Accidents Due to Dumpers and Tippers in Opencast Coal Mines – DGMS Guidelines, Causes & Prevention

🧾 DETAILED NOTES

1️⃣ Introduction

In opencast coal mines, dumpers and tippers are the backbone of material handling operations. However, they are also responsible for a significant proportion of fatal and serious accidents. According to DGMS statistics, more than 35% of opencast mine fatalities are linked to dumper/truck mishaps, including collisions, overturning, and edge failures. Most of these accidents are preventable through proper road design, vehicle maintenance, and operator training.

2️⃣ Common Causes of Dumper and Tipper Accidents

Unsafe Haul Road Design – excessive gradient, poor drainage, and narrow widths.
Over-speeding and poor visibility, especially during fog or night.
Dump edge collapse due to weak berms or overfilled dumps.
Brake failure or poor maintenance of HEMM (Heavy Earth Moving Machinery).
Operator fatigue or untrained drivers.
Improper reversing without spotters or mirrors.
Lack of traffic discipline and violation of Traffic Management Plan (TMP).

3️⃣ DGMS Regulations & Circulars

CMR 2017, Regulation 99: Duties of competent persons for transport control.
CMR 2017, Regulation 101: Haul road construction & maintenance.
DGMS Circular 8 of 2008: Design, construction, and maintenance of haul roads.
DGMS Circular 1 of 2009: Safe operation of dumpers and tippers.
DGMS Tech Circular 2 of 2013: Collision prevention systems and operator fatigue management.
DGMS Circular 5 of 2010: Traffic management and safe working zones.
Mines Act, 1952 – Sec. 23 & 24: Reporting of accidents and inquiries.

4️⃣ Inquiry Procedure

Immediate Reporting: Accident must be reported to DGMS, District Authority, and Police.
Inquiry Committee Formation: Led by Mine Manager, including Safety Officer and Contractor Representative.
Evidence Collection: Photographs, witness statements, vehicle inspection.
Root Cause Analysis: Evaluate mechanical, human, and environmental factors.
DGMS Inspection: Independent verification by Regional Inspector.
Corrective Actions: Road redesign, driver retraining, contractor penalization.

5️⃣ Preventive Measures

(A) Haul Road Design

Width = 3 times the width of the largest dumper (for two-way traffic).
Gradient ≤ 1 in 16, properly cambered and drained.
Parapet walls or safety berms at all edges.
Speed breakers and reflectors at curves and junctions.
Separate roads for dumpers and light vehicles.

(B) Dump Yard Safety

Maintain 1.5 m high parapet wall at dump edge.
Dumping must be under supervision of a competent person.
Reversing alarms and proximity detection systems must be functional.
Safe distance (minimum 3 m) from dump edge during tipping.
Avoid dumping during rainy or low-visibility conditions.

(C) Vehicle Maintenance & Inspection

Daily pre-start inspection by operator.
Monthly mechanical audit under Reg. 126 (1) of CMR 2017.
Brake testing and steering check to be recorded in a HEMM logbook.

(D) Training & Supervision

Drivers to hold valid Heavy Vehicle & Mine Driving Permit.
Simulator-based training recommended by DGMS (2012 circular).
Supervisor must ensure adherence to Traffic Management Plan (TMP).

(E) Traffic Management

One-way traffic wherever feasible.
Clear signboards, reflectors, and speed limits (≤ 25 km/h).
Communication protocol between operators and spotters via VHF or horns.
Night operations must have adequate floodlighting.

6️⃣ DGMS Inquiry Responsibilities

Ensure the contractor and owner share liability under Mines Act Section 18.
Verify insurance and medical arrangements.
Record all evidence and forward findings to DGMS within 15 days.

7️⃣ Case Study (Example: Fatal Accident 2019)

A fatal dumper overturned while reversing at a coal bench edge. The operator was untrained and unbelted. Inquiry revealed the absence of berm and overloading beyond design capacity. DGMS mandated re-design of haul roads and suspension of the contractor for safety negligence.

⚙️ QUICK ONE-LINERS (Revision Points)

Regulation 101 CMR 2017 → Haul road maintenance.
Regulation 99 → Transport supervision duties.
Traffic Management Plan is compulsory.
DGMS Circular 8 of 2008 → Contractor vehicle safety.
Road width = 3 × vehicle width.
Minimum berm height = half wheel diameter.
Speed limit → 20 km/hr for heavy vehicles.
Accident reporting → within 24 hours to DGMS.
Joint inquiry mandatory for contractor accidents.
Fatigue and over-speeding are prime causes.

🧮 DESCRIPTIVE MODEL QUESTION

Q. What are the causes and preventive measures of dumper and tipper accidents in opencast coal mines as per DGMS guidelines?

