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“Tire Safety in the

Mining Industry”

by:

Jami G. Dwyer, P.E., C.M.S.P.

NIOSH Spokane Research Laboratory

Institute for Mine Health and Safety, International Society of Mine Safety Professionals Critical Issues, and Train the Trainer Combined Conference

Salt Lake City, UTMay 24-28, 2004

http://www.cdc.gov/

National Institute for Occupational Safety and Health NIOSH, Spokane, WANational Institute for Occupational Safety and Health NIOSH, Spokane, WA

Today we will cover:Today we will cover:

Fatalities associated with tires, Fatalities associated with tires, 1980-20001980-2000Tire Injuries, 1996-2000Tire Injuries, 1996-2000Tire Tire Safety Safety TipsTipsPrioritization of Prioritization of safetysafety programs programs based on passive databased on passive data


BackgroundBackground


NIOSH Spokane Research LabNIOSH Spokane Research Lab Project: Project: Surface Powered Haulage SafetySurface Powered Haulage Safety

Project Objectives:Project Objectives:Detection of Vehicles or Detection of Vehicles or Personnel in Blind SpotsPersonnel in Blind SpotsMonitoring of Driver Monitoring of Driver AwarenessAwarenessHealth and Safety Hazards to Health and Safety Hazards to Personnel Responsible for Personnel Responsible for Powered Haulage Equipment Powered Haulage Equipment Maintenance and OperationMaintenance and Operation


Hazards to Maintenance Hazards to Maintenance Workers:Workers:

Frequent heavy liftingFrequent heavy liftingHigh pressure hoses and High pressure hoses and vesselsvesselsWork in awkward or Work in awkward or confining spacesconfining spacesExposure to potentially Exposure to potentially hazardous substances (oil, hazardous substances (oil, gas, engine fluids, welding gas, engine fluids, welding fumes, etc.)fumes, etc.)Proximity to moving parts, Proximity to moving parts, hand tools, and hand tools, and machinery.machinery. Source: www.msha.gov

Tire explosion which resulted in a fatality


TIRE FATALITIESTIRE FATALITIESFrom 1980-2001.2From 1980-2001.2

What can we learn from 20+ years of data?What can we learn from 20+ years of data?


But first, a little note on data But first, a little note on data analysis...analysis...

Lesson #1:Lesson #1:When analyzing When analyzing data, it helps to data, it helps to know what you are know what you are looking forlooking for


About the fatality data...About the fatality data...

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


A little more about the fatality A little more about the fatality data...data...

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

*more on this later

Frequency of Tire-Related Frequency of Tire-Related FatalitiesFatalities(1980-2001.2)(1980-2001.2)

0

1

2

3

4

1980

1981

1982

1983

1984

1985

1986

1987

1988

1989

1990

1991

1992

1993

1994

1995

1996

1997

1998

1999

2000

2001

Freq

uenc

y

n = 31

Tire-related fatalities account for a relatively low proportion of Tire-related fatalities account for a relatively low proportion of occupational fatalities in mining. However, focused safety, occupational fatalities in mining. However, focused safety, training, and other prevention efforts should effectively eliminate training, and other prevention efforts should effectively eliminate this cause of death.this cause of death.


What Caused the Tire What Caused the Tire Fatalities?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)

Exploding Tire FatalitiesExploding Tire FatalitiesExample #1Example #1

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

Source: www.msha.gov

Exploding Tire FatalitiesExploding Tire FatalitiesExample #2Example #2

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


Falling Tire FatalitiesFalling Tire FatalitiesExamplesExamples

““TIRE SIZE 6540-39 ... WAS NOT SECURED IN ITS UPRIGHT TIRE SIZE 6540-39 ... WAS NOT SECURED IN ITS UPRIGHT POSITION AND TIRE AND RIM FELL ON EMPLOYEE DAMAGE POSITION AND TIRE AND RIM FELL ON EMPLOYEE DAMAGE FATAL”FATAL”

