Mining Contractor Safety Manual

Mining Contractor Safety Programs

The safety programs needed by a mining contractor depend on the work performed and the mine environments where employees work. A comprehensive manual may include programs covering:

• MSHA Safety and Training
• Site-Specific Hazard Awareness
• Mobile Equipment Safety
• Heavy Equipment Safety
• Lockout/Tagout and Hazardous Energy Control
• Electrical Safety
• Ground Control
• Conveyor Safety
• Machine Guarding
• Crane and Rigging Safety
• Welding, Cutting and Hot Work
• Confined Space Entry
• Fall Protection
• Personal Protective Equipment
• Respiratory Protection
• Hearing Conservation
• Silica Exposure Control
• Hazard Communication
• Job Safety Analysis
• Emergency Procedures

Programs that do not apply to the contractor’s operations can be removed, while additional programs should be included when specialized mining or contractor activities create additional hazards.

MSHA and Mining Contractors

Independent contractors performing services or construction at mine properties may have responsibilities under MSHA regulations.

The contractor should determine which requirements apply based on:

• Type of mine
• Location of the work
• Work activities
• Duration of the work
• Frequency of mine exposure
• Employee exposure to mine hazards
• Equipment operated
• Applicable MSHA standards
• Mine-operator requirements

The contractor should not assume that compliance with its normal OSHA construction or general-industry programs automatically satisfies requirements applicable at a mine.

Contractor and Mine Operator Responsibilities

Mining contractors should coordinate safety responsibilities with the mine’s production operator before beginning work.

Coordination may address:

• Site-specific hazards
• Required training
• Emergency procedures
• Traffic rules
• Restricted areas
• Equipment requirements
• Hazardous energy
• Blasting
• Ground conditions
• Electrical hazards
• Communications
• Personal protective equipment
• Contractor work areas
• Simultaneous operations

Contractor employees should understand both their employer’s safety procedures and applicable mine-specific requirements.

MSHA Part 46 and Part 48 Training

Training requirements depend on the type of mine and the work employees perform.

30 CFR Part 46 generally applies to miners working at shell dredging, sand, gravel, surface stone, surface clay, colloidal phosphate, and surface limestone mines.

30 CFR Part 48 applies to training at other covered mines, including underground mines and other surface mining operations subject to Part 48.

Contractors should determine the applicable training requirements before assigning employees to mine work.

Training obligations may include:

• New miner training
• Newly hired experienced miner training
• Experienced miner training
• New-task training
• Annual refresher training
• Hazard training
• Site-specific hazard awareness training

The specific requirements depend on the applicable regulation and the employee’s work and exposure.

MSHA Training Plan

When required, the contractor should maintain an appropriate MSHA training plan covering its employees.

The plan should address applicable:

• Training subjects
• Training duration
• Training methods
• Trainers or competent persons
• Employee evaluation
• New miner training
• Experienced miner training
• Task training
• Annual refresher training
• Required documentation

Training should be completed and documented according to applicable requirements.

Site-Specific Hazard Awareness

Mine hazards vary substantially from one property to another.

Before beginning work, contractor employees should receive required information concerning hazards they may encounter.

Site-specific topics may include:

• Traffic patterns
• Haul roads
• Mobile equipment
• Restricted areas
• Highwalls
• Ground conditions
• Electrical installations
• Blasting areas
• Conveyors
• Processing equipment
• Water hazards
• Emergency signals
• Evacuation procedures
• Communication systems

Employees should receive additional information when conditions or assignments change and new hazards are introduced.

New Task Training

Employees assigned to new work should receive required task training before performing tasks for which they lack the necessary experience or training.

Task training may be necessary when an employee:

• Operates unfamiliar equipment.
• Performs a new maintenance activity.
• Changes job assignments.
• Uses new machinery.
• Performs unfamiliar mine work.
• Encounters significantly different work methods.

Training should address the health and safety aspects and safe work procedures associated with the task.

Job Safety Analysis

A Job Safety Analysis (JSA) can help mining contractors identify hazards before work begins.

