Metal/Nonmetal

Fatality #23 for Metal/Nonmetal Mining 2014

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m23On December 1, 2014, a 46-year-old contract truck driver with 26 years of experience was killed at a limestone mine.  The articulating haul truck he was operating traveled over a roadway berm and went into a large pond.  Dive teams extricated the victim from the truck.

Best Practices

  • Task train mobile equipment operators adequately in all phases of mobile equipment operation before operating mobile equipment.
  • Conduct adequate pre-operational checks and correct any defects affecting safety in a timely manner prior to operating mobile equipment.
  • Always wear a seat belt when operating self-propelled mobile equipment.
  • Maintain control of self-propelled mobile equipment while it is in motion.
  • Operate mobile equipment at speeds consistent with the conditions of roadways, tracks, grades, clearance, visibility, curves, and traffic.
  • Provide and maintain adequate berms or guardrails on the banks of roadways where a drop-off exists.

Click here for: MSHA Preliminary Report (pdf)

Fatality #22 for Metal/Nonmetal Mining 2014

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m22On November 25, 2014, a 67-year-old truck driver with 10½ years of experience was killed at a sandstone mine.  The victim backed a haul truck to the edge of the overburden dumpsite and started to raise the truck’s bed to dump a load of material.  The bank failed, causing the truck to overturn and fall 30 feet below. The victim died en route to the hospital.

Best Practices

  • Task train all persons to understand safe job procedures.
  • Establish and discuss safe work procedures before beginning work.
  • Identify and control all hazards associated with the work to be performed.
  • Conduct adequate pre-operational checks prior to operating mobile equipment.
  • Always wear a seat belt when operating self-propelled mobile equipment.
  • Examine dumping locations for stability prior to dumping the first load and as ground conditions warrant during the work shift.  Where trucks are loaded out of the stockpile or ground conditions may fail to support the weight of the truck, dump loads a safe distance back from the edge.
  • Maintain berms or similar impeding devices at dumping locations where there is a hazard of overtravel or overturning.
  • Travel in a straight line when backing a truck toward a dump location.  Do not approach on a turn.
  • Monitor persons routinely to determine safe work procedures are followed.

Click here for: MSHA Preliminary Report (pdf)

Fatality #21 for Metal/Nonmetal Mining 2014

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m21On November 18, 2014, a 42-year-old contract supervisor with 19½ years of experience was killed at an alumina operation.  A crane was lifting a 2,500 pound door to be installed on a filtrate tank.  The welded lifting eye on the door broke loose and the door fell, pinning the victim on the concrete floor.

Best Practices

  • Establish and discuss safe work procedures before beginning work.
  • Identify and control all hazards associated with the work to be performed.
  • Task train all persons to understand safe job procedures and to stay clear of suspended loads.
  • Use welded lifting eyes that are specifically intended for lifting and adequately rated for the loads being lifted.
  • Use certified welders and good quality welds when attaching lifting eyes or lugs.
  • Ensure the weld metal is compatible with the base metal of the connecting components and thoroughly clean any rust or scale from a surface prior to welding.
  • Carefully inspect all rigging prior to each use.
  • Attach taglines to loads that may need steadied or to be guided while suspended.
  • Avoid extreme side loading on a lifting eye or lug unless it is designed to handle such loading.
  • Monitor persons routinely to determine safe work procedures are followed.

Click here for: MSHA Preliminary Report (pdf)

Fatality #20 for Metal/Nonmetal Mining 2014

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m20aOn October 10, 2014, a 66-year-old contract truck driver with approximately 11 years of experience was killed at a cement operation.  The driver was inside a loading rack closing the hatch on top of a bulk tanker truck.  When the victim raised the rack to access the hatch, he fell between the rack and rounded side of the truck and then fell to the ground.

Best Practices

  • Establish traffic patterns to ensure safe alignment of vehicles with access equipment.
  • Identify and control all hazards associated with the work to be performed and use methods to properly protect persons.
  • Ensure that persons are trained, including task-training, to address the hazards associated with the work being performed.
  • Always use fall protection when working where a fall hazard exists.
  • Always be aware of your surroundings and any hazards that may be present.

Click here for: MSHA Preliminary Report (pdf)

Fatality #19 for Metal/Nonmetal Mining 2014

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m19aOn September 26, 2014, a 55-year-old maintenance mechanic with approximately 2 years of experience was killed on the surface of an underground salt mine.  The victim was performing maintenance on a forklift in a mill building when the forklift moved forward, pinning him against a wooden support pole.

Best Practices

  • Conduct a pre-operational check to identify and correct any defects that may affect the safe operation prior to operating mobile equipment.  Remove the mobile equipment from service if any defective items are not corrected.
  • Establish and discuss safe work procedures before beginning work. Identify and control all hazards associated with the work to be performed and use methods to properly protect persons.
  • Ensure that persons are trained, including task-training, to address the hazards associated with the work being performed.
  • Block and secure equipment against motion before performing maintenance.
  • Follow the equipment manufacturers recommended maintenance procedures when performing repairs to machinery.
  • Ensure that equipment control switches are in the off position and the brake is set before performing maintenance.
  • Always be aware of your surroundings and any hazards that may be present.

Click here for: MSHA Preliminary Report (pdf)

Fatality #18 for Metal/Nonmetal Mining 2014

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m18On August 25, 2014, a 54-year-old truck driver with 1 year of experience was killed at a limestone mine.  The victim went to a storage building to get some wooden planks.  He climbed a stack of loaded pallets to get to the planks that were near the rafters and fell approximately 8 feet to the ground below.  The next day two coworkers arrived at the mine and found the victim at approximately 6:05 a.m.

