Date of Award

8-17-2025

Document Type

Masters Project

Abstract

This study investigates equipment-related fatal incidents in U.S. underground coal mining from 1993 to 2023, analyzing trends, causes, and the effectiveness of safety measures. Using data from the Mine Safety and Health Administration (MSHA), this study examined 205 fatalities linked to continuous miners, shuttle cars, roof bolters, load-haul-dump (LHD) vehicles, longwall systems, and hoisting equipment. A mixed-methods approach combines the quantitative analysis of accident trends with qualitative models, such as Failure Mode and Effects Analysis (FMEA) and Bowtie Analysis. The findings revealed that powered haulage and machinery accidents were the leading causes of fatalities, with mechanical failures (40%), human errors (28%), and hazardous environmental conditions (20%) being the primary contributors. Critical failures included hydraulic system breakdowns and conveyor malfunctions, whereas unsafe operating practices and fatigue were the dominant human factors. Summer and fall show elevated fatality rates driven by heat stress and production pressures. Regulatory reforms, especially the MSHA and Health Administration’s (MSHA) 2015 proximity detection mandates, have helped reduce fatality rates. However, risks remain due to inconsistent system maintenance and compliance issues. Emerging technologies, such as AI-driven hazard detection, real-time monitoring, and automation, hold promise but require integration with behavioral safety programs. This study proposes actionable recommendations, including stricter policy enforcement, predictive maintenance strategies, ergonomic equipment redesign, and simulation-based training. It emphasizes a systems approach that addresses mechanical, human, and environmental factors of the problem. By bridging theoretical hazard models with practical interventions, this study offers a data-driven framework for reducing fatalities. These insights are valuable for industry stakeholders, safety professionals, and regulators committed to improving mining safety and ensuring that technological progress translates into lives saved.

Handle

http://hdl.handle.net/11122/16329

Download

Share

COinS