Developing a Part 46 Training Plan

Welcome Feb , 2006 “Focus on Safety Week” for Metal and Nonmetal Mines Nationwide

Session Agenda Welcome I. Welcome and Introductory Remarks II.Part 46 Regulatory Review III.Writing a Training Plan IV.Training Resources V.Session Wrap-up

Regulatory Overview

Under Part 46 Who Has to be Trained? Miners and other persons at: Shell dredging Sand Gravel Surface Stone Surface Clay Colloidal phosphate AND Surface Limestone mines

Who is Considered a “Miner”? Any person, including any operator or supervisor, who works at a mine and who is engaged in mining operations; Includes independent contractors and employees of independent contractors who are engaged in mining operations; AND Any construction worker who is exposed to hazards of mining operations.

What is the Minimum Information Required for a Training Plan? 1. Name of production operator or independent contractor, mine name(s), MSHA mine ID number(s) or independent contractor number(s). 2. Name and position of person designated who is responsible for health & safety training.

What is the Minimum Information Required for a Training Plan? 3. General description of teaching methods, course materials, subject areas and approximate time for each subject area. 4. List of persons and/or organizations who will provide training and subject area each is competent to instruct. 5. Evaluation procedures used to determine effectiveness of training.

Who Can Conduct Training? Competent Person – means a person designated by the production-operator or independent contractor who has the ability, training, knowledge or experience to provide training to miners in his or her area of expertise. Must be able to effectively communicate the training subject to miners and to evaluate whether the training given to miners is effective.

Who Can Conduct Training? You may conduct your training State or federal agencies Associations of production-operators or independent contractors Miners’ representatives Consultants Manufacturers’ representatives Private associations Educational institutions

How Should the Training Be Conducted? Classroom instruction Instruction at the mine Interactive computer-based instruction Alternative training technologies Any combination of training methods

What are the Categories of Training Required by the Standard ? New miner training Newly hired experienced miner training New task training Annual refresher training Site specific hazard awareness training Contractor training

New Miner Training New Miner – person who is beginning employment as a miner with a production- operator or independent contractor and who is not an experienced miner. No less than 24 hours of training is required for new miners.

New Miner Training: Before Beginning Work at the Mine (No Less Than 4 Hours) Introduction to work environment; Recognition and avoidance of electrical and other hazards; Review of the emergency medical, escape and emergency evacuation plans, firewarning and firefighting; Health & safety aspects of assigned tasks; Statutory rights of miners; Authority and responsibility of supervisors and miners’ representatives Introduction to rules and procedures of reporting hazards

New Miner Training: No Later Than 60 Calendar Days After Beginning Work at Mine Instruction in use, care and maintenance of self- rescue and respiratory devices (if in use) Review of first aid methods

New Miner Training: No Later Than 90 Calendar Days After Beginning Work at Mine Provide with balance, if any, of the 24 hours of training on any other subjects that promote health & safety for miners.

Newly Hired Experienced Miner Training Experienced Miner – person employed as a miner on or after October 2, 2000 who has completed 24 hours of new miner training under Sect of this part or under Sect of this title and who has at least 12 cumulative months of surface mining or equivalent experience.

Newly Hired Experienced Miner: Before Beginning Work at the Mine Introduction to work environment; Recognition and avoidance of electrical and other hazards; Review of the emergency medical, escape and emergency evacuation plans, firewarning and firefighting; Health & safety aspects of assigned tasks; Statutory rights of miners; Authority and responsibility of supervisors and miners’ representatives Introduction to rules and procedures of reporting hazards

Instruction in use, care and maintenance of self- rescue and respiratory devices (if in use) Newly Hired Experienced Miner: No Later Than 60 Calendar Days After Beginning Work at Mine

New Task Training To be provided to any miner who is reassigned to a new task in which he/she has no previous work experience Train in the health & safety aspects and safe work procedures specific to that new task Provide before the miner performs the new task

Annual Refresher Training No less than 8 hours No later than 12 months after the miner begins work at the mine

Annual Refresher Training Changes at the mine that could adversely affect miners’ health or safety; Other relevant health and safety topics.

Other Relevant Topics Applicable health and safety requirements Hazard Communication Transportation controls and communication systems Escape and emergency evacuation plans Firewarning and firefighting Use of hand-tools and welding equipment Material handling Ground conditions and control Traffic patterns and control Working in areas of highwalls Water hazards Prevention of accidents Explosives Respirators Working around moving objects (machine guarding) Fall prevention and protection

Other Relevant Topics: Equipment - Specific Training Haulage and service trucks Front-end loaders and tractors Conveyor systems Cranes Crushers Excavators Dredges Maintenance and repair

Site-Specific Hazard Awareness Training (SSHAT) Must be provided before any person specified is exposed to mine hazards SSHAT is information or instructions on the hazards a person could be exposed to while at the mine and emergency procedures. Not required for any person who is accompanied at all times by an experienced miner familiar with the hazards.

