Truck collisions and gas outburst highlight ongoing safety risks as NSW Regulator urges stricter controls and compliance across mining operations

Mine operators must verify that haul roads meet required width standards and, where too narrow for dual-lane use, implement controls to manage them as single-lane roads.
By Staff Writer on July 18, 2025
Safety, Occupational Health, Incident Reporting, Emergency Response, ESG, Regulatory Adherence, Workforce, Training and Development, Risk, Risk Assessment, Risk Mitigation
Australia, New South Wales, Broken Hill, Illawarra Region
Base Metals, Energy Minerals, Coal (Thermal and Metallurgical)

The NSW Resources Regulator has reported 37 incidents for the week ending 11 July 2025, including three dangerous occurrences involving haul truck collisions and a significant gas outburst at a coal mine, as part of its ongoing effort to improve mine site safety across the state.

Haul Truck Collisions Raise Concerns On Road Design and Visibility

In separate incidents at underground and open cut mines, haul truck collisions underscored the need for better traffic management and infrastructure checks.

At an underground metals mine (Incident ID: IncNot0049420), two haul trucks collided on a recently opened section of haul road. One operator misinterpreted a collision noise as falling rock and only realised contact had occurred after noticing a damaged mirror at an intersection. A review determined that the haul road was too narrow to safely function as a dual lane road.

The Regulator urged mine operators to verify that roads meet design specifications before use and to implement traffic controls where dimensions fall short. “Traffic management must be tailored to suit actual road conditions,” the report states.

A second incident (IncNot0049435) at an open cut coal mine occurred in a loading area when a haul truck moved forward into a stationary truck’s tailgate. The crash damaged safety equipment on the moving vehicle. The event happened at night, with both drivers unaware of each other’s presence due to poor visibility.

“Lighting plants must be arranged to eliminate glare and shadows,” the Regulator recommended, adding that operators should conduct visual checks before moving vehicles and consider proximity detection systems to reduce mobile equipment interactions.

Mine operators must verify that haul roads meet required width standards and, where too narrow for dual-lane use, implement controls to manage them as single-lane roads.

Methane and CO₂ Outburst at Coal Mine Prompts Investigation

A major strata failure at an underground coal mine (IncNot0049434) resulted in an outburst estimated to have released 2400 cubic metres of gas—comprising approximately 80 percent methane and 20 percent carbon dioxide—and ejected 600 tonnes of stone.

The incident occurred during shotfiring at a stone face. A gas monitor in a nearby return airway recorded a 5.07 percent methane reading for 27 seconds. Fortunately, all personnel had been withdrawn before the blast, and no injuries were reported.

Workers over 200 metres away experienced a strong windblast. The area had previously been classified as high risk due to past outburst activity. The Regulator confirmed that an investigation is underway and further information will be made public once available.

This incident is under investigation and further information may be published later.

International Fatalities Underscore Global Safety Imperatives

The weekly summary also referenced two fatal mining accidents reported by the U.S. Mine Safety and Health Administration (MSHA), reinforcing the importance of safe operating procedures:

  • Highwall collapse: Daniel Holle, a 51-year-old loader operator, was fatally engulfed by collapsing sand at the base of an undercut highwall. Investigators found that unsafe excavation methods and lack of written procedures contributed to the collapse.

  • Conveyor entrapment: Juan Maciel, 57, died after becoming entangled in a tail roller while attempting to remove belt material. The system was unexpectedly reactivated during maintenance. Investigators cited failures to isolate hazardous energy and use lockout/tagout procedures.

Safety Message to Industry

The Regulator has once again reminded mine operators that incidents must prompt proactive risk management. “Engineering controls such as collision avoidance systems, effective lighting, and traffic separation are not optional—they’re essential,” a spokesperson said.

All incident summaries and safety publications are available via the Regulator’s website at resourcesregulator.nsw.gov.au.

Contact:
Resources Regulator
Phone: 1300 814 609
Email: cau@regional.nsw.gov.au
ISSN: 2982-1010 (online)

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