2003 Sand and Gravel Fatalities

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2003 Sand and Gravel Fatalities
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January 13, 2003, a 62-year-old supervisor with
26 years mining experience fell 9 ft to his death.



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Facts

• The victim was standing 9 feet above ground level
  at a door opening discussing the progress of
  repairs with another foreman standing outside on
  a concrete pad at ground level
• The victim was leaning on the top chain handrail
  that was installed across the door opening
• Apparently as the victim exerted outward pressure
  against the chain, the chain link slipped off the
  grab hook attachment on the removable end of the
  chain causing him to fall

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What Would YOU Do?
Ensure that safety chains or handrails are
properly installed, regularly examined and
properly maintained, and are capable of
supporting the weight of a person who might fall
or lean on them.
Design the installation of safety chains to
ensure the termination points remain securely
attached when they are in place.
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February 11, 2003, a 26-year-old press operator
with 2 years 4 months mining experience was
killed by steam at a clay mine
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Facts

• He was performing cleanup inside a reaction tank
  when a steam injection line activated
• Victim was engulfed in high-pressure steam
• The automatically activated electronic control
  for the steam injection line had not been locked
  out
• nor had the manual gate valve for the steam line
  been closed and locked prior to his entering the
  tank
• victim had no prior experience performing this
  task

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What Would YOU Do?
Establish safe procedures prior to performing any
maintenance work
Review all tasks for hazards that may be created
as a result of any major equipment or systems
changes
Thoroughly train employees in safe job procedures.
Provide proper equipment and tools, identify
possible hazards, and wear protective equipment
or clothing.
Lock out equipment controls prior to entering
tanks
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March 24, 2003, a 46-year-old supervisor with 8
years mining experience was killed falling
material
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Facts

• A crane was lifting steel plates that were to be
  used as conveyor belt take-up weights
• victim was positioning the plates when the
  rigging failed and the plates crushed him.

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What Would YOU Do?
Discuss work procedures and identify all hazards
associated with the work to be performed along
with the methods to properly protect persons
Establish safe work procedures that require all
personnel to be positioned where they are not
working under suspended loads.
Train all personnel in safe work procedures.
Use rigging that is free of defects and designed
to safely lift the load.
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March 29, 2003, a 44-year-old supervisor with 19
years mining experience was killed by falling
material.
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Facts

• The victim was assisting with preparing the jaw
  crusher to remove a shim plate
• He was positioned on the conveyor underneath the
  crusher while two co-workers removed the nuts
  holding the toggle block clamp bolts
• When the nuts were removed, the shim- toggle
  block rest fell and struck him

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What Would YOU Do?
Discuss work procedures and identify all hazards
associated with the work to be performed along
with the methods to properly protect persons.
Develop safe work procedures that require all
personnel to be positioned to prevent them from
being exposed to any hazards.
Train all personnel in safe work procedures
Ensure that equipment and machinery components
are properly blocked to prevent accidental
movement before repairs are started.
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April 16, 2003, a 57-year-old oiler with 6 years
mining experience was fatally injured at a
surface stone mine.
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Facts

• victim was observed standing on a narrow platform
  installed over the opening of the jaw crusher
  that was still moving
• was attempting to free a hang up when he
  apparently contacted the moving crusher
  components causing multiple fractures to his leg
• victim was hospitalized and died on April 20,
  2003

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What Would YOU Do?
Discuss work procedures and identify all hazards
associated with the work to be performed along
with the methods to properly protect persons
Before working on or near equipment, ensure that
the equipment power circuits are locked
out/tagged out and that the equipment is blocked
against hazardous motion.
Require all personnel to be positioned to prevent
them from being exposed to any hazards.
Ensure the proper equipment is provided and
personnel are trained in safe work procedures
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June 23, 2003, 47-year old lead mechanic with 27
years of mining experience was fatally injured at
a surface-mine repair yard.
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Facts

• crew was preparing to move a section of a shovel
  mainframe with a front-end loader
• metal mainframe section was to be used at another
  location to block-up another piece of equipment
• After the front-end loader operator positioned
  the bucket over the shovel mainframe section, the
  victim reached under the bucket to attach a chain
  between the mainframe section and the bucket
• the bucket drifted downward, pinning the victim's
  head between the mainframe section and the
  bucket.

