BLASTING ACCIDENTS IN SURFACE MINES,

A TWO DECADE SUMMARY

BY
Harry C. Verakis and Thomas E. Lobb
U.S. Department of Labor, Mine Safety and Health Administration
Technical Support, Approval and Certification Center
Triadelphia, West Virginia
ABSTRACT
In the past decade, approximately 5 billion pounds of explosives were used annually in the
United States. Most of this quantity of explosives was used by the mining industry and coal
mining was the dominant application for explosives. Considering the large amount of
explosives used, the accident safety record for the mining industry has improved
significantly over the past two decades. Blasting accidents are usually a small percentage
of the total number of mining accidents. However, blasting accidents continue to occur and
the severity of these accidents is disproportionately high with respect to other types of
mining accidents. This paper is a summary and an update of the surface mine blasting
accident investigations and studies conducted previously by the Mine Safety and Health
Administration (MSHA) and the former U.S. Bureau of Mines.
A compilation and review of surface coal and metal/nonmetal mine blasting accidents
covering the past two decades were made. The accident data were examined to identify
the trends and primary causes, which continue to be blast area security and flyrock. Forty
(40) percent of the causes of surface mine blasting accidents were attributed to blast area
security, while flyrock represented about 28 percent of the causes. Accident categories
are listed in the presentation of the data, based on the cause of the accident or the activity
that was taking place when the accident occurred. Other causes include premature blasts,
misfires, and disposal of explosives. The injuries, both fatal and nonfatal, caused by the
blasting accidents are tabulated over a two decade period from 1978-1998. A discussion
of the accident data is also presented to increase the hazard awareness and to
emphasize safe blasting practices and the MSHA regulations governing surface mine
blasting operations, Several recent blasting accidents resulting in fatalities are revisited to
emphasize the continuing need for constant vigilance to prevent such accidents.
INTRODUCTION
From the most recent statistics available, the mining industry uses the greatest portion of
explosives manufactured for blasting. In fact, in 1999, coal mining consumed
about two thirds, 67 percent, of the 5 billion pounds of explosives produced in the USA.
Quarrying and nonmetal mining were the second largest consumer of explosives used for
blasting, accounting for about 14 percent of total explosives sales. A considerable amount

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of explosives continue to be used in surface mining and the historical record of blasting
accidents continues to show an overall decline. The reduction in surface mine blasting
accidents is a result of the combined efforts and the accomplishments of explosive
manufacturers and suppliers, mining companies, unions, explosive and blasting
associations such as the International Society of Explosives Engineers and the Institute of
Makers of Explosives and government agencies. Many mining companies have improved
safety programs and emphasize blasting safety in their mining operations. Also, explosive
manufacturers continue to develop products with improved safety properties.
Even though surface mine blasting accidents have declined, they continue to occur and
cause fatalities and injuries. The most common causes continue to be inadequate blast
area security and flyrock.
TRENDS IN THE ACCIDENT DATA
The data for surface metal-nonmetal mines indicate 226 accidents occurred for the two
decade period from 1978 -1998 compared to 187 accidents for surface coal mines. The
trend over the 20 year period is a general decrease in the number of blasting accidents for
both surface coal and surface metal-nonmetal mines. The decreasing trend is shown in
Figure I for surface coal mine accidents and in Figure 2 for surface metal-nonmetal mine
accidents. A comparison of the 20 year blasting accident data for surface coal and s
surface metal-nonmetal mines is shown in Figure 3. It is apparent from Figure 3 that a
larger number of blasting accidents have occurred in surface metal-nonmetal mines as
compared to surface coal mines, although the trend for both continues to be downward.
However, from an analysis of the blasting accident data over the last 5 years from 1994
through 1998 it appears the rate of decrease in accidents for surface metal-nonmetal
mines has not continued as might be expected. On average, from the data shown in
Figure 3, about 8 blasting accidents per year occurred at surface metal-nonmetal mines
over this five year period. This observation from the blasting accident data is more
apparent when a further analysis is made by categorizing the blasting accidents as
discussed below.

TRENDS IN THE ACCIDENT CAUSES

Table I show the categorization of blasting accidents for surface coal and metal-nonmetal
mine operations for the 20 year period, 1978-1998. The blasting accident data is
categorized based on the cause of the accident or activity that occurred when the accident
happened, The major categories are: (1) blast area security, (2) flyrock, (3) premature
blast, (4) misfires, (5) miscellaneous, (6) disposing, (7) fumes, and (8) transporting
explosives.
Blast area security (lst), flyrock (2nd) and premature blast (3rd) are the main causes of
surface mine blasting accidents , both recently and historically. The percentages for the
blasting accident categories indicated above are shown in Table I, with blast area security
representing 40 percent, flyrock , 28 percent, and premature blast, 17 percent.