THE VICTIM “WAS CHANGING 37.25X35 TIRE ON...LOADER THE VICTIM “WAS CHANGING 37.25X35 TIRE ON...LOADER TIRE AND WHEEL FELL OFF HUB OF LOADER AND PINNED TIRE AND WHEEL FELL OFF HUB OF LOADER AND PINNED VICTIM AGAINST SERVICE TRUCK CRUSHING HIM”VICTIM AGAINST SERVICE TRUCK CRUSHING HIM”

““TECHNICIAN FROM AN OUTSIDE TIRE SERVICE COMPANY TECHNICIAN FROM AN OUTSIDE TIRE SERVICE COMPANY WAS IN THE PROCESS OF INSTALLING A NEW TIRE ON A WAS IN THE PROCESS OF INSTALLING A NEW TIRE ON A FRONT END LOADER. FOR UNKNOWN REASONS, THE TIRE FRONT END LOADER. FOR UNKNOWN REASONS, THE TIRE FELL ON THE TECHNICIAN, SUBJECTING HIM TO FATAL FELL ON THE TECHNICIAN, SUBJECTING HIM TO FATAL INJURIES.”INJURIES.”


Examples from actual narratives:

A SUPV & LABORER CHANGING A TIRE ON A LOADER USING A A SUPV & LABORER CHANGING A TIRE ON A LOADER USING A BOOM TRUCK TO LIFT THE TIRE.BOOM TRUCK WAS 14' FROM BOOM TRUCK TO LIFT THE TIRE.BOOM TRUCK WAS 14' FROM OVERHEAD WIRE.THE COME-ALONG HOLDING THE TIRE SNAPPED OVERHEAD WIRE.THE COME-ALONG HOLDING THE TIRE SNAPPED (A METAL HOOK BROKE),THE TIRE DROPPED,THE BOOM TRUCK (A METAL HOOK BROKE),THE TIRE DROPPED,THE BOOM TRUCK CABLE WHIPPED OUT STRIKING THE ELECTRICAL...”CABLE WHIPPED OUT STRIKING THE ELECTRICAL...”

““EMP WAS REPLACING REAR TIRE ON 988A CAT WHEEL LOADER. EMP WAS REPLACING REAR TIRE ON 988A CAT WHEEL LOADER. FENDER WAS HELD IN UPRIGHT POSITION WITH CHAIN COME A FENDER WAS HELD IN UPRIGHT POSITION WITH CHAIN COME A LONG. APPARENTLY CONE A LONG BROKE LETTING FENDER FALL LONG. APPARENTLY CONE A LONG BROKE LETTING FENDER FALL AND FENDER STRIKING EMP ON THE HEAD.”AND FENDER STRIKING EMP ON THE HEAD.”

““EMPLOYEE WAS CHANGING TIRE ON TRUCK. JACK KICKED-OUT EMPLOYEE WAS CHANGING TIRE ON TRUCK. JACK KICKED-OUT FROM UNDER TRUCK STRIKING EMPLOYEE IN CHEST.”FROM UNDER TRUCK STRIKING EMPLOYEE IN CHEST.”


Tire Fatalities due to misuse or Tire Fatalities due to misuse or malfunction of tire-related toolsmalfunction of tire-related tools


Tire-Related FatalitiesTire-Related FatalitiesGrouped by Accident Type 1980-2001.2Grouped by Accident Type 1980-2001.2

..

Explosion42%

Tire Fell on Victim34%

Auxiliary Object

17%

Other7%


Tire-Related FatalitiesTire-Related FatalitiesGrouped by Occupation 1980-2001.2Grouped by Occupation 1980-2001.2

..

3%

7%

6%6% 3% 3% 3%

69%

Mechanic Repairman

Master Mechanic

Welders

Unknown or NEC

Truck Driver

Mine Foreman/MineMgr/Owner

Laborer/UtilityMan/Pumper

Highlft Opr/Frt EndLoader Opr


SAFETY TIPSSAFETY TIPS


Safety Tips to Prevent Tire Safety Tips to Prevent Tire ExplosionsExplosions

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


Safety Tips to Prevent Tire Safety Tips to Prevent Tire ExplosionsExplosions

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.


