where a conveyance may bind or become stuck• maintenance requirements in accordance with the original equipment manufacturer recommendations• testing of safety-related functions in a manner and frequency as required by the designer.

The operators of underground coal mines using this equipment should have all plugs that are approved under MDA Exd 1319 verified as complying with the approvals applicable to these plugs. Documentation showing the actual dimensions, not just pass or fail, should be retained in the verification dossiers for this equipment.Where documentation is not available to show actual flamepath dimensions, plugs approved under this MDA must be removed from service.

Operators are reminded of the potential hazards associated with a dozer on a stockpile.The recommendations in MDG28 Safety for stockpiles and reclaim tunnels should be considered. Dozer operators should have appropriate experience for the task.Mines should ensure all supervisors and workers are trained to identify and notify incidents when a notifiable incident occurs. A dangerous incident (as prescribed in cl179 of the WHS (MPS) Regulation 2014) must be reported immediately to 1300 814 609 and the incident site must be preserved until an inspector arrives on site or otherwise directed by a governmentofficial from the regulator.

Light vehicle operators should consider the potential issues that may affect their foot controls while driving light vehicles, such as clothing and footwear. Seat belts should be worn at all times. Site speed limits should be enforced.

Park-up procedures for light vehicles should be reviewed, especially when workers are in or around the light vehicles.Procedures should consider:• the use of wheel chocks• stable parking.Personal risk assessments should consider gravity as a hazard. Refer to safety bulletin SB13-02, Unplanned movements of vehicles - toomany near misses.

Dangerous

Resistor grids of haul trucks operate at very high temperatures. It is important that these areas be correctly maintained and and kept free of rubbish and debrisElectrical faults, loose electrical connections and damaged electrical wiringare common fire sources on mobile plant. Mines should implement systems thatconsider the electrical wiring recommendations of AS/NZS 4871.6:2013: Electrical equipment formines and quarries - Diesel powered machinery and ancillary equipment.Fire risk assessments, detection and suppression on mobile plant should be inaccordance with AS 5062 Fire protection for mobile and transportable equipment.

Mine operators should:• have procedures for the movement of drills that consider rod management• conduct worker training in hazard identification that should include those hazards presented by gravity• have fit-for-purpose drill rod handling equipment.

Mine tipping procedures should include appropriately designed ‘windrows’ as acontrol. Ground stability should be considered in planning the dump site.Adequate lighting should be provided when tipping occurs at night.

Mine operators are reminded of the obligations under WHS (MPS) Regulation2014 clause 44B – Mining induced seismic activity.The predictability of coal burst is not precise and, as such, mine operatorsshould consider that where an increased coal burst potential has been identified,due to the presence of geological structure or change in stress regime, controlmeasures should be implemented that remove workers from the place of risk.Refer to:- IIR16-05 Austar coal burst- Double fatality at Austar Coal Mine on15 April 2014

Mine operators should:• provide fit-for-purpose windrows as a mitigated control when an operator has lost control of their mobile plant• ensure brake systems remain functional• ensure pre-start checks include brake functionality• ensure operators are trained in emergency procedures.Refer to:SB17-01 Industry reports more truck rollover incidents.SB10-03 Mobile plant - safety critical systemsSA06-12 Maintenance of Safety Critical Systems - Braking, Steering & WarningSystems

Mine operators should review procedures and policy in relation to:• their procedure for ‘clear communication’ between heavy vehicles and light vehicles• the human and organisational factors that may come into play where there are interactions between heavy vehicles.

Hazard: Gravity Risk: Harm to people from falling elevated machine components. Recommendations: • Consider the proximity to a stockpile creating uneven ground when truck operators are attempting to tip a load. • Use level sensors to alert an operator or prohibit tipping on uneven ground. • Ensure tyre pressures are correct and the suspension system is in good condition. Refer to: SB17-01 Industry reports more truck rollover incidents SA03-01 Articulated dump truck rollovers

Hazard: velocity/inertia of vehicles. Risk: harm to people from the unexpected movement of mobile plant. Recommendations: The steering system is a safety critical system that is fundamental to the safe operation of mobile plant. • Steering systems should be maintained to achieve the highest degree of reliability over the mobile plant’s lifecycle. • Steering systems should be maintained in accordance with the original equipment manufacturer’s (OEM) information. • Assess steering failure risks by considering failure modes of steering systems. • Carry out daily prestart safety checks. • Mobile plant operators should be familiar with emergency procedures. • Install windrows as a mitigation control. Refer to: SB10-03 Mobile plant - safety critical systems SA06-12 Maintenance of safety critical systems - braking, steering and warning systems