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In addition, a further analysis of the blasting accident data by categories was made for the
5 year period, 1994-1998. This data is shown in Table 2. Table I shows that for the period
1978 -1998, 55 percent of the blasting accidents were at surface metal-nonmetal mines
and 45 percent at surface co,al mines. However, for the 5 year period , 1994-1998,70
percent of the blasting accidents were at surface metal-nonmetal mines and 30 percent
were at surface coal mines. These differences may be due to the changing economy with
the emphasis on the need for more aggregate from surface nonmetal mines for
construction and highway developments and projects.
Two recent accidents involving a fatality due to inadequate blast area security and a fatality
from flyrock reinforce the main causes of blasting accidents and the continuing need to
address blast area security and flyrock. Both of these accidents are addressed below in
some detail.
REVISITING TWO RECENT FATAL ACCIDENTS
The need for constant vigilance in preventing blasting accidents continues to be evident
from two recent surface mine blasting accidents. Each of these two accidents resulted in a
fatality, Both incidents fall into the two main causes of surface mine blasting accidents,
flyrock and inadequate blast area security.
One of the accidents occurred at a surface limestone mine operation in Pennsylvania and
is placed into the category of flyrock. The victim, an equipment operator with 7 years of
mining experience was fatally injured when he was struck by a piece of flyrock. He was
sitting in the passengers seat of a pick-up truck and was guarding a road leading to the
blast site. Soon after the shot was detonated, a baseball-sized piece of flyrock was
projected through the windshield of the pick-up truck (see Figure 4) and struck him. The
root cause of this accident was the failure to ensure that persons had cleared the blast
area or that persons were in a blasting shelter or protected location prior to initiating the
shot. The blasters failure to clearly delineate the blast area to the mine operator and the
employees was a contributing factor to the accident.
The other accident occurred at a surface coal mine operation in Kentucky and is placed
into the category of blast area security. The accident occurred because of the failure to
provide ample warning, and failure to clear and remove all persons from the blasting site
prior to detonating the blast. Failure to do this resulted in the death of the owner of the
property, who had walked into the blast area shortly before the blast was detonated. The
pathway that the victim traveled using an all-terrain vehicle (ATV) is shown in Figure 5.
Further details on these and other blasting accidents over the past several years may be
found on MSHAs lnternet Site at http//:www.msha.gov under Fatality Information. In
addition, MSHAs blasting regulations for surface coal mines, Part 77, Subpart
N-Explosives and for surface metal-nonmetal mines, Part 56, Subpart E-Explosives may
be found on MSHAs lnternet Site under Statutory and Regulatory Information, Title 30,
Code of Federal Regulations (30 CFR).

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This summary of blasting accident data can be used to more effectively respond to the
challenges that affect the mining industry in the quest to ensure and improve blasting safety
and the public image of blasting at surface mines. Miners and personnel employed by the
mining industry continue to suffer fatal and disabling injuries from blasting accidents.
.
Government, labor, and the blasting and explosives industry and their associated
organizations have made great strides to make blasting safe in the mining industry.
Today, there is more awareness about the effect of blasting on the surrounding
environment and neighboring community and the need to address the safety concerns from
blasting. MSHA is committed to conferences, such as this one, which bring together
management, labor, industry and industry associations, government, and academia to
share their experiences and work toward common goals.MSHA will continue to strive to
reduce mine blasting accidents, to stress blasting safety, and to be involved in the mining
community and public segments that deal with explosives and blasting safety.
REFERENCES
Siskind, David E. and Kopp, John W., Blasting Accidents in Mines, A 16-Year Summary,
Proceedings of the Twenty-First Annual Conference on Explosives and Blasting Technique,
International Society of Explosives Engineers, Vol. II, February
5-9, 1995, pp. 224-239.
MSHA Accident Data Abstracts, Surface Mine Blasting Fatals and Nonfatal Accident
Reports, I 999.
Explosives, Mineral Industry Surveys, U.S. Geological Survey, August 2000.
Yesko, Dennis A., Weber, Charles, J., and Lobb, Thomas E., MSHA Report of
Investigation, Fatal Explosives Accident, Compass Quarries, Inc., Paradise, Lancaster
County, PA, December 21, 1999,6 pages.
Stewart, Buster, MSHA Accident Investigation Report, Fatal Explosives Accident, Big
Creek Mining, Inc., Mine No. 2, Fedscreek, Pike County, KY, February 15, 1999, 5 pages.

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Table 1. - Fatal plus nonfatal surface mine blasting accidents, 1978-98

Table 2. - Fatal plus nonfatal surface mine blasting accidents, 1994-98

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Figure 4 - Flyrock accident fatality--Surface

limestone mine.

Figure 5 - Access (Pathway) leading to

blast site of fatal accident-Surface coal
mine.

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