Answer:
Accidents involving dumpers and tippers mainly occur due to poor haul road design, mechanical failure, and operator negligence. DGMS Circular 8 of 2008 and Reg. 101 of CMR 2017 specify that haul roads must have proper width, gradient, and parapet walls. Regular maintenance, traffic control, and fatigue monitoring systems must be in place. Drivers should be trained and certified, and all vehicles must undergo daily pre-start inspections. Dumping operations must be supervised by competent persons to prevent edge failures and overturning.

🧩 25 DGMS-Based MCQs

Q1. The majority of transport accidents in opencast mines occur due to:

Solution: Haul road traffic (collisions, overturning) is the most significant cause of accidents in opencast transport.

Q2. Regulation governing haul road maintenance is:

Solution: Regulation 101 of CMR 2017 specifically outlines the standards for construction and maintenance of haul roads.

Q3. Minimum haul road width = dumper width ×

Solution: For two-way traffic, the standard guideline is 3 times the width of the largest vehicle, plus berms.

Q4. Speed limit for dumpers in mine premises:

Solution: While site-specific, 25 km/h is a common and recommended speed limit for heavy vehicles in mine premises.

Q5. DGMS Circular 8 of 2008 deals with:

Solution: This circular specifically addresses traffic management, haul road design, and the safety of contractor-operated vehicles.

Q6. Inquiry reports must be sent to DGMS within:

Solution: The detailed inquiry report (after the initial 24-hour notice) is typically required within 15 days.

Q7. Haul road gradient shall not exceed:

Solution: 1 in 16 is the generally prescribed maximum gradient for permanent haul roads to ensure safe vehicle operation.

Q8. Who is responsible for safe transport operations?

Solution: Under the Mines Act, both the mine management (Owner/Agent/Manager) and the contractor share responsibility for safety.

Q9. Minimum berm height along road edge:

Solution: The standard guideline for berm height is that it must be at least half the diameter of the largest tyre using the road.

Q10. Reverse alarm is mandatory for:

Solution: All heavy earth-moving machinery (HEMM), including dumpers, must be fitted with an audible reverse alarm.

Q11. Regulation 99 CMR deals with:

Solution: Regulation 99 of CMR 2017 outlines the duties of competent persons for various operations, including transport control.

Q12. Fatal transport accidents are reported under:

Solution: Section 23 of the Mines Act, 1952, mandates the "Notice of Accident" for fatal and serious incidents.

Q13. Temporary haul roads must be inspected:

Solution: While daily checks are good practice, a formal, recorded inspection is often required weekly for such roads.

Q14. Contractor drivers must be:

Solution: DGMS circulars strictly mandate that all operators of HEMM must be properly trained (VTI) and hold a valid license.

Q15. Poor illumination can lead to:

Solution: Poor visibility on haul roads, especially at night, is a major cause of vehicle collisions.

Q16. Safety signage should be placed every:

Solution: Regular placement of signage (e.g., speed limits, gradients) at intervals like 100m is a common TMP guideline.

Q17. DGMS Circular 1 of 2017 focuses on:

Solution: This circular re-emphasized the importance of verifying vehicle road-worthiness and operator competency.

Q18. Vehicle inspection register is maintained in:

Solution: Form B of the Mines Rules, 1955 is the register of employees, which includes details of competent persons (like drivers). Daily inspection logs are often separate but linked.

Q19. Fatal accident reports are forwarded by:

Solution: The Mine Manager is the statutory head responsible for all official reporting to DGMS.

Q20. The primary aim of DGMS inquiry:

Solution: The main goal of an inquiry is to identify the root cause to prevent future recurrence, not just assign blame.

Q21. Contractors are responsible under which section?

Solution: Section 18 of the Mines Act, 1952, outlines the responsibilities of owners, agents, and managers, which extend to contractor operations.

Q22. Accident evidence includes:

Solution: A thorough inquiry relies on all available evidence: physical (photos, site), testimonial (witnesses), and documentary.

Q23. Traffic Management Plan ensures:

Solution: A TMP organizes traffic routes, speeds, and rules to ensure a safe and smooth flow of vehicles.

Q24. Lack of TMP results in:

Solution: Without a TMP, traffic becomes chaotic, leading to a higher risk of interactions and collisions.

Q25. Corrective action after fatality includes:

Solution: Corrective actions are comprehensive and address all root causes, which may include penalization, training, and engineering changes.

🔗 INTERNAL LINKS

Related Topic	Read More On...
Opencast Safety	Small Opencast Manager Appointment
HEMM Safety	Safety Features in Crawler/Tyre Mounted Machinery
Dump Stability	Design & Monitoring of Pit/Dump Slopes
Accident Reporting	Accident Reporting, Hazard ID & Risk Management

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