Hazard: kinetic energy (velocity) of object. Risk: harm to people by being struck by a moving object. Recommendations: • Risks to health or safety at mines must be managed in accordance with clause 9 the Work Health and Safety (Mines and Petroleum Sites) Regulation. The risk assessment should identify hazards associated with the operation of mulchers and identify the controls required to manage the risks. • Mulchers should have guards that prevent objects being ejected, as well as preventing people being drawn into the mulcher. • Mulchers should only be used on material as specified by the OEM and in accordance with the OEM information. Refer to: SafeWork NSW code Managing the risks of plant in the workplaceHazard: gravity. Risk: harm to people from elevated structures falling. Recommendations: • Where mobile plant can pass under building infrastructure, height signs must be clearly displayed. • Where there is potential contact between the structure and the mobile plant the risk must be well managed. This may include access control systems such as height bars or dangle bars, adequate signage and other warning systems. • Truck operators should be trained on site traffic routes. Refer to: SA04-03 Dump truck trays hit overhead structures

Dangerous

Hazard: velocity/inertia of vehicles. Risk: harm to people from collision between heavy vehicles and light vehicles. Recommendations: This incident highlights the importance of having an effective risk management program in relation to the interaction of light and heavy vehicles at mine sites. It is also a timely reminder to ensure that workers are adequately trained and that the requirements of the roads or other vehicle operating areas principal hazard management plan are followed.• There should always be positive communications. • Light vehicles should give way to heavy vehicles. • Vehicle operators should be reminded of the risks of distractions while driving. •Consider using proximity detection and collision avoidance systems on light vehicles and heavy vehicles.• Consider separation of light vehicles and heavy vehicles on haul roads, where possible.Refer to: Investigation into a fatal collision at Ravensworth open cut mine on 30November 2013

Hazard: velocity/inertia of vehicles. Risk: harm to people from collision between mobile plant. Recommendations: • When mobile plant is operating in close proximity, operators should remain in continual communication and maintain an awareness of the other’s position. • Workers should be trained in sitespecific procedures. • Regular site safety observations should be performed by supervisors to ensure compliance with site procedures. • The use of cameras may assist operators by alarming encroachments. • When reversing mobile plant, operator should check down both the left and right sides.

Hazard: chemical reaction Risk: harm to people from a flammable gas fire/explosion. Recommendations: • Review procedures for drilling into a hard strata where there is potential for gas. • Review should consider ‘wet hole’ drill as a control for reducing the drill tip temperature. • Drill operator training should include any detected gas comes from a reservoir of an unknown quantity • A gas fire underground is a dangerous incident - it requires scene preservation and immediate notification. For guidance on reporting refer to the notification of incident andinjury guide.

Hazard: velocity/inertia of vehicles. Risk: harm to people from collision between mobile plant. Recommendations: Principle hazard management plans for Roads or other vehicle operating areas should consider factors that may affect operator visibility or ability to control a vehicle: o fog, sunlight, storms or dust o fatigue o slippery road conditions o obstructions that affect lines of sight. • Vehicle operating areas should have fit-for purpose barriers such as bunding or windrows to prevent uncontrolled vehicles going over embankments. • Drivers should be reminded to travel at speeds suitable for the conditions.

Recommendations: • Operators and passengers in vehicles should always keep body parts inside vehicles. • Vehicles should be operated with the windows up. • Supervisors should monitor compliance with mine rules for operating vehicles. • Mines should have ‘windows up’ policy on light vehicles. • Mines should have good systems to communicate a change in road conditions to vehicle operators.

Recommendations: • Where fixed guards are used to prevent people from falling or moving objects: o the maximum aperture size of the guard should be less than the object size o the guard should have sufficient strength to withstand the load imposed by the falling or moving object. • Risk assessments should consider the potential for falling/flying objects. • Safety glass should be considered for all windows on vehicles. • Mines should check rear window guards on tip trucks for this risk. Refer to: AS 4024.1601 Safety of machinery - Design of controls interlocks and guarding – Guards - General requirements for the design and construction of fixed and movable guards.

Recommendations: • Maintenance strategies for braking systems on mobile plant should consider all potential failure modes of the braking system, including faults on on wiring systems • Braking systems should be inspected, tested and maintained in accordance with the original equipment manufacturer’s recommendations. • Wiring systems must be fitted with short circuit protection and over current protection (refer to clause 32(2)(n) WHS(MPS) Reg) • Safety critical electrical wiring systems should be designed so faults, including short circuits between different circuits, do not cause unintended operation of machine functions. Refer to: SB10-03 Mobile plant - safety critical systemsSA06-12 Maintenance of Safety Critical Systems - Braking, Steering & Warning SystemsMDG 15 – Guideline for mobile and transportable equipment for use in mines

Recommendations: • Fixed barricading: signs should be provided to prevent access to unsafe areas such as auger holes in the floor. • Consider the use of ‘sleeving’ that extends above the maximum water level so the location of the hole is visible. Refer to: Investigation report – Cobar CSA drowning Report into the death of an underground mine worker

Recommendations:• Plant should not have sharp edges in areas where people may make contact with the plant.• Repairs to equipment should be assessed at their conclusion for the introduction of any new hazards. Inthis case, sharp edges were left after grinding and when the pump was relocated exposed the person to the hazard.

