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HSA Bulletin REPRINT September 1996

Analysis of surface poweredhaulage accidentsJanuary 1990 to July 1996

HSA Bulletin REPRINT September 1996

1Analysis of surface poweredhaulage accidentsJanuary 1990 to July 1996

George M. Fesak, Director, Program Evaluation and Information ResourcesRodric M. Breland, Chief, Safety Division, Metal and Nonmetal Mine Safety and HealthJack Spadaro, Mining Engineer, Program Evaluation and Information Resources

Mine Safety and Health Administration, U.S. Department of Labor, Arlington, Virginia

AbstractThis report addresses surface haulageaccidents that occurred betweenJanuary 1990 and July 1996 involvinghaulage trucks (including over-the-road trucks), front-end-loaders,scrapers, utility trucks, water trucks,and other mobile haulage equipment.The study includes quarries, openpits and surface coal mines utilizingself-propelled mobile equipment totransport personnel, supplies, rock,overburden material, ore, mine waste,or coal for processing. A total of4,397 accidents were considered.This report summarizes the majorfactors that led to the accidents andrecommends accident preventionmethods toreduce thefrequency ofthese accidents.

IntroductionInformation forthis report wasgathered fromMine Safety andHealth Adminis-tration (MSHA)AccidentInvestigationReports, accidentand injury datasubmitted bymine operatorson MSHA Form7000-1, andother studiesconducted byMSHA and theU.S. Bureau of

Mines. All powered haulage accidentsinvolving self-propelled mobileequipment used in surface miningactivities were initially considered.This report, however, is limited tosurface haulage lost time accidentsassociated with water trucks, front-end-loaders, tractor/scrapers, orecarrier/large trucks, ore haulagetrucks, or other utility trucks. Adetailed study of 1,300 truck haulageaccidents is the primary focus of thisreport. Of the 1,300 truck accidentsreviewed, 640 resulted in traumaticoccupational injuries such as severecuts, broken limbs, internal injuries,or burns. During the six and one-halfyear period, 139 fatal accidents

occurred involving surface mobileequipment. Seventy-two of theseinvolved trucks hauling ore, coal, orwaste rock. Another 24 involvedutility trucks, such as maintenancevehicles and water trucks. This paperhighlights some of the critical factorsthat contributed to the occurrence ofthese surface haulage accidents andthe severity of the injuries suffered.

The report discusses each factor,with recommended actions for acooperative safety program involvinginspectors, miners, mine operators,maintenance personnel, equipmentmanufacturers, and mine engineers.The combined resources of MSHAand the mining industry can develop

Roads/Control Dumping Mechanicalfailure

Berms Visibility Loading/unloading

Repairing

Contributing factors—surface haulage accidents, Jan. ’90–Jul. ’96

Factors

250

200

150

100

50

0

INJURIES

HSA Bulletin REPRINT September 1996

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Coalstrippingoperation inKemmerer,Wyo.

A Cat TS475-41working forR.E. Hazard inSan Diego,Calif.

a comprehensive safety program toreduce the number and severity ofpowered haulage accidents at surfacemines.

Steep haulroad gradientsA total of 640 accidents involvingsurface truck haulage equipmentresulted in traumatic injuries orfatalities. Of these accidents, 117occurred on road gradients exceeding7%. A total of 36 fatalities occurredwhere haulroad gradients rangedbetween 8% and 23%. Although roadgradients were not the specific causeof these accidents, the severity ofaccidents caused by broken driveshafts, failed brakes, or overloadedtrucks was increased when thevehicles operated on steep grades.Broken drive shafts or failed servicebrakes almost always caused aserious accident. Trucks with loadsexceeding recommended capacitiesseverely compromised the safeoperation of these vehicles. Generally,metal and nonmetal mining opera-tions use off-road haulage trucks,which travel empty into mine pits andquarries, and are loaded whenclimbing out of the pits. They do,however, use some of this sameequipment to haul water and othermaterial down into mine pits. Coal

mining operations frequently useover-the-road trucks, which aredesigned for highway travel, to haulcoal down steep mountain roads.