JSAs may be appropriate for:

• Equipment operation
• Equipment maintenance
• Conveyor work
• Electrical work
• Welding and cutting
• Crane operations
• Rigging
• Excavation
• Drilling
• Confined-space entry
• Work at heights
• Loading and unloading
• Crusher maintenance
• Screen maintenance
• Field repairs
• Non-routine work

The JSA should identify the steps of the task, hazards associated with those steps, and controls necessary to perform the work safely.

Mine-specific hazards should be incorporated into the JSA.

Pre-Job Planning

Mining contractors should evaluate each project before work begins.

Planning should consider:

• Scope of work
• Mine location
• Site hazards
• Equipment
• Employee qualifications
• Required training
• Energy sources
• Ground conditions
• Traffic
• Blasting
• Weather
• Required permits
• PPE
• Emergency procedures

Changes in conditions should trigger reevaluation of the work plan.

Mobile Equipment Safety

Mining environments frequently contain large mobile equipment operating in areas with limited visibility.

Equipment may include:

• Haul trucks
• Loaders
• Excavators
• Bulldozers
• Graders
• Scrapers
• Water trucks
• Drills
• Service trucks
• Cranes
• Contractor vehicles

Employees should remain alert to equipment movement and understand mine traffic procedures.

Heavy Equipment Operation

Only trained and authorized employees should operate heavy equipment.

Operators should:

• Inspect equipment before use.
• Wear seat belts when provided.
• Understand equipment controls.
• Maintain visibility.
• Observe operating limits.
• Maintain safe speeds.
• Follow traffic rules.
• Stay clear of unstable ground.
• Use appropriate communication.

Equipment defects affecting safe operation should be reported and corrected.

Equipment Inspections

Mobile and heavy equipment should receive required inspections.

Inspections may address:

• Brakes
• Steering
• Tires or tracks
• Lights
• Horns
• Backup alarms
• Cameras
• Windows and mirrors
• Seat belts
• Fire extinguishers
• Hydraulic systems
• Controls
• Guards
• Access systems

Deficiencies affecting safe operation should be corrected according to applicable requirements.

Seat Belts

Employees should wear seat belts where provided and required.

Operators should not rely on enclosed cabs, rollover protection, or other equipment features as substitutes for seat-belt use.

Seat belts should be maintained in usable condition.

Haul Roads and Mine Traffic

Mine traffic can involve extremely large vehicles with long stopping distances and significant blind areas.

Contractor employees should understand:

• Traffic direction
• Right-of-way rules
• Speed limits
• Passing restrictions
• Parking areas
• Berms
• Intersections
• Dump areas
• Loading areas
• Radio procedures
• Light or flag signals

Contractor vehicles should follow mine traffic rules.

Blind Spots

Large mining equipment can have extensive blind areas.

Employees on foot should:

• Avoid equipment operating zones.
• Establish communication with operators.
• Remain visible.
• Wear required high-visibility apparel.
• Avoid approaching equipment without authorization.

Employees should never assume an equipment operator can see them.

Backing Safety

Backing should be minimized when practical.

Before backing:

• Check the area.
• Verify alarms and warning devices.
• Maintain visibility.
• Use spotters when appropriate.
• Follow mine-specific procedures.

Spotters should position themselves where they can remain visible to the operator without entering the equipment’s travel path.

Parking and Unattended Equipment

Mobile equipment should be parked in a manner that prevents unintended movement.

Depending on the equipment and conditions, precautions may include:

• Setting parking brakes
• Lowering attachments
• Chocking wheels
• Parking on suitable grades
• Controlling stored energy

Equipment should not be left in a condition where it can roll, slide, or move unexpectedly.

Ground Control

Mining contractors may work near:

• Highwalls
• Stockpiles
• Slopes
• Benches
• Dumps
• Excavations
• Underground openings
• Loose rock

Ground conditions should be evaluated before employees enter or work in affected areas.

Employees should remain clear of areas where falling, sliding, or collapsing material could create a hazard.

Hazardous ground conditions should be reported promptly.