Recommendations: • Ensure windrows are installed and are of sufficient height to stop mobile plant if it becomes uncontrolled. • Review haul road design and site compliance with design rules. • Remind operators to drive to conditions. • Ensure positive communication of changed road conditions, such as wet roads. • Implement fatigue management arrangements and periodically assess for effectiveness.

Recommendations: • Good maintenance practices are essential in preventing the ignition of combustible fluids from hose or pipe failures. • Where practicable, hoses should be segregated from hot surfaces using hard barriers along with the use of non-flammable coolants. Refer to: AS 5062:2016 Fire protection for mobile and transportable equipment.

Recommendations: • Tyre manufacturers should be engaged to assist with identification of causes of tyre failure. • Regular visual inspections of tyre sidewalls should be done to identify bulges, bubbles, cuts or other damage to ensure risk from tyre failure or blowouts is minimised. Refer to: AS 4457.2-2008 : Earth-moving machinery - Off-the-road wheels, rims and tyres - Maintenance and repair - tyres

Recommendations: • Before using hand-held grinders and polishers, where possible consideration should be given to using alternative tools. • Workers who use hand-held grinders and polishers need to be trained in their correct use and in the potential risks. • Appropriate personal protective equipment should always be worn. Consideration should be given to full face masks.• Hazard identification should be routinely performed before starting work. • Mines should periodically check contractor’s tools and work practices • Adequate supervision should be provided for contractors.

• Tipping areas need to be level without cross grade. • Use level sensors to alert an operator or prohibit tipping on uneven ground. • Ensure that tyre pressures are correct and suspension systems are in good condition. • Tipping areas should be stable and capable of withstanding the truck wheel pressures and should not be prone to subsidence. Refer to: SB17-01 Industry reports more truck rollover incidents SA03-01 Articulated dump truck rollovers

• Trucks should be travelling at appropriate speeds when doing U turns. • Turning areas should be flat with minimal cross grade. • Ensure tyre pressures are correct and suspension systems are in good condition. • Operator practices should be periodically checked. Refer to: SB17-01 Industry reports more truck rollover incidents

• Tradespersons should use correct lifting equipment when working on heavy machine components. • Original equipment manufacturer procedures should be followed. • Tradespersons should be competent in the activity being carried out and be trained for work on the particular type of plant.

• There should always be clear, positive communication between mobile plant operators when working in close proximity. • The size of designated work areas should be sufficient for the movement of mobile plant. • Reversing cameras and proximity detection devices should be used. • Sufficient lighting should be provided when working at night.

• Good maintenance practices are essential in preventing the ignition of combustible fluids from hose or pipe failures.• Where practicable, hoses should be segregated from hot surfaces using hard barriers along with the use of non-flammable coolants.Refer to:AS 5062:2016 Fire protection for mobile and transportable equipment.

• Ensure conveyor idlers are designed with the appropriate life for the intended duty. • Install carbon monoxide monitoring or particulates of combustion sensors to assist in the early detection of a fire. Use appropriate trigger action response plans. • Ensure that a water source is readily available to quickly extinguish a fire. • Check defected conveyor idlers in a timely manner and carry out conveyor inspections regularly. • Consider the recommendations in MDG 1032 and AS/NZS 4024.3611 Refer to: • Mechanical engineering control plan code of practice • MDG 1032 Guideline for the prevention, early detection and suppression of fires in coal mines • AS/NZS 4024.3611 Safety of machinery, Conveyors – Belt conveyors for bulk material handing is incorporated into the mechanical engineering control plan code.

A risk assessment must be carried out before a shooting activity occurs at a mine, refer to clause 9 WHS (MPS) Regulation. The risk assessment should consider, but not be limited to: • the proximity of people in the vicinity of a shooting activity • the potential for the fired slug to ricochet off objects and to unintended areas or parts of the mine.

• Articulated loaders should not be tipping on a cross grade when the bucket is lifted and the machine is articulated. • Pads and areas where LHD-type vehicles are required to tip should be checked as being suitable by a supervisor. • LHD vehicles should be operated within the OEM specified limits, including tipping lines for stability. • Training packages should be reviewed for all machinery to ensure that it includes the limitations of the machine. • Seat constraints fitted must be worn.

