Published on February 22, 2008
2002 Metal/Non-Metal Fatalities: 2002 Metal/Non-Metal Fatalities Slide2: January 9, 2002, a 21 year-old laborer with 14 months mining experience was fatally injured at a surface dimension stone mine. The victim was descending a grade in a front-end loader and exited the machine after losing control. The loader continued down the grade and ran over the victim. Self propelled mobile equipment should be provided with service brakes that are capable of stopping and holding the equipment on the steepest grade that it travels. Seat belts should be provided and worn when operating mobile equipment Preventive maintenance programs should be implemented to identify and repair defects that affect safety on mobile equipment. Slide3: January 12, 2002, a 63-year-old equipment operator with 30 years mining experience was fatally injured at a surface pebble stone mine. The victim was standing by a pick-up truck when he was struck from behind by a run-a-way front-end loader. The loader operator lost control of the equipment after the engine stalled while descending a grade. Slide4: Self propelled mobile equipment should be provided with service brakes that are capable of stopping and holding the equipment on the steepest grade that it travels. Preventive maintenance programs should be implemented to identify and repair defects that affect safety on mobile equipment. Part 46 training should be made available to all employees. Preshift examinations should be conducted prior to operation. Backup alarms should be audible above the surrounding noise level. Slide5: January 21, 2002, a 23 year-old utility person with 5 years mining experience was fatally injured at a surface cement operation. The victim was fatally injured when he climbed into a silo to unplug a blockage and was engulfed by material. A safety harness attached to a lifeline should always be used when persons enter silos, hoppers or surge piles. A second person should constantly adjust the lifeline to eliminate slack. Safe access should be provided and maintained to all working places. Silos should be equipped with mechanical devices or other effective means of handling material so persons are not required to work where they are exposed to entrapment by sliding material. Slide6: January 21, 2002, a 51 year-old loader operator with 6 weeks mining experience was fatally injured at a sand and gravel operation. The victim and a coworker were in the process of draining the water from the log washer at the end of the shift. The victim climbed inside the machine to remove debris and was crushed by the paddles when a third employee inadvertently started the machine from the plant control consol Slide7: Power disconnect switches should be locked out and posted with signed tags by the individuals performing work prior to work commencing. Wherever possible, startup switches should have a time delay along with simultaneous audible and visual warnings to alert persons of impending hazardous motion. Companies should develop and implement procedures that address possible hazards for all maintenance tasks. Slide8: February 1, 2002, a 38 year-old ledge foreman with 10 years mining experience, died of injuries he received on January 14, 2002, when he fell 28 feet at a dimension stone quarry. The victim was positioned between a grout bucket and a ladder near the edge of the ledge. When a large rock was loaded into the bucket, it tipped and knocked the victim off the ledge. A safety harness and a life line should be worn when persons work where there is a risk of injury from a fall. Safe access should be provided and maintained to and from all work areas. Railings or cables should be installed when persons are required to work or travel near the edge of a ledge. Safe work procedures should be established prior to commencing tasks. Slide9: February 13, 2002, a 53-year-old electrician with five years mining experience was fatally injured at a crushed stone operation. The victim and several coworkers were changing a generator on a power shovel. In preparation for lifting the generator, a hoist that was mounted overhead on an I-beam was being trammed into position when it ran off the end of the I-beam, fell and struck the victim who was performing work below. Slide10: Mechanical stops should be installed to prevent over travel of rail mounted hoists. Procedures that evaluate possible hazards and assure prompt corrective action should be implemented prior to work beginning. Mechanical equipment should be inspected prior to use and all defects should be promptly corrected. Slide11: April 4, 2002, a 54 year-old mechanic with 32 years mining experience was fatally injured at the surface lime plant of an underground limestone mine. The victim was positioned on the ground to guard access to the drop area while several co-workers threw filled dust collector bags from the elevated bag house. The victim was struck by one of the bags that weighed about 90 pounds. Slide12: Formal procedures that address possible hazards should be implemented prior to beginning major maintenance tasks. A restricted drop area must be established prior to dropping materials from elevated locations. All persons should be removed from drop areas and barricades or barriers should be installed to prohibit access to protect personnel from falling material. Slide13: March 30, 2002, a 67 year-old process operator (leadman) with 29 years mining experience was seriously injured at a cement operation. The victim was helping clear a blockage inside a cement clinker drag conveyor located in a tunnel. When the access door for the enclosed conveyor was opened, hot clinker spilled into standing water generating a steam outburst that burned the victim. The victim died from his injuries on April 5, 2002. Slide14: A protocol that address potential hazards should be developed prior to beginning major maintenance tasks. Special protective