Inadequate haulage road designand construction has resulted insituations where equipment operators,truck drivers, and other workerswere operating on gradients muchsteeper than recommended by thehaulage equipment manufacturer.Some manufacturers failed to provideguidance on recommended loadlimits for mountainous grades sincethey design their equipment for over-the-road travel, which is regulated bythe U.S. Department of Transporta-

tion. Imprudent engineering,maintenance, and equipmentoperating practices place equipmentoperators and the surroundingworkforce at serious and unnecessaryrisk. Additionally, equipmentoperators who fail to follow appropri-ate traffic rules, do not perform pre-operational checks, disregard safedriving habits, or are inattentive totheir surroundings also place co-workers at great risk. As gradesincrease, payloads and/or operatingspeeds must decrease in order tooperate within the designed operatinglimits of properly maintainedequipment. Equipment which is notproperly maintained, however, is notsafe to operate on any grade.

In 1995, an 18-year-old minerwith 3-weeks experience was fatallyinjured when he lost control of awater truck (converted from a drilltruck) he was driving. The truck hada full 3,560 gallon tank and wastraveling down a haul road with anaverage grade of 8.43 %. In thissituation, inadequate truck brakesand a faulty transmission, combinedwith a steep road gradient and thedriver’s inadequate training andexperience, resulted in a tragedy.

Only six states currently haveregulations limiting the steepness ofhaulroad gradients at surface mines.There is no consensus among them

HSA Bulletin REPRINT September 1996

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Dumpingoverburden

as to maximum grade relative tooverall distance of roadways. Nor arethere general guidelines for correlat-ing equipment size or type with theloads that may be safely transportedover a particular grade. This problemneeds to be studied thoroughly sothat construction guidelines can bedeveloped that are applicable to thesurface mining operations of today.For such a study to be ultimatelybeneficial and useable by the miningcommunity, it must involve inputfrom mine operators, equipmentoperators, and equipment manufac-turers, along with their commitmentto abide by the findings.

Overloading andinadequate maintenanceand their role incontributing tomechanical failures ofbrakes, steering,transmissions, and drivelinesSome of the most frequent accidentsrecorded during the six and one-halfyear period under study were relatedto mechanical failures of brakes,steering, or drive systems. Theseproblems were sometimes aggravatedby overloading trucks and operatingtrucks on steep road gradients.Unfortunately, some accidentinvestigation reports do not containsufficient information concerningtruck weight capacity to determinethe relationship between loadcapacities and accident causes.

Mine operators, contractors, andequipment operators should recog-nize the hazards inherent in overload-ing haulage equipment, particularlyon steep road gradients. Brake,steering, and drive-train effectivenessare reduced dramatically when themanufacturers’ recommended loadinglimits are exceeded. Between January1990 and July 1996, 112 of the 640traumatic injury accidents werecaused by failure of the brake,steering, or drive-train systems.Twenty fatalities on surface haulage

equipment were directly attributed tothe failure of the vehicles’ brakingsystems. This was generally directlyrelated to poor equipment inspectionand maintenance practices.

Although there are a variety ofmaintenance guidelines or standardscurrently in use by the miningindustry regarding surface minehaulage vehicles, there are nouniform guidelines specific to theindustry that address maintenanceand use of off-highway haulageequipment. The Commercial VehicleSafety Alliance (C.V.S.A.) UniformNorth American Out-of-ServiceCriteria is sometimes used for over-the-road vehicle inspection andmaintenance programs at operationsthat use these type trucks. Thiscriteria is utilized in the 50 UnitedStates, Canada and Mexico. At manymine properties, manufacturersmaintenance guidelines are appropri-ately used. MSHA inspection experi-ence, however, has found that asignificant number of older haulageunits do not have manuals readilyavailable for equipment operators.

There are many mining opera-tions with well managed maintenanceprograms for surface poweredhaulage equipment. Their vehicles areroutinely inspected by equipment

operators and qualified mechanicstrained to maintain haulage equip-ment used at these mines. They alsoensure the equipment is operatedwithin it’s design capabilities. Suchgood practices should be encouragedthroughout the mining industry andshared through associations, seminarsand training programs for miners,mechanics, mine operators, engi-neers, and inspectors.