• Braking systems should be inspected, tested and maintained in accordance with the manufacturer’s information. Inspections should include checking that brake pedals can move easily and are free from contamination or material build-up. • Braking systems on shuttle cars hold registered designs. Design changes that affect safety must be registered. • Brake linkages should be designed taking into consideration environmental and ergonomic factors.

• Traversing gradients requires special care when operating dozers.• Dozer operators should carry out an inspection of an area before entering as part of their personal risk assessment.• Dozer operators should always wear seat belts.• Consider tilt alarms to alert operator when excessive cross grades occur.Refer to:MDG 28 Safety requirements for coalstockpiles and reclaim tunnels

• Panel equipment should not be stored in close vicinity to an intersection. • Hazard assessments should consider all activities such as the task of reversing fan trailers around the corner of intersections and uneven floor. • Consider previous shift job preparation. In this case the positioning of the panel feeder in the belt road just inbye of the intersection (not allowing access to tow the fan into) forced the fan to be reversed around the corner. • Ensure no go zones are established around mobile plant.

• Before working or fault finding on mobile plant, a thorough understanding of the brake system functionality is required. In this instance the park brake was not manually applied. • The park brake applied automatically, which meant it disengaged automatically.• Potential hazards associated with fault finding should be considered in a task hazard analysis (Eg ‘Take 5’) with controls identified.• Inspection, testing and maintenance on mobile plant should be done by competent people in accordance with the OEM information.

• Mine operators should review all maintenance procedures to include correct isolation. • Supervisors should complete planned task observations during maintenance work. • Maintenance personnel should fully understand and comply with work procedures. Refer to: MDG 41 Guideline for fluid power system safety at mines Mechanical engineering control plan code of practice

Where practicable, hoses should be segregated from hot surfaces using hard barriers. Review the controls in place to prevent onboard fires, especially associated with components with high surface temperatures (e.g. turbos) with the original equipment manufacturer (OEM) Good maintenance practices and housekeeping are essential in preventing the ignition of combustible fluids from hose, pipe and fitting failures. Refer to AS5062:2016 Fire protection for mobile and transportable plant

Consider impacts to infrastructure when planning blasts. Electrical infrastructure may require isolation.

Review the controls that are in place to prevent monorails from separating. This should include regular inspections of end connections for evidence of overloading or plastic deformation. Inspections also should include correct alignment and support.

Electrical protection systems must be designed and configured to detect and clear short circuits, including arc-faults. Review the inspection and maintenance of all electrical couplings depending on the use and environmental factors.

Review vehicle transport rules with regard to clear vision, adequate machinery lighting, signs and right of way.

All mobile machinery should be regularly inspected and maintained. Review the requirement for wheel stud indicators. All machinery operators have a responsibility to complete a pre-start inspection of a machine.

Mine operators should have systems in place that allow for recognition of changes to tasks resulting from damaged or defective equipment Supervisors should continually review hazard awareness of all workers, especially when equipment is damaged and how this can change its normal performance. Workers should always consider if they are placing parts

Mine operators should have systems in place that manage risks associated with equipment working in close proximity to other plant and structures When mobile plant is operating in close proximity, equipment operators should remain in continual communication and maintain an awareness of the other’s position. Workers should be trained in site-specific procedures relating to working in close proximity to other plant and structures. Regular site safety observations should be performed by supervisors to ensure compliance with site procedures. When reversing mobile plant, operators should check down both sides as well as to the rear of the equipment. The use of proximity awareness systems such ascameras and alarms may assist vehicle operators.Refer to:MDG 2007 - Guideline for the selection and implementation of collision management systems for mining

Mine operators should review the safe standing zones associated with drilling tasks.

Mine operators should ensure the following are in place for conveyor systems at their mine: • Conveyor pulleys are designed with the appropriate life for the intended duty. • Carbon monoxide monitoring or particulates of combustion sensors are be installed in appropriate locations to assist in the early detection of fire and heatings • Alarm set points and trigger action response plans should be developed that suit each installation • A water source is readily available to quickly extinguish a fire at any place along a conveyor belt • Conveyor inspections are undertaken regularly • Temperature for head and tail pulley bearings. Consider the applicable recommendations in MDG 1032 Prevention of coal mine fires and AS/NZS 4024.3611 Refer to: • Mechanical engineering control plan code of practice • MDG 1032 Guideline for the prevention, early detection and suppression of fires in coal mines • AS/NZS 4024.3611 Safety of machinery, Conveyors – Belt conveyors for bulk material handing is incorporated into the mechanical engineering control plan code.

Mine operators should review the preventive maintenance strategies relating to winder controls, including all field devices. This should include regular testing of all equipment and safety devices. Before resetting winder faults, a thorough investigation should be completed by a competent person. Mines should review winder risk assessment and operating procedures to ensure emergency scenarios are adequately addressed. This is especially important for scenarios where workers are in the cage when there is a failure of the winder control systems. Mines should review their emergency management plans to include if and when external rescue resources are notified and mobilised for different scenarios.

