When sparks fly and bolts fail, safety takes the hit—hard lessons from the frontline as mines face fire, shocks, and boom lift chaos

Three dangerous incidents in New South Wales mining operations – and two tragic fatalities overseas – have once again sharpened focus on frontline safety risks and the critical role of systems, supervision, and situational awareness.

According to the NSW Resources Regulator’s Weekly Incident Summary for the week ending 16 May 2025, 37 incidents were reported, with three serious events highlighted. These include a workshop fire at a coal mine, two electric shocks at separate sites, and an earlier catastrophic injury that led to a worker’s surgical amputation.

1. Hot Work, Cold Planning: Flammable Liquid Ignites During Grinding

At an open-cut coal mine, a boilermaker grinding the chassis rails of a dump truck triggered a fire when sparks landed on a trolley holding brake-cleaning fluid beneath the vehicle.

In a well-intentioned but ill-fated response, workers attempted to smother the flames with cloths – inadvertently fuelling the fire. The burning trolley was wheeled outside and tipped, spreading the flammable liquid. A dry chemical extinguisher ultimately put out the blaze. Thankfully, no injuries were sustained, but workers were exposed to smoke and extinguishing agents.

Regulator’s reminder:

• Remove flammable liquids from hot work zones.

• Train workers on emergency protocols and equipment locations.

• Reinforce duties under the Work Health and Safety Act to follow site instructions and procedures.

2. Electric Shock Incidents Highlight Persistent Gaps

Two electric shock cases were reported:

• In an underground metals mine, a worker received a shock while fault-finding near a welder’s plug.

• In a construction materials operation, another boilermaker suffered a shock from a caddy welder.

Key takeaways:

• Welding gloves are not electrical insulators – especially when damp.

• Equipment should be tested, tagged, and maintained regularly.

• Leads with visible damage should be taken out of service.

• Use insulation methods to avoid contact with live circuits during fault diagnosis.

These incidents follow a growing trend flagged by the regulator in previous safety bulletins (e.g., SB20-03 and SB19-03), prompting renewed emphasis on fit-for-purpose equipment and robust maintenance regimes.

3. Investigative Spotlight: Conveyor Catastrophe

A sobering investigation report also revisits a harrowing 2023 incident in which a worker’s arm was surgically amputated onsite after it became entangled in the idler drum of a mobile screen conveyor.

The investigation uncovered widespread deficiencies:

• Missing or non-functional safety guarding and e-stops

• Common practice of tracking belts while guards were removed

• Failure to implement standard risk controls for moving parts

This tragic event serves as a stark reminder that normalised deviation from procedure can be deadly.

4. Fatalities Abroad Reinforce the Basics

Two fatal powered haulage incidents reported by MSHA in the US underscore the importance of situational awareness and structural integrity:

• A 22-year-old saw operator was crushed when a pallet of stone was lowered onto him by a front-end loader operator who had lost sight of him.

• A 32-year-old haul truck operator died after the ground beneath a dump point gave way, rolling the truck multiple times.

Key factors in both cases:

• Inadequate visibility and communication

• Lack of site risk assessment

• Absence of seatbelt use and dump-point stability checks

5. Boom Failure in Queensland: A Hydraulic Wake-Up Call

Back in Australia, Resources Safety & Health Queensland reported an uncontrolled luffing movement on a coal stacker boom due to bolt failure on a hydraulic cylinder. The boom rapidly lifted with a worker onboard, though no injury occurred.

Engineering learnings:

• Assess structural integrity of equipment handling bulk materials

• Review hydraulic system designs under tension

• Factor in wear and corrosion over time – especially with older equipment

• Consider dual-cylinder configurations for critical loads

Takeaway for METS Providers

Whether you're designing stacker booms, supplying portable welders, or delivering fire suppression systems, these incidents expose gaps that METS companies are in a prime position to close.

The Rock Wrangler encourages its readers – particularly those involved in safety-critical systems – to review the Resources Regulator’s findings and consider how their products, services, or advice could help mitigate similar risks across the mining sector.