Highwall Safety

Employees working near highwalls should remain alert to:

• Loose rock
• Cracks
• Overhangs
• Water
• Erosion
• Weather effects
• Scaling activity
• Equipment vibration

Employees should not work beneath unstable ground.

Work should be stopped when conditions indicate an increased risk of falling material or ground failure.

Stockpiles and Material Piles

Stockpiles can shift, collapse, or engulf employees and equipment.

Employees should avoid unsafe positions:

• At the base of unstable piles
• Beneath overhanging material
• On unstable slopes
• Near material being dumped
• In areas where material can slide

Equipment operation around stockpiles should account for visibility, edge conditions, and material stability.

Dump Points and Berms

Employees operating equipment near dump points should follow mine-specific procedures.

Dump locations should be evaluated for:

• Ground stability
• Edge conditions
• Berms
• Visibility
• Lighting
• Equipment positioning

Operators should not rely solely on berms to stop moving equipment.

Conveyor Safety

Mining and aggregate operations commonly use extensive conveyor systems.

Conveyors can expose employees to:

• Nip points
• Pulleys
• Belts
• Rollers
• Idlers
• Take-ups
• Drives
• Moving material
• Unexpected startup

Employees should remain clear of moving conveyor components.

Required guards should remain installed during normal operation.

Conveyor Maintenance

Before performing maintenance, cleaning, adjustment, or repair on conveyors, employees should control hazardous energy.

Maintenance planning should consider:

• Electrical energy
• Belt tension
• Gravity
• Stored material
• Hydraulic energy
• Pneumatic energy
• Moving components

Employees should verify isolation before beginning work.

Crossing Conveyors

Employees should cross conveyors only at designated and appropriately protected crossings.

Employees should not climb over, under, or through operating conveyors.

Crossovers, walkways, and access systems should be maintained in safe condition.

Machine Guarding

Crushers, screens, conveyors, feeders, pumps, fans, and other mining equipment contain moving components capable of causing severe injury.

Required guards should protect employees from hazardous:

• Belts
• Pulleys
• Gears
• Shafts
• Chains
• Sprockets
• Couplings
• Fans
• Other moving machinery

Guards should not be removed while equipment is operating unless specifically permitted by an appropriate procedure.

Crushers and Screens

Crusher and screen maintenance may expose employees to hazardous energy, stored material, suspended components, and unexpected movement.

Before entering or working on equipment:

• Shut down affected equipment.
• Isolate hazardous energy.
• Control stored energy.
• Block components when necessary.
• Control material flow.
• Verify isolation.

Employees should not enter equipment until appropriate controls have been established.

Lockout/Tagout and Hazardous Energy

Mining contractors performing maintenance should establish procedures for controlling hazardous energy.

Energy sources may include:

• Electrical
• Mechanical
• Hydraulic
• Pneumatic
• Gravity
• Pressure
• Thermal
• Stored energy

Employees should identify all energy sources before servicing begins.

Equipment should be isolated, blocked, secured, or otherwise rendered safe according to applicable requirements.

Blocking Against Motion

Elevated or movable equipment components should be securely blocked when employees could be exposed to hazardous movement.

Examples include:

• Loader buckets
• Truck beds
• Crusher components
• Conveyor components
• Hydraulic attachments
• Suspended equipment

Hydraulic pressure alone should not be relied upon to support equipment while employees work beneath or between components.

Electrical Safety

Mine electrical systems may expose employees to significant shock, arc-flash, fire, and equipment hazards.

Only appropriately qualified employees should perform electrical work requiring specialized knowledge.

Electrical work should address:

• De-energization
• Disconnects
• Grounding
• Testing
• Temporary power
• Damaged equipment
• Overhead power lines
• Electrical enclosures
• Wet environments

Employees should report electrical hazards immediately.

Overhead Power Lines

Mining contractors operating cranes, drills, dump trucks, aerial lifts, excavators, or other tall equipment should identify overhead power lines before beginning work.

Planning should consider:

• Equipment height
• Boom movement
• Raised truck beds
• Load movement
• Required clearances
• Spotters
• Travel routes

Employees should treat power lines as energized unless their status has been appropriately established.