All mine operators should consider how they train workers on positional awareness and the potential hazards associated with lapses in concentration.

Mine operators should review their preventive maintenance inspection plans for machinery that has a battery system on board as to the standard of how the battery or batteries are retained. The potential hazards associated with electrical faults associated with batteries should be clearly conveyed to the workforce.

Mine operators should ensure: • where practicable, hoses are segregated from hot surfaces using hard barriers • mechanical protection and restraints for fluid conductors (hydraulic hoses or pipes) are inspected for rubbing and abrasion during maintenance inspections • appropriate maintenance practices and housekeeping are implemented to prevent the ignition of combustible fluids from hose, pipe and fitting failures. Refer to: AS5062:2016 Fire protection for mobile and transportable plant.

Mine operators should ensure appropriate controls are in place to: • prevent an ignition source • detect flammable gas • sufficiently dilute flammable gas.

Mine operators should review the: • appropriate time frame for the defect management of belt rollers and for the removal of spillage along a conveyor • consideration of belt roller life cycle through change management when conveyor speeds have increased. There is an increasing trend in the number of fires on underground conveyors. Key issues identified include: • the quality of inspections including inaccessible areas (eg behind guards, off walk side, etc) • the use of fit-for-purpose rollers and idlers for the location • roller management and the defect management system

Mine operators should ensure: • equipment operators are reminded to investigate any oil leaks and effect repairs and clean up to prevent fires from occurring • hydraulic oil level alarms or shutdown systems are considered to prevent significant loss of hydraulic oil that may result in equipment damage or fire.

Mine operators should review their procedures associated with the handling and transporting of pressurised gas cylinders.

Mine operators and contract companies should review how the assessment of hazards and the introduced controls are done when there is a change in the task that is not covered in the work procedure.

Mine operators should review how the hazards associated with heavy metal covers are controlled, especially lifting and securing against gravity.

Mine operators should review how hazards associated with machines operating on cross grades are assessed and controls are implemented. The assessment should include: • determination of the appropriate machine for the task • maximum cross grades for safe operation of equipment • ensuring that operator training addresses all controls.

Mine operators should review their park-up procedures and how supervisors are monitoring compliance with the procedures.

Good maintenance practices are essential in preventing the ignition of combustible fluids from hose or pipe failures. Consider guidance in Australian Standard 5062:2016 – Fire protection for mobile and transportable equipment. Truck operators should be trained to respond to a fire event (refer to MDG 15 Guideline for Mobile and Transportable Equipment for Use in Mines): • stop the machine safely • shut down all power and the apply park brake • activate the fire suppression system • initiate the mine’s emergency response.

Mine operators should review how hazards associated with operating articulated vehicles are assessed and ensure operator training includes these controls, especially associated with movement of water.

Mine operators should review how inspections of conveyors are completed to ensure all parts of the conveyor are compliant. Mine operators should ensure workers notify supervisors of potential hazards in a timely manner.

Mine operators are reminded to review: • mechanical protection of fluid conductors (hoses) of fuels or oilsrubbing and abrasion of cables and fluid conductors• clamps and fixings of cables and fluid conductors• segregation and separation of mechanical services and electric cables and devices• location of and value of maximum surface temperature• location of fire suppression activation points• fire risk assessment• compliance with Australian Standard5062:2016 – Fire protection for mobileand transportable equipment.

Mine operators should ensure hoses and cables are adequately supported to reduce loads on hose end fittings, particularly where suspended over pedestrian accesses. Manufacturers of hose assemblies should review assembly and proof testing procedures as part of their quality systems.

Mine operators are reminded of the importance of inspections and maintenance of conveyor belts and idlers for the prevention and early detection of fires. Operators should review the effectiveness of: • automatic fire detection systems • condition monitoring programs • inspections for the detection of overheating idlers and rollers. Refer to: Mechanical engineering control plan code of practice clause 5.2.1

Mine operators using articulated dump trucks should: → ensure prestart checks include inspections of tyres for defects → tyres are at correct operating pressures → tyres are changed at the appropriate wear limit → tyres are not operated above original equipment manufacturer recommendations of load or Tkph → roads are maintained to reduce the likelihood of punctures to as low as is reasonably practicable.

Mine operators who conduct abrasive blasting (or manage contractors who conduct abrasive blasting) should: → review the code of practice for abrasive blasting issued by SafeWork NSW → ensure abrasive blasting equipment is compliant with requirements of the code of practice, including deadman controls to be under the direct control of the operator.