End dumping at edges ofdumps and fillsBetween January 1990 and July 1996,136 trucks and other haulagevehicles overturned while dumpingmaterial at edges of dump locations.This type of accident occurred morefrequently than any other. Twenty-five(25) fatalities were reported whiletrucks or other haulage equipment,such as front-end-loaders, werebacking up or end-dumping at edgesof elevated dump locations. Typicallythese locations were excess minespoil fills, waste rock dumps, orestockpiles, processed mine wastes, orvalley fills. Most frequently, thehaulage vehicle backed onto unstablefill material that gave way, or backedthrough a perimeter berm, causingthe vehicle to topple backward downthe slope or onto its side.

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A series ofphotos de-tailing afatality fromthe fall of ahaulage truckover a cliff andthe resultantdestruction.The progres-sion depicts anapproach viewfrom the top;the view frombelow showingthe face of thecliff and thedumping over-hang; the viewstraight downfrom the lip ofthe cliff; andtwo views ofthe completedamage to thevehicle.

Some dumping accidentsoccurred during evening or nightshifts. According to the accidentreports, the work areas wereinsufficiently illuminated for the truckdrivers to see the edges of the dumpswhen backing, and the trucks werebacked too close to the edges of theslopes. The truck operator’s ability toexamine the stability of dump edgesis also severely impaired when vision

is limited at night.In 1996, the 26-year-old driver of

a 190-ton haul truck was fatallyinjured when he traveled through aninadequate perimeter berm, on a258-foot high, 73% slope leachdump. The accident occurred in theearly morning hours, before daylight,and the dump was provided with asingle light plant. The victim was notwearing a seat belt and was thrownthrough the rear window of his truckafter it came to rest 444 feet at thebottom of the dump slope.

Dump locations require continualmaintenance to keep the bermsmaintained and the dump on a slightup slope. The practice of keeping thedump perimeter at a slight upgradeprevents natural water accumulationsfrom absorbing into the dumpperimeter which can create anunstable slope edge. Keeping abulldozer operating during dumpingoperations to maintain this slightupgrade and adequate dump berms isa prudent method of improving truckdriving safety where dumping overthe edges is utilized.

The practice of end-dumping overthe edges of dump locations shouldbe avoided when possible. Miningoperations that dump in this mannershould consider alternative methodsof disposing of rock or wastematerial. Some operations in themining industry dump material shortof the edges of dumps and then pushthe material with bulldozers or otherequipment

Improving truck driver controlduring backing operations bymodifying cab locations and designand rear-view mirror design shouldalso be explored. Additionally, truckdriver training should includethorough discussion and training indumping procedures. It appears thatmany operators need to focus moreand better attention on this area.

Traffic control, blind

spots, berms, and roadsurfacesA number of accidents reviewed inthe survey involved the control oftraffic through surface miningoperations, obstructed visibility, andthe maintenance of road surfaces andsafety berms.

Traffic controlTraffic control rules and safety signsare required at every mine siteregardless of size. Traffic controlrules, signs and markers that guidevehicles safely through the operationare essential to preventing accidents.Some of these operations haveconfusing traffic patterns, whichchange frequently because of miningactivities. These changes are notalways marked in a manner that minesupport personnel understand.Vehicle right-of-ways are normallyestablished at mining operations,however, it is not uncommon formaintenance vehicles to get in thepath of loaded haul trucks. Obviously,a more complex mining operationwith various mixtures of equipmentrequires a very careful analysis oftraffic patterns, signs and establish-ment of rules. Dispatchers should beutilized where the complexity of themining operation warrants.

Road bermsFifty-five (55) accidents occurredwhen trucks over traveled roadberms. Eight (8) fatalities occurredunder these circumstances. Steeproad gradients, berm constructionand maintenance, brake failure, andfailure to use seat belts were listed asfactors in these accident reports.Failure to use seat belts alwaysresulted in more serious injuries andin eight (8) cases fatalities.

Adequate berms or guard railingare required for all elevated roads onmining operations and have proven tobe effective means to reduce seriousaccidents. Road berms are neitherdesigned nor built to stop runawaytrucks. They effectively warn haulage

HSA Bulletin REPRINT September 1996

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The re-mains of a

vehicle thatwas crushedwhen it movedinto the blindspot of a largehaulage truck

equipment drivers about the closeproximity of roadway edges andproperly constructed can effectivelyimpede over travel from elevatedroadways. There are suitablealternative methods to earthen berms,such as guardrails and Jerseybarriers. The most appropriatemethods for the anticipated travel ona roadway should be used.

