Surge Pile Safety Guide

Explore crucial safety improvements for surge pile operations, including high-strength glass windows and remotely-controlled equipment. Follow best practices to safeguard operators and prevent accidents.

Step 1 of 15

Introduction:

Pushing coal on a surge pile is extremely dangerous. Nineteen miners have died in surge pile accidents since 1980, with many close calls.

Step 2 of 15

Accident Scenario:

Bulldozers can fall into hidden cavities where coal has bridged over an underground feeder. Coal covers the machine, breaking windows and filling the cab with coal.

Step 3 of 15

Protection Methods:

Two ways to protect operators are: providing cab windows strong enough to withstand burial pressure, and using remotely-controlled equipment.

Step 4 of 15

MSHA Testing:

High-strength glass can withstand burial pressure in surge pile accidents. This was demonstrated through both laboratory and full-scale field tests.

Step 5 of 15

Source of Glass:

The high-strength glass used is manufactured by PPG Industries and was originally developed for use in cockpit windows of the F-111 fighter jet.

Step 6 of 15

Demonstration Setup:

Caterpillar D9 Dozer with high-strength windows was used. A ramp was made on the back side of the stockpile, and the dozer was covered in coal increments using a D11.

Step 7 of 15

Verification of Glass Strength:

High-strength glass is produced with a special manufacturing process. The glass was verified to withstand 20 psi burial pressure, equivalent to 35 feet of coal.

Step 8 of 15

Purpose of Strong Cab Windows:

The purpose of strong cab windows is to provide a "safe refuge" for the operator during an accident, ensuring their safety in surge pile operations.

Step 9 of 15

Rescue Strategy:

Mines should have plans for equipment excavation. Start removing coal from the side of the cavity to avoid breaking cab windows during rescue operations.

Step 10 of 15

Operators’ Feedback:

Operators believe high-strength glass could save lives despite the cost. Various operators have expressed positive responses about its potential benefits.

Step 11 of 15

Remote Control Equipment:

Using remotely-controlled equipment can remove operators from potential danger. This approach is already used in other industries and is a valid alternative.

Step 12 of 15

Best Practices:

Provide two self-rescuers and emergency lighting in equipment. Install gates on feeders, use TV cameras for real-time observation, and identify feeder locations with markers.

Step 13 of 15

More Best Practices:

Install lights to indicate active feeders, allow operators to shut down feeders and belts from the cab, avoid operating over feeders, and ensure communication between workers.

Step 14 of 15

Training and Safety:

Prohibit walking on the pile, keep equipment facing the feeder near the drawhole, and provide hazard training, especially for new workers and contractors.

Step 15 of 15

Additional Resources:

For more information on surge pile safety, visit MSHA's web page