Mine operators should review the effectiveness of inspections of older work areas for stability of wall and roof material that may degrade over time.

Mine operators should review the critical controls in their strata failure management plans to identify and quickly respond to any areas of concern. Some mines have implemented a strata defect system including trigger action response plans (TARPs), which specify a timely response. This system is considered good practice and has reduced the incidence of roof falls at these operations. It is important that all personnel are familiar with the TARPs. They should understand the action that need to be taken if a change is detected.

Mine operators should: → consider the position of workers when loads are being moved. This should include no-go zones → ensure that adequate supervision is present when workers not familiar with site-specific procedures are performing work → ensure workers are appropriately trained in assessing risks associated with every task → ensure that equipment is regularly maintained and is fit for purpose.

Mine operators should: → review how strata inspections are undertaken after weather events. → consider the location of roadways in relation to the base of high walls.

Following a fire on mobile plant, mine operators should: → conduct a thorough investigation by a competent person to determine the cause of the fire, fuel sources and heat sources, surface temperatures and controls to prevent reoccurrences → assess and repair fire-affected areas of the plant before returning to service → train workers to identify fire risks such as fuels or oil leaks or worn hoses → review the fire risk assessment for the item of plant → report the issue to the OEM

Mine operators should review work procedures that could include the hazards associated with objects falling from height.

Mine operators should review how hazards associated with unloading trucks are assessed. Spotters should also be considered when loading and unloading trucks.

Workers are reminded to keep their hands clear of nip points and edges where objects could unexpectedly fall or close causing a crush injury.All mine operators should review their procedures associated with the introduction to site of contractor’s equipment. All contractors should review how their equipment is maintained in a compliant state.

Mine operators should maintain and adjust alignment of drill heads and carousels for return of drill pipe to minimise the risk of decoupling when unsecured. Inspections of mobile plant should be plant model specific and include alignment and wear in drill masts and guides where applicable.

Mine operators should review how hazards associated with the potential change in workloads are assessed and controlled.

Mine operators should review how the hazards associated with machine interaction are controlled. Such a review should consider: → positive communications→ proximity detection technology→job design (segregation)→planning

Mine operators are reminded to review:→ mechanical protection of fluidconductors (hoses) of fuels or oils→ rubbing and abrasion of cables andfluid conductors→ clamps and fixings of cables and fluidconductors→ segregation and separation ofmechanical services and electriccables and devices→ location of and value of maximumsurface temperature→ location of fire suppression activationpoints→ compliance with Australian Standard5062:2016 – Fire protection formobile and transportable equipment.

Mine operators should review maintenance procedures including adjustments lifecycle management of drive belts in accordance with manufacturer's recommendations on fixed plant installations

Mine operators should review how roads, especially ramps, are watered and howoften they are inspected for “dry lines”. They should also review how statutoryofficials communicate and correct potential hazards.

Mine operators should review how compliance with road rules is assessed,especially leading into holidays or end of rosters.

Mine operators should review how employees and contractors assess the change in risk when there is a change in working conditions.

Mine operators should review how potentially flammable materials, includingglues are assessed. They should also review “No Go Zones” around and abovesuch hot work areas.

Mine operators should review their preventative maintenance inspections for electrical cables to prevent shorts and arcing related fires. The review should include: inspections for cable and sheathing damage lifecycle management (age of replacement) for cables.

Mine operators should ensure defect reporting and pre-start inspections are being used effectively to maintain safe operating plant. Safety critical systems such as braking and steering systems should be inspected, maintained and tested in accordance with the manufacturers recommendations.

This incident is currently being investigated by the Resources Regulator.

This incident is currently being investigated by the Resources Regulator.

Mine operators should review park-up procedures with operators for specific plant with operators. Safety critical systems such as braking and steering systems should be inspected, maintained and tested in accordance with the manufacturer’s recommendations.

Mine operators should review:→ procedures associated with watercarts wetting roads and theappropriateness of dry lines→ how wet roads are assessed for use→ how hazards associated with wetroads are communicated.

The frequency of maintenance should be addressed and change-out of hosesneeds to consider the application and duty cycle of the hose.

Mine operators should review their machines against AS 1657 Fixed platforms, walkways, stairways and ladders - Design, construction and installation and against the original equipment manufacturer’s (OEM) design. Review: • Safety alert SA14-05 Mine worker injured after falling from grader access ladder• IIR Worker seriously injured in fall from articulated dump truck.Mine operators should implement systems that verify that workers follow the procedures provided when setting up for jobs. Any major change to work practicesshould follow a change management process, which includes communicationand training of the workforce.

Mine operators should engage with OEMs to investigate methods of reducing the surface temperatures of engine components. Mine operators should review theirmaintenance and pre-use inspections to include all components of hydrauliccircuits that can practically be inspected.

