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“Tire Safety in the Mining Industry” by: Jami G. Dwyer, P.E., C.M.S.P.

“Tire Safety in the Mining Industry” by: Jami G. Dwyer, P.E., C.M.S.P. Institute for Mine Health and Safety, International Society of Mine Safety Professionals Critical Issues, and Train the Trainer Combined Conference Salt Lake City, UT May 24-28, 2004. NIOSH Spokane Research Laboratory.

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“Tire Safety in the Mining Industry” by: Jami G. Dwyer, P.E., C.M.S.P.

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  1. “Tire Safety in the Mining Industry”by:Jami G. Dwyer, P.E., C.M.S.P. Institute for Mine Health and Safety, International Society of Mine Safety Professionals Critical Issues, and Train the Trainer Combined Conference Salt Lake City, UT May 24-28, 2004 NIOSH Spokane Research Laboratory

  2. Today we will cover: • Fatalities associated with tires, 1980-2000 • Tire Injuries, 1996-2000 • Tire Safety Tips • Prioritization of safety programs based on passive data

  3. Background

  4. NIOSH Spokane Research LabProject: Surface Powered Haulage Safety • Project Objectives: • Detection of Vehicles or Personnel in Blind Spots • Monitoring of Driver Awareness • Health and Safety Hazards to Personnel Responsible for Powered Haulage Equipment Maintenance and Operation

  5. Tire explosion which resulted in a fatality Source: www.msha.gov Hazards to Maintenance Workers: • Frequent heavy lifting • High pressure hoses and vessels • Work in awkward or confining spaces • Exposure to potentially hazardous substances (oil, gas, engine fluids, welding fumes, etc.) • Proximity to moving parts, hand tools, and machinery.

  6. TIRE FATALITIES From 1980-2001.2 What can we learn from 20+ years of data?

  7. But first, a little note on data analysis... • Lesson #1: • When analyzing data, it helps to know what you are looking for

  8. About the fatality data... • All data was obtained from the Mine Safety and Health Administration’s (MSHA) on-line files of raw data from the accident and injury 7000-2 forms filed by mining operators and contractors as required under 30 CFR Part 50 from 1980 through the 2nd quarter of 2001. (n = 575,853 reported cases) • Since accidents and injuries related to tires occur across a broad range of accident categories, records with narratives containing keywords “tire,” “rim,” “lug,” and “wheel” were extracted. It is assumed that no tire-related accidents occurred without one of these keywords in the narrative. (data subset n = 11,442 records)

  9. A little more about the fatality data... • The data subsets were further separated into fatal vs. non-fatal accidents (n = 88 fatality records containing one or more keywords) • Each narrative was read and assigned to a self-defined accident category*. Records not related to tire safety (n = 57) were discarded. • From this data, it was determined that 31 tire-related fatalities occurred between 1980 and 2001.2 *more on this later

  10. Frequency of Tire-Related Fatalities(1980-2001.2) n = 31 Tire-related fatalities account for a relatively low proportion of occupational fatalities in mining. However, focused safety, training, and other prevention efforts should effectively eliminate this cause of death.

  11. What Caused the Tire Fatalities? • Explosions: In many cases, workers were applying heat to the rim or lugs which caused an expansion in air pressure in the tire. • Tire Fell on Victim: Tire was improperly secured and tipped over or fell from a height onto the victim. • Auxiliary Equipment: Worker was fatally injured when tools or equipment used in tire-related activities fail, are used improperly, or are the primary source of injury (examples include items such as jacks, tire irons, hand tools, boom trucks)

  12. What Caused the Tire Fatalities? • Explosions: In many cases, workers were applying heat to the rim or lugs which caused an expansion in air pressure in the tire. • Tire Fell on Victim: Tire was improperly secured and tipped over or fell from a height onto the victim. • Auxiliary Equipment: Worker was fatally injured when tools or equipment used in tire-related activities fail, are used improperly, or are the primary source of injury (examples include items such as jacks, tire irons, hand tools, boom trucks)

  13. Exploding Tire FatalitiesExample #1 • On April 22, 1998, a 39-year old maintenance worker with 8 years of mining experience was killed and two coworkers seriously injured at a limestone operation. A scraper tire was placed flat on the ground and they were attempting to remove the brake drum from the rim. The tire was not deflated and they had used an oxygen/acetylene torch to cut the brake drum when the tire exploded. Source: www.msha.gov

  14. Exploding Tire FatalitiesExample #2 • On February 17, 1999, a 35-year-old  technician (contractor operator)  with 10 years experience was fatally injured at a sand and gravel operation. The victim used a fork lift attached to a chain while attempting to remove a wheel assembly from a dump trailer in preparation to repair the brakes. After these attempts failed to free the wheel, he applied heat to the back side of the wheel with an oxygen/acetylene torch and the tire ruptured. Source: www.msha.gov

  15. What Caused the Tire Fatalities? • Explosions: In many cases, workers were applying heat to the rim or lugs which caused an expansion in air pressure in the tire. • Tire Fell on Victim: Tire was improperly secured and tipped over or fell from a height onto the victim. • Auxiliary Equipment: Worker was fatally injured when tools or equipment used in tire-related activities fail, are used improperly, or are the primary source of injury (examples include items such as jacks, tire irons, hand tools, boom trucks)

  16. Falling Tire FatalitiesExamples • “TIRE SIZE 6540-39 ... WAS NOT SECURED IN ITS UPRIGHT POSITION AND TIRE AND RIM FELL ON EMPLOYEE DAMAGE FATAL” • THE VICTIM “WAS CHANGING 37.25X35 TIRE ON...LOADER TIRE AND WHEEL FELL OFF HUB OF LOADER AND PINNED VICTIM AGAINST SERVICE TRUCK CRUSHING HIM” • “TECHNICIAN FROM AN OUTSIDE TIRE SERVICE COMPANY WAS IN THE PROCESS OF INSTALLING A NEW TIRE ON A FRONT END LOADER. FOR UNKNOWN REASONS, THE TIRE FELL ON THE TECHNICIAN, SUBJECTING HIM TO FATAL INJURIES.” Source: www.msha.gov