In 1994, a 50-ton haul truck withdefective service brakes was travelingdown a 17% grade, went through aberm and tumbled 55 feet to thebottom of an embankment. The truckdriver was not wearing a seat beltand died as a result of the accident.Blind spots

Forty-fix (46) accidents occurredwhen haulage truck driver vision wasobstructed due to the configurationor location of the cab. Fifteen (15)of those were fatal accidents in whichobstructed visibility from the drivers’cabs was determined to be asignificant factor in the cause of theaccident. Fifteen (15) of theseaccidents also involved large capacityhaulage vehicles running over smallervehicles and crushing them. All ofthese accidents were fatal. Eighty-seven (87) accidents occurred whenhaulage trucks ran into stationaryobjects, loading equipment, oranother haulage truck. Eight (8)fatalities occurred because of suchcollisions. Although some of thesecollisions may have occurred becauseof driver error, accident investigationsindicate that others occurred becausethere was poor communicationbetween truck drivers or there wasobstructed visibility between vehicles.

Driver error is used far too often toexplain away poor design or workprocedures.

Many trucks have zones in whichthe drivers cannot see the ground,other vehicles, or pedestrians fordistances greater than 100 feet fromthe driver’s seat. These “Blind-spot”hazards have caused or contributedto a large number of fatal accidentsduring the past six and one-halfyears. Haulage equipment manufac-turers, the Society of AutomotiveEngineers (SAE), and the miningindustry should initiate a cooperativeeffort to improve design of haulagevehicles and warning systems.Innovative cab designs, locations andinstallation of discriminating warningdevices, video cameras, and otherstate of the art “blind area surveil-lance systems” would greatly reduce“blind-spot” hazards. Fatalities thatoccurred where obstructed visibilityfrom the drivers’ seats existed mayhave been avoided with effectivediscriminating warning devices,cameras, mirrors or improved cabdesigns.

In 1995, a maintenance supervi-sor in a pick-up truck, following anoff-road haul truck with a disabledradio, was backed over by the haultruck after he stopped on a haulroadin the truck’s “blind-spot” area. Inthis situation individuals were awareof rules and procedures establishedby the mine operator, however, theywere not following them. The haultruck driver had stopped in an activeroadway to talk with an oncomingtruck driver about his broken radio,rather than returning to the shop orsome other safe location as requiredby company procedure. Also, themaintenance supervisor had stoppedwithin the “blind spot” area of thehaul truck, another violation ofestablished rules. Communicationswas also a factor in this accidentsince the haulage truck’s radio wasbroken and driver’s were improvis-ing.

In 1996, a 46-year-old electrician

was fatally injured when a 240-tonhaulage truck ran over the utilitytruck he was driving. The haul truckwas parked when the utility truckcame along the side of it. As the haultruck driver began pulling forward,he turned to the right and ran overthe electrician. The “blind-spot” tothe truck driver’s side was 73 feetand there was no side discriminatingwarning alarm on this truck.

Slick roadsSixty (60) accidents involving truckssliding on slick road surfaces werereported to MSHA. Five (5) of theseaccidents resulted in fatalities. Mineoperators should curtail or appropri-ately modify operations duringinclement weather when roadsurfaces become slick because ofsnow, freezing or wet conditions. Alloperations should have contingencyplans to activate when weather has anadverse effect on continued safeoperations.

Mine operators construct mineroads according to geographiclocation, traffic type, expectedweather conditions and frequency ofuse. Haul roads are not always builtwith adequate consideration forpotential adverse weather. Poordrainage and failure to properlysurface the roads often create veryslick road conditions duringinclement weather conditions.Additionally, mine operators some-times attempt to maintain dailyproduction goals when conditionshave deteriorated, which exposesminers to serious haulage hazards.