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What Would YOU Do?
Securely block raised equipment to prevent
accidental movement before working beneath such
components.
Ensure that personnel are trained to recognize
hazardous work procedures, including working in
pinch points where inadvertent movement could
cause injury.
Discuss work procedures and identify all hazards
associated with the work to be performed, along
with the methods to protect personnel.
Maintain good communication between co-workers.
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April 21, 2003, a 58-year-old weigh master, with
15 years experience, was fatally injured at a
surface stone operation.
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Facts

• The weigh master was in a scale house at the mine
  when a pickup truck, driven by another mine
  employee, struck and entered the building
• Reportedly, the driver of the vehicle suffered a
  blackout at the time of the accident due to a
  medical condition.

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What Would YOU Do?
Ensure that operators of self-propelled mobile
equipment maintain control of the equipment while
it is in motion.
Ensure that all persons operating any vehicles,
mobile equipment, or machinery on mine property
are physically and medically capable to perform
such tasks.
When taking medications, follow the
physician's/pharmacist's instructions before
operating any self-propelled mobile equipment.
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September 5, 2003, 28 year-old utility man, with
10 years of mining experience, was fatally
injured when a 55 gallon drum exploded.
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Facts

• The utility man was fatally injured while the
  mechanic and two other employees located
  approximately 8 to 10 feet away received flash
  burns
• For reasons unrelated to work, the victim was
  using an unlit torch to introduce acetylene into
  an empty 55-gallon anti-freeze drum when an
  explosion occurred

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What Would YOU Do?
Ensure that employees review Material Safety Data
Sheets (MSDS) and understand the flammability and
combustibility characteristics for materials
stored in containers prior to commencing work
activities.
Do not cut into an enclosed container with an
open flame without taking proper safety
precautions.
Prior to commencing work, examine containers and
identify their contents.
Fill containers with water or other inert
materials prior to cutting or welding to prevent
the ignition of flammable material or gasses.
Examine torches before using them. Ensure proper
maintenance, handling, and use of torches. Ensure
that employees do not engage in horseplay.
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September 9, 2003, 36-year old utility person
with 4 years of mining experience was fatally
injured at a surface coal mine when a metal hook
broke loose from the hitch of a stuck truck being
towed.
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Facts

• Crew using 2 pickups to move shovel power cable
• One truck became stuck in mud
• A nylon tow rope was hooked between trucks
• First pull, bumper hook broke on front truck
• Hook went through window of rear truck killing
  operator

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What Would YOU Do?
Use only tested and approved mechanisms for
pulling or towing.
Obtain approval of manufacturer for modifications
to original towing equipment
Ensure employees are properly instructed on
proper towing practices.
Ensure vehicles have sufficient traction for
surface conditions.
Conduct audits (observations) of specific tasks
to ensure proper techniques are employed and
tools/materials are maintained. Never exceed the
rated capacity of a tow vehicle or towing
equipment.
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April 25, 2003, a 39-year-old equipment operator
with 2 years mining experience was fatally
injured at a surface sand and gravel mine.
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Facts

• victim was operating an excavator near the edge
  of an embankment in the pit
• The ground under the excavator failed causing the
  excavator to slide down the embankment and fall
  onto its side, crushing the victim inside the
  cab.

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What Would YOU Do?
Establish safe work procedures and job specific
task training to identify all hazards associated
with the work to be performed.
Avoid operating equipment parallel to and close
to the edge of steep slopes in unconsolidated
material.
Examine the highwall and ground conditions to
establish a safe working distance from the edge
of the highwall, prior to operating equipment and
as ground conditions change.
Train all personnel in safe work procedures.
Ensure that seat belts are worn when operating
self propelled mobile equipment.
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May 21, 2003, a 50-year-old foreman with 29 years
mining experience was fatally injured at a
surface sand and gravel operation.
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Facts

• victim was in the process of making a splice in a
  480-volt power cable that energized a water pump
• As the victim attempted to remove the insulation,
  he contacted a live conductor, which resulted in
  a fatal electrical shock.

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What Would YOU Do?
Buried power conductors and cables, especially
those located beneath roadways, should be
enclosed in conduit.
Ensure that the power is deenergized and the
power circuits are locked out and tagged out
before work is done on the circuits.
Discuss work procedures and identify all hazards
associated with the work to be performed along
with the methods to properly protect personnel.
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June 14, 2003, a 25-year repair crew foreman,
with 4½ years experience, was fatally injured at
a sand and gravel operation.
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Facts

• The victim was positioning a wedge bar to secure
  the upper liner plate in a stationary jaw crusher
• Apparently the liner shifted and fell, striking
  the victim.