Mine operators should review the potential access to any old underground adits on site and potential for gasses to layer in gullies and old box cuts The adequacy of seals for old underground mine workings should also be reviewed.

Mine operators should review their dumping procedure, especially hazards associated with reversing up a stockpile around unconsolidated ground.

Pre-task job assessments must be undertaken before the commencementof any task.

Mine operators should review their procedures for appropriate ventilation tocontrol flammable gas. Mine operators should also review their procedures associated with drilling relating to how flammable gas is detected and controlled.

Incident investigations are ongoing. This incident is a reminder for all driversand operators of trucks and heavy vehicles to drive to conditions.

A section 195 notice was issued to the mine to prevent workers from going underground. Mine operators should review: → procedures for appropriate ventilation to control flammable gas→ how areas of potentially flammable gases are identified and controlled→ their broad-brush risk assessments to determine if frictional ignitions area principal hazard for the mine.

Mines should communicate the incident through site communication and check that grease points and greasing equipment is serviced, maintained and free from mechanical damage.Lessons that should be communicated through tool box talks including:→ compliance with correct parking procedures→ being situationally aware of hazards.Mine operators should consider:→ audible warning systems and/or visual alarms that warn of the lack ofpark brake application→ interlocking that automatically applies the park brake when the operator leaves the operator’s position (i.e. door interlock). Functional testing of park brake application warning systems.→ the recommendations in safety bulletin SB13-02 Unplanned movements of vehicles - too many near misses.

The incident investigation for the root cause is ongoing, although it appearsto be electrical.→ The incident should be communicated at site tool box talks.→ Operators should ensure they are familiar with isolation and emergency procedures.

Mine operators and people in control of plant with dump bodies should reviewengineering controls to prevent the vehicle being driven with the dump bodyin the raised position. Interlocks and warning alarms are potential controlsconsidered to be reasonably practicable.

Mine operators should review how statutory officials and supervisors monitor compliance to all mine rules and procedures.

Mine operators should review:→ how hazards associated with any task are assessed→ the quality of inspections that are completed post-task for new hazards that have been inadvertently introduced to the work area.

The fire appears to have been caused by hydraulic oil making contact with hot exhaust components. There was a hose failure from rubbing abrasion. → Mine maintenance personnel should be vigilant when conducting inspections to inspect hoses for evidence of rubbing and abrasion or missing clamps or fittingsMine operators should inspect high pressure cleaning equipment to ensure the hose, connection fittings and lance (gun) are assembled correctly from original equipmentmanufacturer (OEM) recommended and rated components.→ Hose-to-gun connection should contain a swivel connection or methods to prevent the connection from becoming unscrewed if twisting occurs in the hose.

→ Vehicle operator controls such as clutch, brake and throttle pedals should be inspected and maintained to operate effectively. → Drivers should report defective controls through pre-use inspections.

Investigation of this incident should highlight to mine operators that traffic management plans should include: → Operational risk assessments should be completed on all new plant to ensure the level of risk is not increased. → Positive communications process should be used at mines for all vehicle interactions. → Mine operators should review how statutory officials and supervisors monitor for compliance to mine rules and procedures.

Principle hazard management plans for roads or other vehicle operating areas should consider factors that may affect operator visibility or ability to control a vehicle: → Fog, sunlight, storms or dust obstructions that affect lines of sight. → Vehicle operating areas should have fit-for purpose barriers such as bunding or windrows to prevent uncontrolled vehicles going over embankments. → Drivers should be reminded to travel at speeds suitable for the conditions.

Mine operators should review what controls are in place for manual handling tasks that are carried out regularly.

→ Operators of truck-mounted cranes should be trained and competent in the deployment and stowage of the crane. A specific sequence and procedure may be required depending on the make and model type.→ Mine operators should review what training their statutory officials and supervisors have received in the requirements to preserve a scene after a notifiable incident.

Mine operators should review the following in relation to this incident: → Ensure operators are trained in the use of the specific vehicle type. → Operators in training should be supervised according to their level of experience. → Communication systems such as two-way radios should be checked for correct operation during pre-start checks.→ Truck suspension systems should be maintained and without defects to operate as intended. → Tipping areas should be flat or within specified limits for the truck. → Warning devices should be supplied for operators if the truck breeches cross grade limits. → Review SA04-24 Dump truck tip

Mine operators should review their fatigue policy and how it is complied with on site. Mine operators should review haulage road risk controls (bunding; guard railing etc) and to ensure they are adequate.

Mine operators should review: → training and confirm that workers understand their obligations to report incidents at the time of the event. → electrical control plans to ensure that workers conduct quality pre-use checks to all equipment before it is used.