Communications,loading/unloadingmaterials,maintenance andrepair, and seatbeltsCommunicationsMost modern complex surface miningoperations have effective communica-tions systems in place to enhancedriver safety and the safety of the

HSA Bulletin REPRINT September 1996

6A 240-toncapacityhaul truck canbe loaded in 7or 8 passesfrom the 994loader with its21-cubic yardbucket.

vendors or contractors entering themining operations. Such goodpractices of communication shouldbe freely shared in the miningcommunity and regulatory agenciesand the practices should be adoptedthroughout the industry. Forty six(46) of the obstructed visionaccidents reviewed in the six andone-half year period may have beenavoided with adequate communicationbetween the drivers of vehiclesinvolved in the accidents and/or acentral dispatching operation. Poorcommunications and obstructedvision were determined to be aprimary cause in 15 of the fatalaccidents involving collisions.

Unsafe practices whilerepairing vehiclesSudden movement of vehicles beingrepaired resulted in eight (8)fatalities. Pressure to get equipmentback into service resulted ininadequate safety precautions duringsome maintenance and ended intragedy. For instance, unchockedtrucks rolled over mechanics workingbeneath them; several maintenancepersonnel were run over after pullingtheir work trucks into blind spotareas of other vehicles; victims fellfrom elevated access decks andengine compartments with oil spillson them; and maintenance personnelattempted to test equipment they werenot qualified to operate. Most ofthese accidents could have beenprevented if the mechanics andmaintenance personnel werethoroughly trained in the hazardsassociated with the sudden orunexpected movement of equipment.

In 1995, a 46-year-old mechanicwas fatally injured while working onthe exhaust system of a utility truck.He accidentally shorted the truck’sstarter solenoid and caused theengine to start, running the rearwheels over him. The truck’stransmission was in gear, the wheelswere not chocked, the battery wasnot disconnected, and the parking

brake was not set. A change in any ofthese factors would likely haveprevented this tragedy.

Safety practices whileloading/unloadingmaterial/suppliesFourteen (14) fatalities occurredwhile truck drivers and others wereattempting to load or unload materialsuch as mine equipment, conveyorsystems, and “I” beams. Theseactivities usually involve employeesfrom the mining operation assisting adelivery truck driver. Although thework of loading and unloading canbe very hazardous, many operationsdo not have an effective program forensuring communications anddefining the responsibilities of thesepersons. Signals to lift, lower, andmove forward are not uniformlyapplied and often result in miscom-munication. Additionally, many of thepeople assigned the tasks of loadingand unloading equipment andsupplies have not been trained in saferigging practices or proper communi-cations between equipment operatorsand ground personnel.

Seat beltsFailure of drivers to use seat beltshas caused serious injuries when self-propelled mobile equipment over-turned or collided with other vehiclesor stationary objects. Accident reportsreviewed in this analysis indicate thatin more than 200 accidents duringthe study period, the drivers of thisequipment had failed to use seat

belts. Most mine operators instructequipment operators to use seatbelts, but many do not have aprogram which reinforces their useand ensures equipment operators areusing them consistently. Also, there isa misconception among equipmentoperators that it is usually better tojump from an out of control piece ofequipment than to ride it out.Fatalities have occurred whenequipment operators apparentlyjumped from the vehicle. In nearlyevery instance the condition of theequipment operator’s compartmentindicated the drivers would have beenprotected if they had worn their seatbelts. MSHA has documentedtestimonials from equipmentoperators who have survived fallingfrom highwalls, benches androadways because of their use of seatbelts.

Recommendationsfor developing asurface haulageaccident preventionprogramThe following issues and recommen-dations are based on the findings ofthis study. Implementation of theserecommendations can help reducethe frequency and severity of poweredhaulage accidents at surface coalmining and metal and nonmetalmining operations and mineralprocessing areas.

Issues should be addressed andultimately resolved utilizing acooperative effort between equipment

HSA Bulletin REPRINT September 1996

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A Euclid170-ton

capacity (R-170) rear dumphauler at workin the CyprusCopper Mine inPima, Ariz.

manufacturers, mine operators,miners, mine safety representatives,engineers, State agencies, and MSHAto identify, develop, and implementpractical solutions. Some issuesrequire one or more of theseparticipants to effect a solution andthe appropriate entity should take thelead on specific recommendations.

This cooperative effortshould address thefollowing issues:Review current material and developgeneral mining industry guidelines forthe design, construction, andmaintenance of haulage roads. Theseguidelines should be followed as nearas practicable at metal, nonmetal,and coal surface mining operations.An engineering and design manualfor mine haulage road constructionand maintenance should be devel-oped.

