Broken Hill mine fire and Appin arc flash expose deep safety flaws as NSW Regulator pushes for urgent reforms in contractor and risk management systems

The NSW Resources Regulator has released two major safety investigation reports highlighting systemic failings at two mining operations in the state, with one incident involving a serious underground fire at Perilya’s Broken Hill Southern Operations and another where an electrician suffered burns from an arc flash at Appin Mine North.

Perilya Mine Fire Exposes Oversight and Risk Failures

The final causal investigation into the 12 January 2025 underground fire at Perilya Southern Operations revealed that the incident stemmed from a series of critical safety and contractor management failures during a polyurethane foam (PUR) void fill project more than 1,000 metres below ground.

The fire led to the emergency evacuation of 46 workers, five of whom were temporarily trapped in a fresh air base until it was safe to exit. Though no injuries were reported, the Regulator found a “systemic breakdown of contractor management, hazard awareness, procedural compliance, and risk governance” was responsible.

Key contributing factors included:

• Use of unlicensed and inappropriate quantities of PUR (2 tonnes—ten times above coal sector safety guidelines).

• Poor hazard identification and inadequate risk assessments.

• Contractor competency assumptions without verification.

• Inadequate emergency preparedness and delayed evacuation due to cultural and procedural gaps.

Notably, neither fire watch nor thermal monitoring tools were employed, and despite visible signs of smoke and charring on the foam, emergency procedures were delayed due to misplaced confidence in the chemical’s “fireproof” properties.

The Regulator has recommended that mine operators overhaul their contractor engagement, chemical risk management, and emergency response frameworks, warning that introducing new chemicals like PUR without due diligence could have catastrophic consequences.

Appin Arc Flash Incident Under Investigation

Separately, the Regulator has launched an investigation into an arc flash incident at Appin Mine North (Westcliff Colliery) on 7 June 2025, in which an electrician sustained burns to his left hand.

The incident occurred during fault-finding work on a 415V distribution board. A racking handle, used improperly as a levering tool, contacted a live phase and the earthed frame, triggering a phase-to-earth arc blast. The worker was injured by the resulting flash.

The Regulator is now examining the adequacy of training, supervision, equipment, and procedures, as well as the responsibilities of the persons conducting business or undertaking (PCBUs). The incident has raised fresh concerns over task-based electrical safety protocols in mining.

Changes to Explosives Licensing

SafeWork NSW has also announced that from 21 July 2025, all applications for security clearance licences for explosives must be lodged in person at a Service NSW centre. Applications for other explosives-related licences may still be submitted online via the SafeWork NSW website, which began accepting digital submissions on 20 June.

The move discontinues previous Australia Post lodgement options and is intended to streamline verification processes and improve licensing security.

Upcoming Events and Deadlines

The Regulator’s annual safety campaign concluded on 4 July, with results expected to be published shortly. Meanwhile, all 2024–25 work health and safety (WHS) reports are due by 31 July. Operators of low-activity or exploration sites may be exempt but must confirm this through the Regulator portal.

Early bird registrations are now open for several industry events:

• Mechanical Engineering Safety Seminar (MESS) – 6–7 August, Hyatt Regency Sydney.

• Mining Safety Seminar – 29–30 October, Shangri-La Sydney.

• Electrical Engineering Safety Seminar – 12–13 November, Shangri-La Sydney.

For full investigation findings and further information, visit resourcesregulator.nsw.gov.au.