clothing and equipment should be provided and worn to protect persons from environmental hazards or irritants. Water should not be permitted to accumulate where it could come in contact with hot materials. Slide15: April 22, 2002, a 22 year-old drill operator with one year mining experience was fatally injured at a dimension stone quarry. The victim was drilling in the quarry when his clothing became entangled in the rotating drill steel. Equipment operators should stop drill rotation when performing tasks near the rotating steel. Loose fitting clothing should not be worn when working around drilling machinery. Slide16: April 24, 2002, a 22-year-old mechanic with five months mining experience was fatally injured at a crushed stone operation. The victim was conducting a performance test on the parking brake. He drove the loader up a 16 percent ramp when it stopped, rolled backwards and struck the edge of a waste pile. The loader rolled on its side and the victim, who was not wearing a seat belt, was thrown out of the cab. Slide17: Brake tests should be performed first in a non -hazardous environment to ensure all systems are fully functional before testing the brakes on the steepest typical operating grade. Brake holding tests should only be conducted near the base of the grade and only where a safe escape route is provided. Equipment operators should wear seatbelts whenever the vehicle is in motion. Self-propelled mobile equipment should be provided with service brakes capable of stopping and holding the equipment on the steepest grade it travels. Slide18: May 3, 2002, a 62-year-old contract dozer operator with 20 years of experience, drowned at a surface limestone operation. The victim was operating a dozer to level a pad for a dragline, when he over traveled the edge of the pad and sank. Several hours later, a dragline moved into position and began extracting material from the pit. The dragline brought up several pieces of the dozer. A search for the victim started immediately, but he was not found until May 6, 2002. Determine the relationship of the water's edge to the work area prior to operating mobile equipment. Provide flotation devices in the operator's cab on mobile equipment working near water. Slide19: June 1, 2002, a 32 year-old conveyor attendant with 5 years mining experience was fatally injured at an open pit copper operation. The victim became entangled in a tripper conveyor pulley. Always lock out or block moving machinery against motion before working nearby unless all pulleys and pinch points are guarded or located where persons can not contact them. Ensure that accessible pinch points on conveyor pulleys are guarded from contact. Establish and enforce policies that prohibit work or travel near unguarded machinery components. Slide20: June 3, 2002, a 41 year-old maintenance mechanic with 11 years mining experience was fatally injured at a cement operation. The victim and co-workers had cleared a plugged chute and then jogged the kiln feed bucket elevator to make sure it was free. The elevator drive assembly failed and the victim was struck by metal fragments. Locate operating controls for pumps, motors and rotating components away from potential trajectory paths. Test all safety systems, including reverse movement protection features, on a regular basis. Establish a schedule for rebuilding or replacement of equipment. Slide21: June 12, 2002, a 35-year-old maintenance worker with 7 years mining experience was fatally injured at an alumina operation. The victim was drilling out scale that had accumulated inside heater tank pipes. The drill motor, detached from the gear box, fell from the drill mast and struck the victim. Slide22: Establish procedures that require scheduled inspections and maintenance of equipment. Ensure adequate pre-operational checks are conducted and identified needs for maintenance are properly addressed. Ensure component fasteners meet or exceed manufacturer's specifications and are adequately tightened. Provide backup secure methods for components subjected to constant vibration. Slide23: July 2, 2002, a 51-year-old laborer with 21 weeks mining experience was fatally injured at a surface crushed stone mine. He was removing a support structure on a portable conveyor. The conveyor was positioned on a hydraulic jack supported by two wooden blocks when it shifted and fell crushing the victim. Train all personnel in hazard recognition and safe work procedures. Ensure that blocking material is competent, substantial, and adequate to support and stabilize the load. Ensure that equipment is properly blocked to prevent accidental movement. Never block with steel on steel or depend on hydraulics to support a load. Slide24: August 5, 2002, a 56-year-old maintenance worker with 27 years of experience was fatally injured at a lime plant. The victim was found lying inside one of the rooms of a dust collector bag house. Apparently, after the victim entered the room, the door inadvertently closed and he could not get out. Conditions inside the room were hot and dusty. Slide25: Establish safe work procedures and ensure that they are being followed by personnel assigned to do maintenance work. Ensure that safe entry procedures are being followed and examine exit routes at all bag houses. Provide latches on both sides of all doors. Maintain communications with personnel working in remote locations. Always use personal protective equipment appropriate for the assigned task. Slide26: August 6, 2002, a 47-year-old contract switchman with 25 years of experience, was fatally injured at a trona mine. The accident occurred at night. The victim, switching cars at a surface load out area, was caught between a 15-car train he was riding and a stationary car as the train moved. Provide illumination sufficient to recognize hazards in all work areas. Identify possible hazards and safe work procedures before moving rail cars. Provide