Mine operators should review their site security controls to prevent unlawful trespassers. They should take into consideration that the general public may not be aware of the potential hazards of a mine site.

Mine operators should review: → how the potential hazards associated with a blocked discharge hose/pipe are recognised and controlled. → the direction that bleed valves discharge

Mine operators should review suitability of structural integrity and inspection programs for areas of high vibration and/or corrosion.

In relation to hydraulic systems and equipment, mine operators should ensure: → case drains and return lines are installed as per design drawings → workers have adequate information, training and competencies for the task → commissioning activities and checks for maximum working pressure, relief settings, flows etc are completed.

Refer to the recommendations in SA18- 03 Two workers suffer serious fluid pressure injuries in separate incidents

Mine operators and contracting companies should review procedures associated with the installation of roof bolts to ensure all potential hazards have been considered and appropriate controls have been introduced. Mine operators should review how their workforce have been trained in task hazards awareness.

All mine operators should review: → how a change in road conditions are communicated to all the workforce. → how statutory officials monitor change and their corrective actions to change.

Mine operators should review how planned tasks capture all potential hazards when assessing a task. Consideration should also be given to the expertise of those involving in assessing the task

Mine operators should review any previous industry incidents, not just site incidents associated with a piece of plant, machinery or task. This should also be considered when developing a lifecycle management plan for plant or machinery.

Mine operators should review: → if they have considered the potential change in risk when there is a change from normal production tasks → that their current trigger action response plans (TARPs) achieve a proactive result.

Mine operators should be competent to work on hydraulic systems including assembly of fittings and sealing components. → Mechanical protection and safeguards should be used to mitigate the risk of release of hydraulic fluid pressure should also be used as far as reasonably practicable. Further information can be found in MDG 41 Fluid power system safety.

Mine operators should review their training procedures for new starters and the detailed instructions and procedures that are provided.

Mine operators should review their stockpile ramp design and construction to ensure there is sufficient width and grade to achieve safe access.

Good maintenance practices are essential to preventing fires on mobile plant. Heat shields and lagging designed to prevent combustible materials from contacting very hot surfaces must be regularly inspected and maintained. Maintenance practices should also include securing loose combustible items such as rubber door seals to prevent contact with hot surfaces.

Mine operators should conduct thorough service and inspection activities prior to returning equipment to service. Service points and connections subject to vibration of compressed air systems should be checked and installed in accordance with manufacturers recommendations, such as torque specifications, lubrication, thread locking and sealing compounds.

Mine operators should make repairs in accordance with OEM recommendations or make alterations only under an appropriate engineering change management system. Repairs not made to original specification can introduce hazards previously engineered out.

Mine operators should reinforce the importance of correct parking procedures with operators of heavy mobile plant and equipment to ensure they are fundamentally stable, and that park brakes are applied. Warning devices such asalarms or interlocks provided to ensure park brakes are applied prior to exiting thevehicle should be regularly tested or inspected to ensure operational effectiveness.

Mine operators should reenforce the importance to complete every task as per the procedure in place for the task. Mine operators should highlight that every task takes time. Rushing or taking shortcuts can create unexpected hazards.

Mine operators should review how hazards communicated to the workforce are correctly controlled in the workplace. Areas of risk in a construction site should be demarcated to ensure people are aware of structures. Mine operators should also review how supervisors ensure compliance with procedures.

Effective no-go zones were a critical control in this incident. Mine operators should engage supervisors and workers to uphold compliance with no-go zones.

Mine operators and contractors working with high pressure portable apparatus should ensure that: → pre-use inspections are available for workers → pre-use inspections address both mechanical and electrical safeguards → guarding such as hose sleeves, metal or flexible covers should be considered for all parts of the equipment where there is potential hazard of fluid release due to the failure of hoses, fittings and seals. → provisions are made for the torque wrench to remain stable while the operator uses a remote control device at a safe distance f

Mine operators should review how workers are trained and assessed in recognising when a critical control is not in place or to the correct standard, such as windrow design. Mine operators should review how their supervisors monitor critical controls and actions to be taken where critical controls are identified as being inadequate.

Mine operators should review how workers and supervisors are trained in recognising the potential hazards associated with all energy sources. This is especially important when there is the potential for an unexpected stored energy associated with blockages to be released without warning. This is the third similar incident within a short period: 1. Mud / slurry pump - blocked delivery. 2. Air pump – blocked delivery. 3. Airline – blocked outlet. All workers involved were in the ‘line of fire’.

Mine operators should review the life cycle management of wheel bearings for the operating conditions at their mine including: → when trucks are operated within the gross vehicle limits by the manufacturer → axle loads (front versus rear) are within the limits recommended by themanufacturer→ wheel bearings are being maintained and replaced in accordance with themanufacturer’s recommendations.

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