Excavation and Trenching

Contractors performing excavation at mine properties should evaluate hazards associated with:

• Cave-ins
• Underground utilities
• Mobile equipment
• Spoil piles
• Access
• Water
• Hazardous atmospheres
• Nearby structures

Excavation work should be coordinated with mine operations and applicable regulatory requirements.

Drilling Safety

Contractors performing drilling should control hazards associated with:

• Rotating equipment
• Drill steel
• High-pressure systems
• Moving machinery
• Dust
• Noise
• Ground conditions
• Equipment stability

Employees should remain clear of rotating components and pinch points.

Required guards should remain in place.

Silica Exposure

Drilling, crushing, cutting, grinding, excavation, material handling, and other mining-related work can generate respirable crystalline silica.

Contractors should evaluate employee exposure and establish controls appropriate to the work.

Controls may include:

• Wet methods
• Local exhaust
• Enclosures
• Cab filtration
• Work practices
• Respiratory protection

Employees should receive training concerning silica hazards and required controls.

Dust Control

Dust should be controlled where employee exposure or reduced visibility creates a hazard.

Controls may include:

• Water
• Dust collection
• Ventilation
• Enclosed equipment
• Cab filtration
• Road watering
• Work practices

Dust accumulation should also be evaluated where combustible or other hazardous dust may be present.

Respiratory Protection

Mining contractors may encounter:

• Silica
• Welding fumes
• Diesel particulate matter
• Dust
• Gases
• Vapors
• Process chemicals

When respiratory protection is required, employees should use respirators selected for the hazard and follow the applicable respiratory-protection program.

Program elements may include medical evaluation, fit testing, training, inspection, maintenance, and appropriate cartridge or filter selection.

Hearing Conservation

Drills, crushers, screens, conveyors, mobile equipment, pneumatic tools, and other mining equipment can generate hazardous noise.

Employee exposures should be evaluated and appropriate controls implemented.

Controls may include:

• Equipment maintenance
• Enclosures
• Isolation
• Distance
• Administrative controls
• Hearing protection

Employees should participate in required hearing-conservation activities.

Personal Protective Equipment

PPE requirements should reflect the contractor’s work and mine conditions.

Common PPE may include:

• Hard hats
• Safety glasses
• Face shields
• Safety-toe footwear
• Work gloves
• High-visibility apparel
• Hearing protection
• Respiratory protection
• Fall protection

Specialized work may require additional electrical, chemical, welding, or task-specific PPE.

Fall Protection

Mining contractors may work on:

• Crushers
• Screens
• Conveyors
• Structures
• Platforms
• Tanks
• Equipment
• Buildings
• Elevated work areas

Fall hazards should be evaluated and appropriate protection provided.

Employees should use designated access systems and required fall protection.

Ladders and Access

Employees should use ladders, stairs, platforms, and access systems designed and maintained for safe access.

Employees should:

• Inspect ladders before use.
• Maintain three points of contact.
• Keep access ways clear.
• Avoid climbing equipment where safe access is not provided.
• Protect ladders from vehicle traffic.

Damaged access equipment should be removed from service or corrected.

Scaffolding

Contractors performing maintenance, construction, and installation work may use scaffolds at mine properties.

Scaffolds should be erected, inspected, accessed, and used according to applicable requirements.

Employees should understand:

• Capacity
• Access
• Fall hazards
• Falling objects
• Electrical hazards
• Weather conditions

Crane and Rigging Safety

Mining contractors may use mobile cranes, overhead cranes, hoists, chain falls, and rigging to install and repair mine equipment.

Lift planning should address:

• Load weight
• Crane capacity
• Rigging
• Ground conditions
• Load path
• Power lines
• Employee positioning
• Communication

Employees should remain clear of suspended loads.

Rigging

Slings, shackles, hooks, lifting beams, and other rigging equipment should be selected for the load and inspected before use as required.

Employees should understand:

• Load weight
• Sling capacity
• Sling angles
• Hitch configuration
• Center of gravity
• Sharp edges
• Load stability

Damaged rigging should be removed from service.