communications between personnel assigned to move rail cars. Maintain continuous clearance of at least 30 inches from the farthest projection of moving railroad equipment on at least one side of the tracks. Slide27: August 17, 2002, a 31-year-old contract miner with 4 years of experience was fatally injured in a tunnel construction project at an open pit copper mine. A transformer switch, mounted on a rail car, was being moved forward as construction advanced. The victim was electrocuted when he contacted a 480 volt cable and a junction box to move them from rubbing the rail car. The cable and junction box were part of the lighting system located along the side of the tunnel. Slide28: Protect circuits against excessive overloads by fuses or breakers of the correct type and capacity. Ensure that all metal enclosing or encasing electrical circuits is grounded or provided with equivalent protection. Provide equipment grounding conductors, with a sufficiently low impedance to limit the voltage to ground, for metal enclosures. Slide29: August 20, 2002, a 20-year-old truck driver, with one year of experience, was fatally injured at a crushed stone mine. The victim backed his dump truck under a bin to receive material being washed from the bin. He exited the truck and stood on a concrete support foundation. While the victim was talking with the lead man situated above the bins, another haul truck backed under an adjacent bin and struck him causing fatal injuries. Slide30: Establish procedures that require all personnel to be positioned so they are not exposed to self-propelled moving equipment. Ensure that equipment operators proceed cautiously when entering areas with tight clearance or areas where personnel are present. Establish procedures that require communications to be maintained between equipment operators and their co-workers. Slide31: September 10, 2002, a 58 year-old contract drill operator with 15 years drilling experience was fatally injured at a crushed stone operation. The victim had positioned the truck-mounted chassis drill, set the jacks and raised the truck chassis off the ground. He was raising the drill mast into position when a previously damaged jack foot connection may have allowed the "ball end" to suddenly drop into the receiving socket. This caused the drill to become unstable, tip over and crush the operator inside the operator's cab. Slide32: Ensure pre-operational checks are conducted and identified needs for maintenance are properly addressed. Establish procedures that ensure jack components are locking in position properly and the unit is level before positioning mast. Use adequate cribbing to prevent the jacks from sinking into the ground. Know the limitations of your drill and follow the procedures in the operators manual. Slide33: September 10, 2002, a 57 year-old equipment operator with 25 years mining experience was fatally injured at a crushed stone operation. The victim was approaching the stone load out when apparently the rear brake line ruptured. The truck left the road, traveled several hundred feet and struck a tree. The victim, who was not wearing the seat belt provided, was found on the ground near the truck. Slide34: Ensure pre-operational checks are conducted and identified needs for maintenance are properly addressed. Establish procedures that require scheduled inspection and maintenance of mobile equipment. Ensure that service brakes will stop and hold equipment prior to operating mobile equipment. Enforce policies that require seat belts be worn by mobile equipment operators. Slide35: September 16, 2002, a 42 year-old welder with 2 years mining experience was fatally injured at a crushed stone operation. The victim was lying on a wet, metal screen deck welding a wear plate in a confined area when he apparently touched the energized welding rod to his chest and received an electrical shock. Slide36: Establish procedures that require welders to cover metal with approved insulated mats or dry wood when lying to weld in confined areas. Ensure that maintenance activities are planned and possible hazards are eliminated. Provide the proper supplies and equipment to complete all tasks. Slide37: September 23, 2002, a 30 year-old contract employee with 18 months experience was fatally injured at a cement plant. The victim apparently climbed out of the elevated man lift platform to gain access to a work location on the metal roof when he lost his footing and fell 46 feet to the ground. Slide38: Train all employees, including contractors, in hazard recognition and ensure they follow all safety requirements. Establish secure anchor locations and require harnesses attached to secure lines be utilized by persons at elevated locations. Maintain continuous fall protection when working at elevated locations. Slide39: September 23, 2002, a 43 year-old plant operator with 17 months experience was fatally injured at a crushed stone operation. The victim was removing fines that had packed around a winged tail pulley of a belt that had been buried by spillage. As the spillage was removed, the bound conveyor belt moved backward a short distance and caught the victim's arm between the belt and the tail pulley. Slide40: Ensure manufacturer's recommendations are reviewed and miners are trained regarding maintenance tasks prior to beginning work. Identify and discuss possible hazards and address steps to eliminate them. Ensure the proper tools are provided and used to complete all required tasks. Block all equipment or machinery components to prevent possible movement. Slide41: October 12, 2002, a 52-year-old co-owner of a sand and gravel operation was fatally injured. The victim accompanied her husband to the mine to assist in setting up a new weighing facility while he used a front-end loader to fill in dirt around the newly installed truck scales. Apparently the victim inadvertently walked into the path of the loader as