Winch sling failure, loader fire hazard and haul truck instability among latest NSW mine safety incidents

By Staff Writer on June 9, 2025
Safety, Safety Training, Incident Reporting, Emergency Response, ESG, Legislative Updates, Audit and Inspection, Workforce, Training and Development, Health and Well-being Programs, Risk, Risk Assessment, Risk Mitigation
Australia, New South Wales, Hunter Valley, Illawarra Region, Central West Region, North America, United States, West Virginia
Energy Minerals, Coal (Thermal and Metallurgical)

The NSW Resources Regulator has released its latest weekly incident summary for the period ending 30 May 2025, detailing 28 reportable incidents, including three serious events that highlight ongoing safety challenges in both underground and open cut coal mines.

Underground Winching Operation Sparks Conveyor Incident

In one of the week’s most serious incidents, a synthetic sling failure during the installation of conveyor belting at an underground coal mine resulted in an uncontrolled belt movement spanning several hundred metres. The incident occurred during the winching of belting through a newly installed drift conveyor system.

According to the Regulator (Incident No. IncNot0049184), the sling—used to rig the winch rope to the belt pulling tongue—failed, causing a loss of friction at the drive drum. The belt slipped back and began accelerating inbye along the carry side, eventually concertinaing both inbye and 150 metres outbye of the bootend.

While no workers were physically harmed due to strict access control and sentry placement, the Regulator emphasised the need for mechanical engineering control plans that specifically account for the risk of unintended mechanical energy release.

The agency advised mine operators to:

  • Ensure slings are correctly rated, in good condition, and suitable for the task,

  • Reinforce training for identifying hazards associated with stored energy and winching loads, and

  • Establish safer systems of work when plant interaction is involved.

Haul Truck Stability Threatened by Ground Slump at Open Cut Site

Another dangerous incident (IncNot0049200) occurred at an open cut coal mine when a loaded haul truck’s position 5/6 tyre slumped due to weak, weathered ground beneath the loading bay. The shift in terrain caused the vehicle to slide backwards into a hole, lifting the position one tyre off the ground and risking a full overturn.

Prompt action by an excavator operator, who used the machine’s bucket to stabilise the truck, prevented a potential rollover.

The Regulator recommended that mine operators:

  • Maintain level loading areas free of cross grades,

  • Regularly inspect ground conditions, particularly following wet weather,

  • Confirm that operating surfaces are capable of supporting vehicle loads.

Loader Damages Explosives in Fire Risk Incident

A third incident (IncNot0049193) involved a loader that ran over two boosters while exiting a shot pattern at an open cut coal mine. Although no detonation occurred, the potential for a fire or explosion prompted calls for stricter controls on shot floor traffic management.

Recommendations included:

  • Clearly marked and communicated travel routes on the shot floor,

  • Use of cones or signage for demarcation,

  • Implementation of effective spotting protocols and communication via two-way radios.

The Regulator stressed that explosive materials should not be in proximity during non-related loading activities.

International Fatality in U.S. Highwall Drilling Incident

The summary also highlighted an international fatality report from the U.S. Mine Safety and Health Administration (MSHA). A 73-year-old highwall drill operator with 46 years of experience was killed when the ground beneath his drill collapsed. The MSHA found that the site lacked proper procedures for edge work and failed to barricade unstable ground conditions.

For further guidance and incident reports, industry participants are encouraged to consult the Resources Regulator website at resourcesregulator.nsw.gov.au.

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