Welding, Cutting and Hot Work

Maintenance and construction contractors frequently perform welding, cutting, brazing, and grinding.

Hot-work planning should address:

• Combustible materials
• Fire protection
• Compressed gases
• Ventilation
• Welding fumes
• PPE
• Fire watch
• Adjacent operations

Mine-specific hot-work procedures should be followed.

Compressed Gas Cylinders

Compressed-gas cylinders should be properly identified, secured, protected, stored, and transported.

Employees should inspect:

• Cylinders
• Valves
• Regulators
• Hoses
• Connections

Oxygen equipment should be protected from oil and grease.

Damaged or leaking cylinders should be handled according to established procedures.

Confined Space Entry

Mining contractors may enter tanks, bins, silos, hoppers, vessels, pits, sumps, and other confined spaces.

Before entry:

• Identify the space.
• Evaluate hazards.
• Test the atmosphere when required.
• Isolate hazardous energy and material.
• Establish ventilation.
• Provide appropriate PPE.
• Establish communication.
• Plan for rescue.

Employees should not enter a hazardous confined space without required controls.

Bins, Hoppers and Silos

Employees should not enter bins, hoppers, silos, or similar areas containing material unless procedures protect them from engulfment, material flow, equipment movement, and other hazards.

Before entry:

• Stop material flow.
• Isolate equipment.
• Control hazardous energy.
• Evaluate atmospheric hazards.
• Establish appropriate entry procedures.

Employees should never walk on material that could bridge or collapse beneath them.

Blasting Areas

Contractors should understand mine blasting procedures and restricted areas.

Employees should follow:

• Warning signals
• Evacuation requirements
• Barricades
• Reentry instructions
• Blast schedules
• Mine communications

Contractor employees should not enter blast areas without authorization.

Explosives

Only appropriately trained and authorized personnel should handle explosives or blasting agents.

Other contractor employees should remain clear of explosives storage, loading, and blasting operations unless their work requires authorized access.

Mine-specific explosives procedures should be followed.

Material Handling

Mining contractors may handle heavy components, steel, pipe, conveyor parts, motors, pumps, tools, and construction materials.

Mechanical assistance should be used when practical.

Employees should avoid:

• Suspended loads
• Pinch points
• Unstable materials
• Improper lifting
• Placing hands beneath unsupported components

Materials should be stored to prevent rolling, sliding, or collapse.

Loading and Unloading

Loading and unloading equipment and materials should be planned.

Hazards may include:

• Shifting loads
• Suspended loads
• Mobile equipment
• Rigging
• Trailer movement
• Falls
• Pinch points

Employees should anticipate that loads may shift when chains, straps, or binders are released.

Hand and Power Tools

Tools should be appropriate for the task, inspected, maintained, and used according to manufacturer requirements.

Employees should inspect:

• Guards
• Handles
• Electrical cords
• Air hoses
• Abrasive wheels
• Controls

Damaged tools should be removed from service.

Hazard Communication

Contractors may use or encounter fuels, lubricants, solvents, welding materials, process chemicals, explosives-related materials, and other hazardous substances.

Employees should have access to applicable Safety Data Sheets and understand labeling and protective measures.

Mine-specific chemical hazards should be communicated to contractor employees when applicable.

Fueling and Flammable Materials

Fueling operations should control ignition, spill, and vehicle-movement hazards.

Employees should:

• Shut down equipment when required.
• Control ignition sources.
• Use approved equipment.
• Avoid overfilling.
• Respond promptly to spills.
• Maintain fire protection.

Fuel-storage areas should be maintained according to applicable requirements.

Fire Prevention

Contractors should control ignition sources and combustible materials.

Fire-prevention procedures may address:

• Hot work
• Fuel
• Electrical equipment
• Mobile equipment
• Combustible materials
• Fire extinguishers
• Emergency communication

Employees should know how to report a fire and respond to mine emergency signals.

Housekeeping

Good housekeeping helps prevent slips, trips, falls, fires, and equipment hazards.

Employees should control:

• Tools
• Hoses
• Cords
• Scrap
• Spills
• Packaging
• Removed equipment parts
• Welding materials

Travelways, platforms, emergency equipment, and electrical access should remain clear.