Develop new training for mineinspectors, miners, mine operators,safety specialists, and engineersregarding haulroad design andmaintenance utilizing “best practices”available in the industry.

Mine operators and MSHA shouldconduct an inventory and technicalevaluation of existing haulroads inareas where road gradients may be a

factor in haulage safety. Identifyunsafe haulroads and haulagepractices and take corrective actions.Share good ideas and methods withothers in the industry, includingvarious mining associations.

Associations should activelyparticipate in the development ofsurface haulage guidelines. They canhelp ensure information is presentedin the most efficient manner to thelargest groups possible by coordinat-ing training efforts for mines theyrepresent. At the present time, a jointtask group involving industry, MSHA,and manufacturers, is developing acomprehensive surface haulage safetyprogram.

Mine operators should plan mineroad construction according togeographic location, traffic type,expected weather conditions andfrequency of use. Contingency plansshould be developed for adversechanges in weather.

MSHA should offer a technicalreview process for all new haulroadconstruction that includes review byteams of qualified professionalsexperienced in haulroad design andconstruction.

Traffic Control

Assemble and consolidate a trafficcontrol manual to assist miners, mineoperators, mine engineers, and MSHAinspectors to establish reasonableuniformity in the implementation oftraffic control methods.

Road BermsContinued proper construction andmaintenance of road berms isrequired. Mine operators shouldensure that berms are appropriate forthe largest equipment which travelsthe roadway and that they areconstructed properly.

Berm maintenance programswhich include routine berm inspec-tions and appropriate maintenanceshould be established at all miningoperations.

Develop guidelines for construc-tion of safety berms and roadsurfaces to foster uniformity incompliance. Stress the importance ofadequate berm base width andcompaction, in addition to normalheight requirements.

Dumping locations andmethodsDevelop general industry guidelinesfor construction of ore and wastedumps. These guidelines should giveexamples of factors to consider, suchas weather, compaction, loadedequipment weights, slope stability offills and perimeter berms. Thisguideline should describe the bestmethods of maintenance of the dumplocations and the dangers associatedwhen undercutting ore or wastestockpiles.

Develop guidelines regarding end-dumping of material at pit or quarryperimeters or at edges of dumplocations, fills, and stockpile areas.Consider best safety practices, suchas dumping short of the edges andpushing material with bulldozers orother equipment more suitable forworking safely at the perimeters.Distribute guidelines with descriptionsof the best practices available tominers, the mining industry, and

HSA Bulletin REPRINT September 1996

8MSHA mine inspectors.

Enhance awareness within theindustry of the hazards associatedwith dumping material at the edges ofdump locations, fills, stockpiles andhighwalls and develop an industry-wide analysis of “best practices” toprevent these kinds of accidents fromrecurring. Gather data regarding thesafest methods for construction, andmake the information available to themining industry, miners, and MSHAmine inspectors.

Distribute training materials toequipment operators regarding riskswhen backing trucks and end-dumping material near unstabledump locations, fills, stockpiles, andhighwalls. Truck driver trainingshould include thorough discussionand training in dumping procedures.Have mine inspectors present trainingmaterials at mine sites and tradeassociation meetings.

EquipmentGood maintenance practices shouldbe encouraged throughout the miningindustry and shared throughassociations, seminars and trainingprograms for miners, mechanics,mine operators, engineers, andinspectors. The C.V.S.A. UniformNorth American Out-of-ServiceCriteria or other appropriate methodsfor removing unsafe haulageequipment from service should bewell understood and used by truckdrivers, mechanics, equipmentoperators and inspectors.

Information on pre-operationalinspections, inspection checklists,equipment operational manuals andcommon traffic rules should bedistributed widely. This informationshould identify the difference indefects which need immediateattention and those which can bescheduled for repair when conve-nient. Defects which create animminent danger should be clearlydefined, such as the loss of servicebrakes.

Manufacturers should review

operating manuals and ensure theyare complete and that hazardousoperations and proper maintenancepractices are covered. Equipmentshould have safety features whichwould prevent inadvertent starting ofthe equipment when it is in gear,including features to allow amechanic to safely jump a solenoidfor maintenance purposes. Manufac-turers should also provide informa-tion regarding safe load limits for allequipment. This should includerelevant data regarding gradientranges for safe operation.