it was backing. Slide42: Establish procedures that prohibit entering the work area of mobile equipment unless the operator is aware of your presence. Ensure that you make eye contact with mobile equipment operators before approaching their work areas. Slide43: October 14, 2002, a 25-year-old front-end loader operator, with 3 months mining experience was fatally injured at a sand and gravel operation. The victim parked his loader near the toe of a 33 foot highwall and left the operator's cab when material sloughed off the highwall and buried him. Slide44: Train all employees in hazard recognition and ensure they follow all safety requirements. Ensure that loose ground and overhanging material is taken down or block all access to those areas. Adopt mining methods that will maintain wall, bank or slope stability in all work areas. Slide45: October 17, 2002, a 45-year-old front-end loader operator, with 11 years mining experience was fatally injured at a sand and gravel operation. The victim and a coworker were positioned on a conveyor attaching lifting chains suspended from the bucket of a track mounted back hoe. The victim was caught between the back hoe bucket and the conveyor frame when the boom and bucket moved unexpectedly. Slide46: Identify possible hazards and take necessary action to ensure safe operation prior to beginning repair or maintenance tasks. Block all equipment or machinery components to prevent possible movement. Establish procedures that require mobile man lifts be used where safe access is not provided. Slide47: October 21, 2002, a 48-year-old equipment operator with 11 years mining experience was fatally injured at a sand and gravel operation. The victim was operating a front-end loader feeding a power screen plant when he backed one of the wheels over a drop-off. The loader, which was not provided with a ROPS cab, rolled over, crushing the victim. Slide48: Establish procedures that restrict the use of front-end loaders manufactured prior to June 30, 1969 to flat ground. Ensure that berms are provided on elevated edges of roadways where a drop-off exists. Ensure adequate pre-operational checks are conducted on all self- propelled mobile equipment and defects are promptly corrected. Slide49: October 24, 2002, a 27-year-old fuel handler with 2 years 7 months mining experience was fatally injured at a cement operation. The victim was attempting to bleed air from the liquid waste-fuel system when the in-line grinder ruptured. The escaping waste fuel ignited, engulfing the victim in flames. Slide50: Ensure process safety management principles are used to identify possible hazards related to waste fuel handling. Establish safe work procedures and train employees for each task, including a general knowledge of the system and its hazards. Ensure all safety system monitoring and shutdowns are installed correctly, are operational and are tested periodically. Ensure appropriate personal protective equipment, including fire retardant clothing is worn by all persons entering or working in areas where hazardous/flammable material spills or releases are possible. Locate pump start/stop switches remotely and require pumps be shut down prior to bleeding off pressurized waste fuel systems. Ensure in-line pressure relief devices are installed on all pressurized waste fuel systems. Install flow sensing devices which automatically shut down the pump if flow stops for any critical period of time. Slide51: October 17, 2002, a 49-year-old mine rescue team trainer with 26 years mining experience and a 38-year-old co-trainer with 2 years mining experience were fatally injured, at an abandoned underground gold mine. Both were participating under oxygen in an exercise to evaluate conditions in this mine. As the team was walking up the steep decline to return to the surface, the victims experienced breathing difficulties and collapsed. The first victim was pronounced dead at the scene. The second victim was transported to a medical facility where he succumbed to his injuries on October 23, 2002. Slide52: Ensure all self contained breathing apparatus are properly checked and equipped as to manufacturers recommendations prior to their use. During non emergency exercises, ensure that underground mine areas that rescue teams plan to enter are ventilated and free of serious hazards. Maintain continuous communications with the surface whenever mine rescue personnel encounter toxic gases, explosive gases or any conditions that pose serious danger. Slide53: November 13, 2002, a 30-year-old dozer operator with 11 years mining experience was fatally injured at a crushed stone operation. The victim was pushing up previously shot rock near the base of a 21-foot highwall. A large portion of the highwall failed, collapsing the ROPS on the dozer and fatally injuring the victim. Slide54: Train employees in hazard recognition and ensure they follow all safety requirements. Inspect highwalls thoroughly prior to work being performed. Ensure loose ground and overhanging material is taken down or block all access to those areas. Adopt mining methods that ensure mobile equipment is operated perpendicular to the face of a highwall. Slide55: December 9, 2002, a 47-year-old truck driver with 1 year10 months mining experience was fatally injured at a crushed stone operation. The victim was in the process of removing a 12 foot long section of a walkway attached to a portable inclined conveyor. As he was cutting a metal attachment using an acetylene torch, the section of walkway collapsed on him. Slide56: Analyze maintenance tasks and identify possible hazards prior to the commencement of work. Establish job procedures to eliminate hazards and ensure personnel are trained to utilize the proper equipment and tools. Secure all equipment or machinery components to prevent movement. Ensure personnel are adequately trained and assisted as necessary when performing maintenance work.