An analysis of equipment-related

fatalities in U.S. mining operations

Dr. Vladislav Kecojevic

Massey Foundation Professor of Mining Engineering,

West Virginia University, United States

XVII International Seminar on Safety in Mining Operations, Lima, Peru, April 24-26, 2013.
 Outline
 Background on U.S. mining fatalities

 Mining equipment-related fatalities

 Risk assessment of equipment-related

fatalities

 Safety program by the Mine Safety and Health

Administration (MSHA)

 Leadership safety message

Number of fatalities in U.S. coal, metal and non-metal mines per
year (source of data: MSHA, 2013)
Total number of fatalities: 1995 - 2012 (source of data: MSHA, 2013).
Total number of fatalities: 1995 - 2012 (source of data: MSHA, 2013).
 Total number of fatalities in surface and underground mining
(1995-2012): 998

 The highest number of fatalities is attributed to the general

category of Equipment (660 or 66.1%).

 Equipment: MSHA classification (machinery, powered

haulage and hoisting).

Source of photo: MSHA Source of photo: MSHA

Equipment-related fatalities: 1995 - 2012
Miscellaneous Equipment

Source of photos: MSHA

Miscellaneous Equipment

crusher

Source of photos: MSHA

Miscellaneous Equipment

Source of photos: MSHA

 Haul Trucks

Number of fatalities for haul trucks: 1995 - 2012

(123 in surface mines out of 144 in total)
 Front-end Loaders

Number of fatalities for front-end loaders: 1995 – 2012

(45 in surface mines out of 53 in total)
 Dozers

Number of fatalities for dozers: 1995 – 2012

(34 in surface mines out of 40 in total)
 Belt Conveyors

Number of fatalities for belt conveyors: 1995 – 2012

(48 in surface mines out of 60 in total)
 Drilling Machines

Number of fatalities for drilling machines: 1995 – 2012

(16 in surface out of 23 in total)
 Establish hazards
 Analyze risks
 Evaluate risks
 Data Collection
 MSHA investigation reports which are publicly accessible
from the MSHA web site.

 Historical fatality data for the period from 1995 through 2006.

 A typical report is approximately ten-pages long and contains

the age and work experience of the victim, a description of
the fatality investigation, discussion, root cause analysis, and
conclusions.
 Haul Trucks

Note: two fatalities are caused by unknown hazard.

Hazard “Failure of victim to respect haul truck working area”
Source of photo: MSHA
Hazard “Failure of victim to respect haul truck working area”
Source of photo: MSHA
Hazard “Failure of victim to respect haul truck working area”
Source of photo: MSHA
Hazard “Failure of mechanical/electrical/hydraulic components”
Source of photo: MSHA
Hazard “Failure to set parking brake/chock when leaving the truck”
Source of photo: MSHA
Hazard “Failure to control truck”

Source of photo: MSHA

Hazard “Failure to give warning before moving truck”

Source of photo: MSHA

Hazard “Failure to use safety line while working on the truck bed”

Source of photo: MSHA

Hazard “Failure to recognize adverse site/geological conditions”

Source of photo: MSHA

Hazard “Failure to recognize adverse site/geological conditions”

Source of photo: MSHA

 Source of photo: MSHA

Hazard “Failure to provide adequate berm at dump sites or haul roads”

 Source of photo: MSHA

Hazard “Failure to provide adequate berm at dump sites or haul roads”

Hazard “Failure to provide adequate berm at dump sites or haul roads”

Source of photo: MSHA

Hazard “Failure to maintain safe distance from power lines”

Source of photo: MSHA

Hazard “Failure to lower truck bed after dumping”
Source of photo: MSHA
Hazard “Failure to switch on head lights” Source of photo: MSHA
Drilling Machines
 Source of photo: MSHA

Hazard “Failure to identify adverse site/geological conditions”

 Source of photo: MSHA

Hazard “Failure to control equipment”

 Source of photo: MSHA

Hazard “Failure to follow adequate maintenance procedure”

Belt Conveyors
 Source of photo: MSHA

Hazard “Failure to provide adequate maintenance procedure”

Hazard “Failure to follow adequate maintenance procedure”

Source of photo: MSHA

 Source of photo: MSHA

Hazard “Failure to follow adequate maintenance procedure”

 Source of photo: MSHA

Hazard “Failure to provide safe crossing facility”

 Source of photo: MSHA

Hazard “Failure of mechanical components”

Front-end Loaders
 Source of photo: MSHA

Hazard “Failure of mechanical/electrical/hydraulic components”

 Source of photo: MSHA

Hazard “Failure to set parking brake before leaving equipment”

 Source of photo: MSHA

Hazard “Failure to identify adverse site/geological conditions”

 Source of photo: MSHA

Hazard “Failure to provide adequate sign/signal”

 Dozers

Note: two fatalities are caused by unknown hazard.