A cooperative effort should beinitiated to develop guidelinesregarding field testing of brakingsystems on the wide variety of self-propelled mobile equipment. Thisinformation should be shared withother manufacturers, associations,mining industry personnel, and MSHAto achieve as much consistency aspossible.

Equipment manufacturers shouldensure original equipment manufac-turer (OEM) parts are available forall equipment. If parts are no longeravailable, they should notify industryassociations and MSHA. Informationshould be shared with the miningindustry when black-market parts arefound to have been manufactured andsold.

Improve truck driver control ofbacking operations by modifying cablocation and design as well as rearview mirror locations should also beexplored.

Operating proceduresEstablish guidelines for determiningtruck and other haulage equipmentoperating load carrying capability.Develop procedures to be undertakenby mine operators and MSHA mineinspectors for determining loadamounts, such as weight factors fortype material being hauled, wateramounts being hauled and developlists describing equipment capacities.Load carrying capability guidelinesmust take into account haulroad

designs and gradients, along withintended operating speeds. MSHAinspectors should have this informa-tion readily available to share withmine operators during inspectionactivity.

Manufacturers should provideinformation to clients relative toproper equipment usage and assist intraining and developing mineequipment operator training pro-grams.

Encourage equipment operatorseat belt use by having MSHA mineinspectors emphasize the advantagesof seat belt use during regularinspections and “walk and talk”training sessions. Develop handoutmaterial which describes the use andadvantages of wearing seat belts.Testimonials from equipmentoperators who have had accidentsand survived would be of interest tothose who use the equipment. Mineoperators, miners representatives,equipment manufacturers, and tradeassociations should stress theimportance of seat belt use at everyopportunity.

Clarify the methods to be used fortesting brakes and other safetyfeatures on haulage equipment.Develop field methods for theequipment operator and mechanic.

All operations should havecontingency plans to implement whenweather has an adverse effect oncontinued safe operations.

Prepare guidelines regarding theestablishment of communicationssystems at surface mine operations.Radios, signal systems and otherforms of communications forequipment operators should be madeavailable for older equipment that isstill in use. This equipment should bestandard on any new equipment.

Blind spotsHaulage equipment manufacturers,the Society of Automotive Engineers(SAE), and the mining industryshould initiate a cooperative effort toimprove the design of haulage

HSA Bulletin REPRINT September 1996

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Over 40%of people

killed in heavyequipment-relatedfatalities werenot theoperators ofthe equipment

vehicles and warning devices.Innovative cab designs, and theinstallation of discriminating warningdevices, which include front/side/rearvideo cameras, and the installation ofother state of the art “blind areasurveillance systems” would greatlyreduce “blind-spot” hazards.

Review Bureau of Mines andindustry publications regarding novelcab design concepts and use them inthe design of new haulage vehicles.Training

Miners’ representatives, safetycommittee members, and personsrepresenting the mine operator insafety matters should take an activepart in promoting miner awareness ofsurface haulage accidents. Seriousaccidents noted in this study mighthave been avoided if equipmentoperators had been made aware ofthe important role they play inequipment maintenance, safeoperations, insight to potentialproblems, training and their right tohave safe equipment to operate andsafe roads to travel. Additionally, theyshould actively take part in makingcustomer and delivery drivers awareof potential hazards in areas wherethey interact with them. They cansignificantly help in communicatingthe responsibilities they have for eachother when unloading materials.

Form a joint industry/minertraining committee to develop andconduct a haulage safety trainingprogram in conjunction with MSHA.Utilize mine sites with varied haulageequipment in conjunction with MSHAsafety training programs for mineoperators, truck drivers, safety

engineers, technicians, equipmentoperators, and others associated withsurface mine haulage.

Use experienced truck drivers andmaintenance personnel to conducttraining. Use a mentoring typeprogram, where a work group canchoose from their peers the driverthey would most like teaching theirson, daughter or close friend tooperate equipment. Seek activeparticipation from equipmentoperators in sharing their expertisewith others.

Continue to train MSHA mineinspectors, mine employees andsupervisors in the identification ofunsafe dumping procedures and loadout practices and remedial actions totake when necessary.