Best Practices

  • Establish and discuss safe work procedures before beginning work. Identify and control all hazards associated with the work to be performed and use methods to properly protect persons.
  • Ensure that persons are trained, including task-training, to understand the hazards associated with the work being performed.
  • Develop a plan to store supplies and other items in an accessible way to ensure ease of retrieval and transportation.
  • Always be aware of your surroundings and any hazards that may be present.
  • Provide and maintain a safe means of access to all working places.  Always work from a stable position.
  • Do not assign a person to work alone in areas where hazardous conditions exist that would endanger his or her safety.
  • Account for all persons at the end of each shift.

Click here for: MSHA Preliminary Report (pdf)

Fatality #17 for Metal/Nonmetal Mining 2014

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fab14m17-02On August 2, 2014, a 53-year-old plant operator with 25 years of experience was killed at a sand and gravel mine.  The victim was working under the raised bed of a dump truck when the wooden block supporting the load suddenly failed, allowing the bed to fall and pin him.  The victim was working alone and was not found until 10 a.m. on August 3, 2014.

Best Practices

  • Establish and discuss safe work procedures before beginning work. Identify and control all hazards associated with the work to be performed and use methods to properly protect persons.
  • Ensure that persons are trained, including task-training, to understand the hazards associated with the work being performed.
  • Before working on equipment, block all raised components against hazardous motion and ensure persons are positioned in a safe location.
  • Follow the safe work procedures provided by the manufacturer when performing all maintenance or repair work.  If provided, always use the manufacturer’s provided safety device or features for securing components against hazardous motion.
  • Ensure that blocking material is competent, substantial, and adequate to support and stabilize the load.  Blocking must be strong enough and secured to prevent any unintended movement.
  • Never block with steel on steel or depend on hydraulics to support a load.  Mechanical blocking can be achieved by installing a hinged prop leg.
  • Do not assign a person to work alone in areas where hazardous conditions exist that would endanger his or her safety.

Click here for: MSHA Preliminary Report (pdf)

Fatality #16 for Metal/Nonmetal Mining 2014

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ftl2014m16On July 23, 2014, a 51-year-old contract truck driver with 30 years of experience was killed at a cement operation while delivering a load of fly ash. The victim exited the truck to remove the tarp. A front-end loader backed down a ramp and struck the victim, pinning him against the truck.

Best Practices

  • Task train all persons to stay clear of mobile equipment.
  • Be aware of the location and traffic patterns of mobile equipment in your work area.
  • Before moving mobile equipment, look in the direction of travel and use all mirrors and cameras to ensure no persons are in the intended path.
  • Sound the horn to warn persons of intended movement and give them time to move to a safe location.
  • Operate mobile equipment at reduced speeds in work areas.
  • Ensure that backup alarms and lights on mobile equipment are maintained and operational.
  • Remain in your truck when mobile equipment is being operated nearby.
  • Communicate with mobile equipment operators and ensure they acknowledge your presence.  Stay in the line of sight with mobile equipment operators.  Never assume the equipment operator sees you.
  • Before operating equipment, always ensure other persons are clear and safely positioned.

Click here for: MSHA Preliminary Report (pdf)

Fatality #15 for Metal/Nonmetal Mining 2014

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ftl2014m15On July 21, 2014, a 28-year-old assistant plant manager with 11 years of mining experience was killed at a sand and gravel dredge operation.  He was riding in an aluminum boat that became stuck in low water on top of 480 volt energized power conductors.  The victim was electrocuted when he exited the boat, attempting to pull slack on the power conductors.

Best Practices

  • Establish and discuss safe work procedures before beginning work. Identify and control all hazards associated with the work to be performed and use methods to properly protect persons.
  • Train all persons to understand the hazards associated with working near energized electrical conductors.
  • De-energize power and ensure that the circuit is visibly open before working near energized conductors that may have damaged insulation.
  • Lock and Tag! Place YOUR lock and tag on the disconnecting device.
  • Use properly rated Personal Protective Equipment (PPE) including Arc Flash Protection such as a hood, gloves, shirt, and pants.
  • Ensure electrical conductors are properly rated and designed for the applications used.
  • Ensure that ground fault protection is provided to protect persons
  • Ensure that all electrical systems are safely designed and properly installed.

Click here for: MSHA Preliminary Report (pdf)

Fatality #14 for Metal/Nonmetal Mining 2014

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ftl2014m14On June 18, 2014, a 41-year-old production supervisor with 19 years of mining experience was killed at a sand and gravel mine.  The victim and two contract workers were attempting to remove an impeller that was seized onto the threaded shaft of a centrifugal pump.  After several failed attempts to unscrew the impeller, heat from a torch was applied to the enclosed hub on the impeller.  While applying heat, the hub exploded and metal fragments struck the victim.

Best Practices

  • Establish and discuss safe work procedures before beginning work. Identify and control all hazards associated with the work to be performed and use methods to properly protect persons.
  • Train all persons to understand the hazards associated with the work being performed.
  • Do not apply heat or open flame where enclosed spaces such as impeller hubs, mounted tires, suspension struts, or tanks may be subject to explosion except as directed by the manufacturer.
  • Always examine materials before applying heat, cutting, or welding to ensure gases from the applied heat can vent.
  • Never apply heat to materials before ensuring that flammables/combustibles/explosive materials are not present.
  • Never apply heat to materials where pressure build up is possible.
  • Do not apply heat or open flame where lubricants, oil, or grease are present.
  • Use special tools, provided by the manufacturer, to loosen an impeller on a pump.
  • Refer to the maintenance manual, warning labels on the pump, or contact the manufacturer for special safety precautions.

Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf), Overview (powerpoint), Overview (pdf).