  17. What Caused the Tire Fatalities? • Explosions: In many cases, workers were applying heat to the rim or lugs which caused an expansion in air pressure in the tire. • Tire Fell on Victim: Tire was improperly secured and tipped over or fell from a height onto the victim. • Auxiliary Equipment: Worker was fatally injured when tools or equipment used in tire-related activities fail, are used improperly, or are the primary source of injury (examples include items such as jacks, tire irons, hand tools, boom trucks)

  18. Tire Fatalities due to misuse or malfunction of tire-related tools Examples from actual narratives: • A SUPV & LABORER CHANGING A TIRE ON A LOADER USING A BOOM TRUCK TO LIFT THE TIRE.BOOM TRUCK WAS 14' FROM OVERHEAD WIRE.THE COME-ALONG HOLDING THE TIRE SNAPPED (A METAL HOOK BROKE),THE TIRE DROPPED,THE BOOM TRUCK CABLE WHIPPED OUT STRIKING THE ELECTRICAL...” • “EMP WAS REPLACING REAR TIRE ON 988A CAT WHEEL LOADER. FENDER WAS HELD IN UPRIGHT POSITION WITH CHAIN COME A LONG. APPARENTLY CONE A LONG BROKE LETTING FENDER FALL AND FENDER STRIKING EMP ON THE HEAD.” • “EMPLOYEE WAS CHANGING TIRE ON TRUCK. JACK KICKED-OUT FROM UNDER TRUCK STRIKING EMPLOYEE IN CHEST.” Source: www.msha.gov

  19. Tire-Related FatalitiesGrouped by Accident Type 1980-2001.2 .

  20. Tire-Related FatalitiesGrouped by Occupation 1980-2001.2 .

  21. SAFETY TIPS

  22. Safety Tips to Prevent Tire Explosions • Safety tips1: • NEVER apply heat to a rim or rim assembly that has an inflated (or deflated) tire mounted on it. Even deflated tires may explode. • Personnel should stand out of the trajectory of a tire when inflating or inspecting the rim assembly. • The use of barriers or restraining devices is recommended where applicable. • Do not inflate beyond manufacturer-recommended pressure. 1Tire and Rim Safety Awareness Program, MSHA Instruction Guide No. 60, 1996

  23. Safety Tips to Prevent Tire Explosions • Safety tips (continued): • Properly design roads to avoid rough terrain and excessive braking which may cause heat to build up on a tire. • Perform PM on brakes to avoid excessive heat generation or malfunction. • Avoid overloading of trucks.

  24. Safety tips: Fix tires securely when using boom trucks, slings, fork lifts, or bead hooks to move tires. Set tires flat on ground or far enough away from personnel that if a tire does tip over all personnel are clear. Warning: watch for rolling tires, and do not walk beneath suspended loads! Lugs, rims, and other accessories on large equipment are heavy enough to cause fatal or disabling injuries. Use the same precautions with these items. Safety Tips to Prevent Tire Fatalities From Falling Tires SRL photo

  25. Safety tips: Always use tools in the manner for which they are intended. Inspect jacks, hydraulic lifts, slings, and chains before use. Do not work beneath suspended loads or equipment. Secure vehicle with brakes, chocks, etc. to avoid rolling. Where possible, work on a clean, dry, flat surface. Maintain shop housekeeping. Safety Tips to Prevent Fatalities from “Auxiliary Equipment” SRL photo

  26. TIRE-RELATED INJURIES From 1995-2001.2

  27. About this data... • The same narrative keyword extraction techniques used in the fatality data analysis were used to separate non-fatal accident data. • Only those records directly linked to tire incidents causing reportable, lost-time accidents were included in this analysis. • Injury data time period: 1995-2001.2

  28. About this data (continued)... • This initial injury analysis used the MSHA accident/illness classifications to categorize data. • Non-fatal tire-related incidents were found in all of the following MSHA classifications: • “Exploding Vessels Under Pressure” • “Hand Tools” • “Falling, Rolling, Sliding Rock or Material of Any Kind” • “Handling Material” • “Machinery” • “Powered Haulage”, and • “Other”

  29. Distribution of Lost Days as Reported by Accident Category Tire-related Injuries 1995-2001.2

  30. Most lost days in “Handling Material” Highest average lost days in “Exploding Vessels” Most accidents in “Hand Tools” Lost Days Summary by Accident CategoryTire-related Injuries 1995-2001.2

  31. Data Analysis of Tire-Related Injuries

  32. Days Lost Summary by ActivityTire “Handling Material” Injuries 1995

  33. In summary... • Multiple analyses of tire-related injury data are useful for determining which categories have the most lost days, highest accident frequencies, what types of injuries are occurring, etc. • However, more detailed information about what REALLY happened is necessary to formulate useful safety interventions.

  34. Future Work • In-depth injury analysis using narrative classification techniques instead of MSHA accident category classifications. Determine the root causes of each accident to focus safety interventions. • Tire safety manual for mine maintenance personnel and recommendations for reducing lost-time injuries. • In-depth analysis of all injuries and accidents to equipment maintenance personnel to focus future research.

  35. Questions? Contact: Jami G. Dwyer NIOSH – Spokane Research Lab 315 E. Montgomery Ave. Spokane, WA 99207 (509)354-8000 Email: JDwyer@cdc.gov

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