Hazard “Failure to control equipment” Source of photo: MSHA
 Source of photo: MSHA

Hazard “Failure to control equipment”

Hazard “Failure to identify adverse site/geological conditions”
Source of photo: MSHA
 Source of photo: MSHA

Hazard “Inappropriate task for equipment”

 Severity and Probability of equipment-related
fatalities

Severity S - judged from the total number of fatalities

associated with the hazard in the twelve-year study period.

Hazard Severity Classification

Severity Definition
High Associated with more than 12 fatalities in the examined years
Medium Associated with 6-12 fatalities in the examined years
Low Associated with less than 6 fatalities in the examined years
 Severity and Probability of equipment-related
fatalities

Probability (Pr) - the likelihood that the hazard will contribute

to a fatality - calculated as the number of years in the study
period in which a fatality was attributed to a given hazard
divided by the total number of years.

Hazard Probability Classification

Probability Definition
Almost certain Fatal incident will occur with a probability of Pr = 1.00
Very likely Fatal incident will occur with a probability of 0.50  Pr < 1.00
Likely Fatal incident will occur with a probability of 0.16  Pr < 0.50
Possible Fatal incident will occur with a probability of Pr < 0.16
 Haul Trucks

Belt Conveyors
Front-end Loaders

Dozers
Risk Matrix: Haul Trucks
Risk Matrix: Belt Conveyors
Risk Matrix: Front-End Loaders
Risk Matrix: Dozers
 Risk Matrix: Drilling Machines

 Risks are ranked according to their probability and

severity in a relative manner rather than in an absolute
form. It helps avoid underestimating or overestimating
risks involved in this assessment.
 Age of victim and number of fatalities
(surface and underground equipment)

Note: 92 reports have no record

 Mining experience and number of fatalities
(surface and underground equipment)

Note: 85 reports have no record

SLAM Program
by MSHA
Current Project: Integrated Surface Mining Safety System
 Establish information management system for real-time
situational awareness.
 Provide a non-distractive User Interface for equipment
operators/drivers and an integrated, informative console for mine
operation management.

Speeding – Seat Belt – Reduced Visibility – Critical Intersections –

- Mandatory Maintenance – Headlights – Illuminations on the Site –
- Non-invasive Eye Detection and Tracking for Drivers Fatigue –
- Proximity Warning System
"We can no longer run our mines with
an unspoken assumption that a
certain number of accidents are
simply inherent in our business. You
want that number to be zero, and the
public wants the number to be zero.
And we must all make it our business
to see that this happens."

J. Brett Harvey, President and CEO of Consol Energy

“Safety of workers trumps everything we do
including production and profit.”

J. Brett Harvey, President and CEO of Consol Energy

Our Ultimate Measure of Success
Sending Miners Home

Every Day ……… Every Shift

Thank You !
 References

Kecojevic, V., Komljenovic, D., Groves, W., Radomsky, M.

(2007). An Analysis of Equipment-Related Fatal Accidents in
U.S. Mining Operations: 1995-2005. Safety Science. Vol. 45,
Issue 8, pp. 864-874, Elsevier.

Groves, W., Kecojevic, V., Komljenovic, D. (2007). Analysis

of Fatalities and Injuries Involving Mining Equipment. Journal
of Safety Research. Vol. 38, Issue 4, pp. 461-470, Elsevier.

Komljenovic, D., Groves, W., Kecojevic, V. (2008). Injuries in

U.S. Mining Operations – A Preliminary Risk Analysis. Safety
Science. Vol. 46, Issue 5, pp. 792-801, Elsevier.
 References
Md-Nor, Z.A., Kecojevic, V., Komljenovic, D., Groves, W.
(2008). Risk Assessment for Haul Truck-Related Fatalities in
Mining. SME Mining Engineering, Vol. 60, No. 3, pp. 43-49,
Society for Mining, Metallurgy, and Exploration.

Md-Nor, Z.A, Kecojevic, V., Komljenovic, D., Groves, W.

(2008). Risk Assessment for Loader- and Dozer-Related
Fatal Incidents in the U.S. Mining. International Journal of
Injury Control and Safety Promotion, Vol. 15, No. 2, pp. 65-75,
Taylor & Francis.

Kecojevic, V., Md-Nor, Z.A, Komljenovic, D., Groves, W.

(2008). Risk Assessment for Belt Conveyor-Related Fatal
Incidents in the U.S. Mining Industry. Bulk Solids & Powder
Science & Technology, Vol. 3, No. 2, pp. 63-73. Vogel
Transtech Publications.