Working Around Water

Mining contractors may work near:

• Ponds
• Sumps
• Settling basins
• Dredging operations
• Water-filled pits
• Processing areas

Work should be evaluated for drowning and fall hazards.

Appropriate barriers, flotation devices, rescue equipment, or fall protection should be provided where required.

Weather Conditions

Mine contractors frequently work outdoors in changing conditions.

Planning should consider:

• Heat
• Cold
• Lightning
• High winds
• Rain
• Snow
• Ice
• Reduced visibility

Weather can also affect haul roads, highwalls, slopes, ground stability, crane operations, and equipment access.

Heat Stress

Employees performing strenuous work in hot mine environments should receive appropriate heat-stress protection.

Controls may include:

• Drinking water
• Rest
• Shade
• Acclimatization
• Work scheduling
• Employee monitoring

Employees should recognize symptoms of heat-related illness and report them promptly.

Cold Stress

Cold weather can affect employees, equipment, walking surfaces, and ground conditions.

Controls may include:

• Appropriate clothing
• Warming opportunities
• Protection from wind and moisture
• Work scheduling
• Employee monitoring

Snow and ice should be controlled on access ways and working surfaces.

Emergency Procedures

Mining contractors should understand both company emergency procedures and mine-specific emergency requirements.

Potential emergencies include:

• Fires
• Equipment incidents
• Ground failures
• Electrical incidents
• Chemical releases
• Explosions
• Blasting incidents
• Confined-space emergencies
• Medical emergencies
• Severe weather

Employees should understand alarm signals, communication methods, evacuation routes, assembly locations, and emergency contacts.

First Aid and Medical Response

Mining contractors should ensure employees understand procedures for obtaining first aid and emergency medical assistance.

Employees should know:

• How to summon help
• Mine emergency contacts
• Worksite location information
• Available first-aid resources
• Emergency transportation procedures

Serious injuries should be reported immediately according to company and mine procedures.

Incident Reporting

Employees should promptly report:

• Injuries
• Illnesses
• Near misses
• Equipment damage
• Hazardous conditions
• Property damage

The contractor should coordinate required incident notifications with the mine operator.

Incidents should be investigated to identify causes and appropriate corrective actions.

Mining Contractor Safety Training

Employees should receive training appropriate to their assigned duties, mine exposure, and applicable MSHA requirements.

Training may include:

• MSHA Part 46 or Part 48 training
• Site-specific hazard awareness
• Task training
• Mobile equipment
• Ground control
• Conveyor safety
• Hazardous energy
• Electrical safety
• PPE
• Fall protection
• Cranes and rigging
• Hot work
• Confined spaces
• Silica and dust
• Emergency procedures

Training should be documented as required.

Employee training should be reviewed whenever job assignments, equipment, work methods, mine conditions, or applicable requirements change.

Building a Mining Contractor Safety Manual

A Mining Contractor Safety Manual should be customized to the contractor’s actual work rather than relying solely on a generic construction, industrial, or OSHA safety manual.

A contractor performing welding and mechanical maintenance at aggregate mines may require a different combination of programs than an electrical contractor working at underground mines, a heavy-equipment contractor performing earthwork, or a construction contractor installing processing equipment.

The manual should reflect the types of mines where employees work, applicable MSHA training requirements, mine-specific hazards, contractor activities, mobile equipment, tools, maintenance procedures, employee qualifications, and customer requirements.

Contractors working at multiple mines should also recognize that site-specific hazards and procedures can change significantly from one property to another.

The completed safety manual should provide practical procedures employees and supervisors can use while supporting MSHA and applicable OSHA compliance, employee training, task planning, JSAs, equipment inspections, incident investigations, contractor coordination, and the company’s overall safety-management system.

Customized Mining Contractor Safety Manuals

Get a Mining Contractor Safety Manual customized for your mine-site construction, maintenance, heavy equipment, conveyors, crushers, electrical work, welding, mobile equipment, excavation, drilling, cranes and rigging, silica exposures, confined spaces, and other mining contractor hazards.