NSW mine incidents highlight safety system failures, drill rig mishap, and diesel engine over-revving risks

Three serious workplace incidents involving mining operations in New South Wales have prompted fresh calls for vigilance, with the state’s Resources Regulator issuing its latest Weekly Incident Summary for the week ending 28 March 2025.

Of the 36 reportable incidents, three have been highlighted by the Regulator for their seriousness and relevance across different mine types and working environments.

Truck rolls backwards after engine failure on ramp

In the first incident, a haul truck operating in a construction materials setting lost power while stationary on a ramp, rolling approximately 30 metres backwards before coming to rest on a bench. The operator had stopped with the engine running, awaiting the completion of another task. Upon resuming, the truck’s engine cut out after the operator released the handbrake and footbrake. Attempts to engage the retarder and footbrake were unsuccessful, and the operator was forced to steer the vehicle over a water diversion bund to bring it to a halt.

The incident, listed as Dangerous incident | IncNot0048820, is under investigation. The Regulator reminded mine operators of the importance of maintaining and reviewing safety-critical systems—particularly braking, steering, and emergency controls—throughout their lifecycle.

Offsider injured by drill string at underground metals mine

In another dangerous occurrence (IncNot0048838), a diamond drill offsider was pinned against a wall by the rear of a drill string while working in an underground metals mine. The offsider had been walking past the drill string in a confined space when the drill operator mistakenly selected the rod pulling function instead of rod feeding, causing the string to move unexpectedly and trap the worker.

The injured offsider was transported to hospital for assessment. The Resources Regulator has urged mine sites to reinforce the use of positive communications during drilling operations and to ensure operators are always aware of offsiders’ positions before activating drill movements.

Engine over-revving incident in underground coal mine

A third incident, reported at an underground coal mine (IncNot0048800), involved a personnel transport vehicle with a diesel engine that remained at high revs even after the operator removed pressure from the accelerator pedal. The operator used the footbrake and coasted the machine into a cut-through before attempting to shut down the engine. However, the main isolator failed to deactivate the engine, requiring the use of a strangler valve.

Investigations revealed an internal fault in the fuel pump—a broken linkage had jammed the fuel rack open. The incident highlights the elevated risk of explosion in methane-rich environments when explosion-protected diesel engines malfunction. The Regulator emphasised the importance of emergency shutdown systems being fully operational and effective in such circumstances.

nternational fatality prompts safety reminders

Also included in this week’s report is an international incident reported by the US Mine Safety and Health Administration (MSHA), in which a 45-year-old technician suffered fatal injuries from thermal and chemical burns after stepping into an unbarricaded sump opening. The worker died nearly a month later from complications related to exposure to a hot, caustic mixture at a processing mill. Investigators cited a failure to install protective barricades and poor housekeeping as contributing factors.

The Resources Regulator reminds all duty holders in the mining sector of their ongoing legal obligations to ensure workplace safety and due diligence in addressing potential hazards. Additional information, alerts, and reports can be accessed via the Regulator’s website at resourcesregulator.nsw.gov.au.