Haul truck fatal accidents and injuries continue to be a significant concern for the mining industry. However, the availability of high-quality training materials continues to be limited. Near-miss incident accounts, if packaged well, could help fill this gap, because for every fatality, there are hundreds of reportable accidents and thousands of undocumented near misses. Researchers from the National Institute for Occupational Safety and Health (NIOSH) collected detailed accounts of 21 near-miss incidents in virtual interviews with mineworkers at surface mining operations across the country. From these interviews, researchers created four simulation videos using the Unity game engine. The simulation videos bring these events to life through first-person retelling and various visual perspectives of actual events. Each video exemplifies a critical safety message and a common haul truck hazard. This paper describes the process of taking narratives and turning them into impactful visual stories using graphic simulation. NIOSH plans to co-release these simulation videos with the Mine Safety and Health Administration (MSHA) to the mining industry to raise awareness and ultimately help reduce haul truck-related accidents and fatalities in mining.

Nonfatal injuries from slips, trips, and falls (STF) that occur at surface mines can result from inadequate lighting. Mobile equipment operators are among the occupations associated with the nonfatal incidents reported to the U.S. Mine Safety and Health Administration (MSHA). In addition, getting on/off the equipment (ingress/egress) frequently adds to the highest proportion of nonfatal incidents. Accordingly, researchers at the Pittsburgh Mining Research Division (PMRD), National Institute for Occupational Safety and Health (NIOSH) conducted a field study to investigate lighting on haul trucks and wheel loaders with regard to glare and illuminance levels recommended by the Illuminating Engineering Society (IES). The objective was to determine whether two light-emitting diode (LED) area luminaires—a Mr. Beams® (model MB390 Ultrabright) (area luminaire-1) and a NIOSH-developed Saturn (custom-designed for a mine roof bolter study) (area luminaire-2)—could complement a headlamp luminaire. Measured levels of visual tasks, with the headlamp alone and the area luminaires plus the headlamp, demonstrated that illuminance met or exceeded IES-recommended levels. Nevertheless, the area luminaires illuminated a much broader area, which is key to increasing hazard awareness. Discomfort and disability glare were lower with area luminaire-1 than with area luminaire-2. Differences in glare were more noticeable for newer models of haul trucks and loaders featuring updated ingress/egress system designs. This study demonstrates that commercially available luminaires, such as area luminaire-1, are capable of complementing headlamp lighting, and can thus improve a miner’s ability to detect and avoid STF hazards.

It is critical for the safety of miners to be able to escape, unaided, during a mine emergency. Self-escape is challenging in the presence of smoke that can occur during a mine emergency. To assist self-escape, coloured markers in underground mines designate the primary/secondary escapeways, but no universal colour code exists. Ten participants were tested to recognize the colour and designation (primary/secondary) of fluorescent yellow–green (FYG), yellow (Y), white (W) and green (G) escapeway markers in both a clear and smoked-filled environment. The overall misidentification rate for all colours was 1.9% and 18.1%, respectively, in clear and smoke conditions. FYG had the highest misidentification percentage for both conditions. For the marker designation tests, participants were most accurate in clear conditions (100.0%) for the FYG + W, Y + G, G + W and W + FYG combinations, and least accurate (89.6%) for the Y + FYG combination, while for smoke conditions participants were most accurate for the G + Y combination (95.8%). The overall effect of colour combination was significant, indicating that the colour combination for primary/secondary recognition is a significant factor where the G + Y combination was best. It can be inferred from these data that the colour combination is an important factor in participants’ ability to recognize primary/secondary escapeway markers in smoke conditions.

Near misses recorded and reported by workers can provide awareness to the potential causes of injury and prompt safety management initiatives. Although most companies require near-miss reporting, it is unclear what the value of these reports are, if any, and how they influence subsequent actions or controls to reduce on-the-job risks. Researchers at the National Institute for Occupational Safety and Health (NIOSH) conducted a case study with an aggregates company in which near-miss reports were analyzed at each of their locations over an entire quarter during the summer of 2018. Within that quarter, workers recorded 249 near misses. Of those, 167 were valid near misses that occurred at work. Researchers coded the reports using a qualitative 5 × 5 risk matrix. Of the 167 near misses, 19% were deemed low risk, 25% moderate risk, 30% high risk, and 26% critical risk. Several patterns in the near-miss incidents were documented, including classification of incidents and common corrective actions referenced (i.e., elimination/substitution, engineering control or redesign, work process/procedures, and personal protective equipment). The analysis provides insight into ways that risk communication and management programs can be improved to reengage workers and their situational awareness on the job.

Recent advances in computing, rendering, and display technologies have generated increased accessibility for virtual reality (VR). VR allows the creation of dynamic, high-fidelity environments to simulate dangerous situations, test conditions, and visualize concepts. Consequently, numerous products have been developed, but many of these are limited in scope. Therefore, the National Institute for Occupational Safety and Health researchers developed a VR framework, called VR Mine, to rapidly create an underground mine for human data collection, simulation, visualization, and training. This paper describes the features of VR Mine using self-escape and proximity detection as case studies. Features include mine generation, simulated networks, proximity detection systems, and the integration and visualization of real-time ventilation models.

Proper lighting plays a critical role in enabling miners to detect hazards when operating a roof bolter, one of the most dangerous mining machines to operate; however, there has not been any lighting research to address the walk-thru type of roof bolter commonly used today. To address this, the Saturn light was designed to directly address walk-thru roof bolter safety by improving trip hazard illumination. The visual performances of 30 participants that comprised three age groups were quantified by measuring each participant's visual performance in detecting trip objects positioned on the two floor locations within the machine's interior working space. The lighting conditions were the existing compact fluorescent lights (CFLs) and the Saturn LED area light developed by NIOSH researchers. Three intensities of the Saturn lights were used, 100%, 75%, and 50%, all of which resulted in better visual performance, and up to a 48% reduction in average trip detection time compared to the CFL. For the Saturn trip object miss rates were <0.5% for all age groups in contrast to the CFL, which ranged between 32.5% for the youngest group and 50.4% for the oldest group.

Roof bolting typically follows the extraction of a commodity to help keep the roof from collapsing. During 2004 to 2013, roof bolter operators had the highest number of machinery-related injuries, accounting for 64.7 percent, at underground coal mines. This paper analyzes U.S. roof bolter fatal and nonfatal lost-time injury data at underground work locations for all commodities from 2004 through 2013 and determines risk indices for six roof bolting tasks. For fatal and nonfatal incidences combined, the roof bolting tasks in order of the highest to lowest risk index were bolting, handling of materials, setting the temporary roof support (TRS), drilling, tramming, and traversing. For fatalities, the roof bolting tasks in order of the highest to lowest risk index were handling of materials, setting the TRS, bolting, drilling, traversing, and tramming. Age was found to be a significant factor. Severity of injury, indicated by days lost, was found to increase with increasing age as well as with increasing experience, largely due to the confounding of age and experience. The operation of the roof bolting machine used in underground mining should be a research priority given the high frequency and severity of incidents. The results also suggest that temporal factors may exist, so additional research is warranted to better understand these factors and potentially develop interventions. This research provides a data-driven foundation from which future research can be conducted for safety interventions to reduce the frequency and severity of incidences involving the roof bolter activities of bolting, handling of materials, and setting the TRS.