Safety Tips to Prevent Tire Safety Tips to Prevent Tire Fatalities From Falling TiresFatalities From Falling Tires

SRL photo

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 Fatalities Safety Tips to Prevent Fatalities from “Auxiliary Equipment”from “Auxiliary Equipment”

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. SRL photo


TIRE-RELATED TIRE-RELATED INJURIESINJURIES

From 1995-2001.2From 1995-2001.2


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


About this data About this data (continued)(continued)......This initial injury analysis used the MSHA accident/illness This initial injury analysis used the MSHA accident/illness classifications to categorize data.classifications to categorize data.Non-fatal tire-related incidents were found in all of the Non-fatal tire-related incidents were found in all of the following MSHA classifications:following MSHA classifications:

““Exploding Vessels Under Pressure”Exploding Vessels Under Pressure”““Hand Tools”Hand Tools”““Falling, Rolling, Sliding Rock or Material of Any Kind”Falling, Rolling, Sliding Rock or Material of Any Kind”““Handling Material”Handling Material”““Machinery”Machinery”““Powered Haulage”, andPowered Haulage”, and““Other”Other”


Distribution of Lost Days as Reported by Distribution of Lost Days as Reported by Accident CategoryAccident Category

<1 %

56%

3%

6%

19%

16%

HandlingMaterials

Hand Tools

ExplodingVesselsMachinery

PoweredHaulage

Falling, Rolling,Sliding Mat'l.

Tire-related Injuries 1995-2001.2Tire-related Injuries 1995-2001.2


Lost Days Summary by Accident Lost Days Summary by Accident CategoryCategory

Tire-related Injuries 1995-2001.2Tire-related Injuries 1995-2001.2

% Lost % Lost DaysDays

Lost days Lost days chargedcharged

Avg days Avg days lostlost

MedianMedian # of # of AccidentsAccidents

Handling Handling MaterialMaterial

56%56% 76567656 3131 1616 8787

Hand ToolsHand Tools 19%19% 25312531 2929 1212 217217Exploding Exploding VesselsVessels

16%16% 21022102 4949 2828 4343

MachineryMachinery 6%6% 770770 2323 1919 1010Powered Powered HaulageHaulage

3%3% 423423 3838 2929 1111

Falling/Falling/Rolling/Sliding Rolling/Sliding Matl.Matl.

<1%<1% 9191 4646 ---- 22

Most lost days in “Handling Material”

Highest average lost days in “Exploding Vessels”

Most accidents in “Hand Tools”


Data Analysis of Tire-Related Data Analysis of Tire-Related InjuriesInjuries

Hand Tools Injuries

050

100150200250300350400450500

Abd

omen

Ank

le

Bac

k

Che

st

Elbo

w

Eyes

Face

Face

, NEC

Fing

ers

Foot

(not

Han

d

Hea

d, N

EC

Hip

s

Kne

e

Leg,

NEC

Low

er

Low

er L

eg

Mou

th

Mul

tiple

Shou

lder

Toes

Trun

k,

Trun

k, N

EC

Upp

er A

rm

Wris

t

Body Part

Lost

Day

s

024681012141618

Lost Days (total) Frequency


Days Lost Summary by ActivityDays Lost Summary by ActivityTire “Handling Material” Injuries 1995Tire “Handling Material” Injuries 1995

838

263

219

85 76

30 286 5

0

100

200

300

400

500

600

700

800

900

Liftingtire /wheel/or

otherassociated

object

Bending over Removing tire Assemblingtire

Tire or wheelfell on victim

Struck byobject

Putting tire on Moving tire Auxiliaryequipment

failure


In summary...In summary...

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


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


Questions?Questions?

Contact:Contact:

Jami G. DwyerJami G. DwyerNIOSH – Spokane Research LabNIOSH – Spokane Research Lab315 E. Montgomery Ave.315 E. Montgomery Ave.Spokane, WA 99207Spokane, WA 99207(509)354-8000(509)354-8000Email: [email protected]: [email protected]

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