InformationDevelop public awareness programsin selected regions where there arehigh concentrations of surface miningoperations. Provide industry person-nel, miners, and the public, includingfamilies of miners, with descriptionsof hazards associated with surfacemine haulage and methods to avoiddangerous conditions. Motivate thoseat risk to become involved in thesolutions for improving theirworkplace safety.

Encourage the mining industry touse preventative safety maintenanceprograms.

SummaryThe primary tools to make aneffective change in the numbers ofsurface powered haulage accidentsare available through some MSHAand industry training programs andregulatory efforts. Policy clarification,sound engineering, development ofguidelines where necessary, and theassimilation current information, canachieve further reductions in thenumber of fatalities and traumaticinjuries.

This paper attempts to define thehazards associated with mobilepowered haulage equipment at

surface mines and specifically, truckhaulage. The mining industry,manufacturers, miners, and MSHArecognize the serious risks to minepersonnel created by steep haulroadgradients, mechanical failure of safetyfeatures on haulage equipment,dumping at edges of fill and dumplocations, “blind-spots,” slick roadsurfaces, and uncontrolled trafficthrough mine operations.

There is a substantial need forthe mining industry, manufacturers,miners, and MSHA to work togetherto develop uniform methods for theconstruction of haul roads andequipment. Additionally, the develop-ment of haulage equipment safetymaintenance programs, traffic controlprograms, and engineering programsthat eliminate “blind-spot” hazardsare essential for improving consis-tency within the industry. There isalso a need to evaluate the hazards tothose who do not regularly operatemobile equipment. Several victims inthis study were maintenance employ-ees who did not operate equipmenton a daily basis. Additionally, thecauses and influences of thehazardous conditions or workpractices of miners need to befurther explored if we are to identifytrends that all in the mining industryshould address.

Communications, seat belt use,and the exercise of safe workpractices while repairing or unload-ing vehicles are also areas of concernthat must be addressed by the miningindustry, manufacturers, miners, andMSHA on a day-to-day basis.Contractors, customers, delivery truckdrivers, and other mine visitors mustreceive adequate training, instruction,and, where appropriate, someguidance to help educate them aboutpotential hazards associated withmine environments.

Training programs and vigilanceby mine workers, supervisors, mineoperators and mine inspectors willultimately result in safer work places.

In June of this year, a Surface

HSA Bulletin REPRINT September 1996

10Haulage Task Group was formed thatincludes persons from MSHA, theDepartment of Energy’s Safety andHealth Research Center (formerly theBureau of Mines), surface coal andmetal/nonmetal mining industries,and equipment manufacturers. TheTask Group is exploring what cancollectively be done to confront theincreasing number of surface haulagelost-time accidents and fatalitiesoccurring at both coal and metal/nonmetal mines. The proceedingsfrom the Task Group will be in theform of “Best Practices” and will bepublished for use by the mining

industry. These resource materialswill be shared with operators throughMSHA’s cooperative efforts.

References:Aldinger, J.A. and C.M. Keran. 1994 “ AReview of Accidents During SurfaceMine Mobile Equipment Operations”Paper in Proceedings of 25th AnnualInstitute on Mining, Health, Safety andResearch, pp. 99-108.

Aldinger, J.A. and J.P. May. 1995“Overview of Bureau Research DirectedTowards Surface Powered HaulageSafety” Paper in Proceedings of 26thAnnual Institute on Mining, Health,Safety and Research, pp. 121-132.

Aldinger, J.A. and J.M. Kenney and C.M.Keran, 1995 “Mobile Equipment

Accidents in Surface Coal Mines” U.S.Bureau of Mines IC 9428

Ault, J.C. and W.W. Kaufman. 1977“Design of Surface Mine Haulage Roads- A Manual” U.S. Bureau of Mines IC8758

Accident Investigation Reports, 1989 -1995. Mine Safety and HealthAdministration, U.S. Department ofLabor

“Haulage Fatalities at Surface Mines,”1991-1994. Mine Safety and HealthAdministration, U.S. Department ofLabor

“Metal and Nonmetal Fatal AccidentAnalysis” 1993 -1995. Mine Safety andHealth Administration, U.S. Departmentof Labor