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What Would YOU Do?
Identify hazards associated with the task to be
performed and implement measures to ensure
persons are properly protected.
Before removing or installing components, ensure
that procedures have been implemented to secure
the component against hazardous motion.
Require all personnel to be positioned to prevent
them from being exposed to any hazards.
Ensure the proper equipment is provided and
personnel are trained in safe work procedures.
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July 22, 2003, a 51-year-old truck
driver/maintenance worker, with 24 years
experience, was fatally injured at a sand and
gravel operation.
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Facts

• A rubber tired crane was used to move a section
  of a conveyor that was being dismantled
• The victim was steadying the conveyor as it was
  being placed on the ground
• He received a fatal electrical shock when the
  boom of the crane struck a 7,200-volt energized
  over head power line.

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What Would YOU Do?
Identify hazards associated with the task to be
performed and implement measures to ensure
persons are properly protected.
Discuss the procedures developed to safely
perform the task with all personnel that will be
performing the work.
De-energize the power or take other precautionary
methods before operating equipment near energized
high-voltage power lines.

• Require all personnel to be positioned to prevent
  them from being exposed to any hazards.

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September 29, 2003, a 55-year-old dredge
operator, with 32 years experience, was fatally
injured at a surface sand and gravel mine.
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Facts

• The victim exited a control booth, located
  adjacent to a dump hopper, and walked down the
  hopper ramp
• At the same time, a front end loader operator
  dumped a load at the hopper, backed down the
  ramp, and struck the victim.

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What Would YOU Do?
Ensure that foot traffic is restricted in areas
where mobile equipment travels.
Ensure, by signal or other means, that all
persons are clear before moving equipment
When approaching large mobile equipment, do not
proceed until eye contact is made with, or
approval obtained from, the equipment operator.
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October 1, 2003, a 45-year-old superintendent,
with 27 years experience, was fatally injured at
a surface sand and gravel operation.
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Facts

• victim was operating a crane to lift a hydraulic
  power pack that was positioned on the bank of a
  settling pond
• The outrigger pads were not fully extended at the
  time of the lift
• When the power station was raised and swung
  toward the left, the crane tipped over on the
  ground, pinning the victim inside the cab

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What Would YOU Do?
Consult the equipment operator's manual for
proper procedures prior to performing the task.
Ensure that personnel are trained to use the load
chart.
Ensure that all stabilizers are extended and set
prior to lifting or moving the load.
Ensure that the load is securely rigged prior to
lifting or moving it.
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October 1, 2003, a 39-year-old laborer/operator,
with 4½ years experience, was fatally injured at
a surface dredge operation.
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Facts

• The victim was using a forklift, near the edge of
  a dredge pond
• to relocate the dredge's high voltage cable
• He drowned when the embankment sloughed off
  causing the forklift to tip in the pond

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What Would YOU Do?
Evaluate the stability of the ground prior to
operating mobile equipment near any drop off or
edge.
Ensure that mobile equipment is positioned a safe
distance from the edge prior to performing work.
Require flotation devices be worn by persons
operating mobile equipment in the vicinity of
water.
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November 23, 2003, a 44-year-old company vice
president with 2 years mining experience was
fatally injured at a crushed stone operation.
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Facts

• The victim was using a steel bar to dislodge a
  blockage in an impact crusher.
• The bar contacted a moving crusher component
  causing it to be propelled and strike the
  victim's neck

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What Would YOU Do?
Before working on or near equipment, ensure the
equipment power is off, it is locked out/tagged
out, and has been blocked against hazardous
motion.
Identify possible hazards associated with the
work to be performed along with the methods to
properly protect persons
Discuss work procedures before beginning work Use
proper tools and equipment for the job and ensure
personnel are trained in safe work procedures
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December 20, 2003, a 37-year-old truck driver
with 9 months mining experience was fatally
injured at a sand and gravel operation.
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Facts

• The victim had dumped a load of material and
  pulled forward approximately 20 feet with the
  truck bed in the raised position.
• He climbed onto the truck frame and was caught
  between the frame and the bed when the bed
  unexpectedly lowered.

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What Would YOU Do?
Follow the safe work procedures in the operator's
manual when performing all maintenance or repair
Before working on equipment, block all raised
components against hazardous motion and ensure
personnel are positioned in a safe location
Train all personnel in safe work procedures
before beginning work and use the proper tools
and equipment for the job