NSW regulator warns of rising mine vehicle incidents as dozer, haul truck and drill rig collisions highlight urgent need for improved safety controls

A string of recent dangerous incidents across New South Wales mine sites has prompted the state’s Resources Regulator to renew calls for stricter controls and improved situational awareness in vehicle operations, following the release of its latest Weekly Incident Summary for the week ending 23 May 2025.

The regulator recorded 39 reportable incidents, with three serious cases highlighted to underscore persistent hazards involving mobile equipment interactions at both open cut and underground coal mines.

Dozer Collides with Haul Truck

In one incident at an open cut coal mine, a dozer operator conducting clean-up work reversed and collided with a queued dump truck, striking the vehicle’s position 6 tyre. The operator had failed to identify that a second truck had entered the area, underscoring a lapse in situational awareness.

Industry advisory: "Situational awareness must remain a key control when operating mobile plant," the Regulator stated. "Operators should consider upgrading to modern collision avoidance technologies and prioritise physical separation between machinery over procedural communication."

The incident adds weight to Safety Bulletin SB24-01, which flagged an uptick in bulldozer-related incidents earlier this year.

Shearer Load Roll-Over Incident

In another high-risk event at an underground coal mine, a transport truck rolled while carrying a disused shearer body loaded on inappropriate pans. Despite the load being well secured, its centre of balance was compromised due to uneven support from gate/transition pans instead of standard run-of-face (ROF) pans. The truck tipped on a flat road while cornering slowly, though the driver escaped injury.

Regulator’s guidance: "Transport procedures must specify the correct equipment for loading. The responsibility for load safety cannot rest solely with the driver, especially when unfamiliar with mining machinery."

Haul Truck Clips Drill Mast

The third incident involved a haul truck clipping a drill rig mast on a haul road. The truck driver, interpreting a flashing indicator light as a signal to pass, proceeded without confirmation and struck the rig.

The Regulator stressed that positive communication requires two-way confirmation, not assumption. "Supervisors must enforce compliance with communication protocols and prioritise higher order controls such as equipment segregation and proximity sensors."

Rollovers on the Rise

The summary follows the recent release of a statewide safety bulletin highlighting a notable increase in heavy vehicle rollovers—with 40 incidents reported over the past year across coal, construction, metalliferous, and industrial mineral sectors.

Of these:

• 21 occurred at coal mines

• 12 at construction sites

• 5 at metalliferous operations

• 2 at industrial mineral sites

The bulletin urges all operators to revisit rollover risk controls, including load balance assessments, haul route design, and operator training.

Amputation Incident Report Published

The Regulator also published findings into a 2023 entanglement incident at the Cadia East Underground Mine near Orange, where a worker’s left arm was amputated after it became entangled in a rotating drill steel on a jumbo rig.

The investigation identified multiple failures in risk management and exposure controls and includes detailed recommendations now available via the Regulator’s website.

Broader Safety Trends

In related developments, the Queensland Mineral Mines and Quarries Inspectorate has also released its latest quarterly report, spotlighting:

• High potential incidents

• Brake failures

• Injuries from suspended loads

• Respiratory dust hazards in underground mines

The report forms part of a national trend toward increased scrutiny of vehicle and load-handling operations across Australia's mining sectors.

Access the Reports

For full details on these incidents, safety alerts, and bulletins, visit: resourcesregulator.nsw.gov.au

Contact
Resources Regulator
516 High Street, Maitland NSW 2320
Phone: 1300 814 609
Email: cau@regional.nsw.gov.au

Editor’s Note:
All mine operators are reminded of their legal obligations under the Work Health and Safety Regulation 2017 to implement higher order risk controls where possible, reserving administrative measures such as verbal communication as a last resort.