Who Must Receive SSHAT? Office or staff personnel Scientific workers Delivery workers Customers, including commercial over-the-road drivers Construction workers Maintenance or service workers Vendors or visitors

Independent Contractor Training Production-operator has responsibility for providing SSHAT and information regarding the contractor’s responsibility to comply with MSHA training requirements:  New miner training  Newly hired experienced miner training  New task training  Annual refresher training

Developing a Part 46 Training Plan

Five Steps to Compliance

2005 Metal / Nonmetal Fatal Accident Review

MNM Fatals

MNM Fatalities by Commodity * Trona, Lime, Platinum, Pumice, Phosphate, Iron Ore, Sandstone, Potash, Copper

MNM Fatalities by Classification

MNM Fatalities by Mine Size

MNM Fatalities by Age

MNM Fatalities by Mining Experience

MNM Fatalities by Activity

MNM Fatalities by Occupation

Root Causes Note: Fatalities may have several root causes.

MNM Fatalities –

METAL/NONMETAL DAILY FATALITY REPORT-End of Year FATALITIES CHARGEABLE TO THE MNM MINING INDUSTRY UGUGS UGUGS UGUGS UGUGS UGUGS ELECTRICAL EXP VESSELS UNDER PRESSURE EXP & BREAKING AGENTS FALL/SLIDE MATERIAL FALL OF FACE/RIB/HIGHWALL FALL OF ROOF OR BACK FIRE HANDLING MATERIAL HAND TOOLS NONPOWERED HAULAGE POWERED HAULAGE HOISTING IGNITION/EXPLOSION OF GAS/DUST INUNDATION MACHINERY SLIP/FALL OF PERSON STEP/KNEEL ON OBJECT STRIKING OR BUMPING OTHER YEAR TO DATE TOTALS COMBINED YEAR TO DATE TOTALS END OF YEAR TOTAL

Fatalgrams and Fatal Investigation Reports Metal and Nonmetal Mines

METAL/NONMETAL MINE FATALITY - - On January 27, 2006, a 60-year old heavy equipment operator with 10 years mining experience was fatally injured at a crushed stone operation. He was operating a dozer to prepare a bench for drilling. The dozer traveled over the edge of a 50-foot highwall and fell to the quarry floor, submerging the cab in several feet of mud and water.

METAL/NONMETAL MINE FATALITY - - On January 27, 2006, a 60-year old heavy equipment operator with 10 years mining experience was fatally injured at a crushed stone operation. He was operating a dozer to prepare a bench for drilling. The dozer traveled over the edge of a 50-foot highwall and fell to the quarry floor, submerging the cab in several feet of mud and water. Best Practices Stop, Look, Analyze, and Manage (SLAM) each task to identify all potential hazards before performing work. Maintain and wear seat belts when operating machinery. Always keep the blade between yourself and the edge of the highwall when operating a dozer on the highwall bench. Operate equipment so that control is maintained. Reduce the throttle position and know how to immediately stop the dozer when working near the edge of the highwall. Provide adequate illumination when work is performed during non-daylight hours.

METAL/NONMETAL MINE FATALITY - On January 6, 2006, a 39-year old mechanic with 12 years mining experience was fatally injured at a sand and gravel operation while working on a front-end loader. The front and rear sections of the loader had been separated at the articulation joint and each section was independently supported with jack stands. The victim was positioned between the left rear tire and frame to remove a hydraulic hose. The frame of the loader tipped forward on the tires and swiveled to the left on the rear axle oscillation trunnion, pinning him.

METAL/NONMETAL MINE FATALITY - On January 6, 2006, a 39-year old mechanic with 12 years mining experience was fatally injured at a sand and gravel operation while working on a front-end loader. The front and rear sections of the loader had been separated at the articulation joint and each section was independently supported with jack stands. The victim was positioned between the left rear tire and frame to remove a hydraulic hose. The frame of the loader tipped forward on the tires and swiveled to the left on the rear axle oscillation trunnion, pinning him. Best Practices Stop, Look, Analyze, and Manage (SLAM) each task to identify all potential hazards before performing maintenance work. Practice safe work habits during the entire task. Consult and follow the manufacturer's recommended safe work procedures for the maintenance task. Train miners in safe work procedures before beginning repairs. Securely block equipment against all hazardous motion at all times while performing maintenance work. If the equipment being blocked has multiple degrees of movement of freedom, exercise extreme caution because some instability modes may not be obvious.

METAL/NONMETAL MINE FATALITY - On November 18, 2005, a 52-year old repairman with 33 years mining experience was fatally injured at a crushed stone operation. A rubber-tired boom truck was being used to lift a motor from its mounting base. The victim, who was attempting to pry the motor free, was struck by the motor when it unexpectedly swung against the crusher as it came free.

METAL/NONMETAL MINE FATALITY - On November 18, 2005, a 52-year old repairman with 33 years mining experience was fatally injured at a crushed stone operation. A rubber- tired boom truck was being used to lift a motor from its mounting base. The victim, who was attempting to pry the motor free, was struck by the motor when it unexpectedly swung against the crusher as it came free. Best Practices Stop, Look, Analyze, and Manage (SLAM) each task to identify all potential hazards. Practice safe work habits during the entire task. Disassemble all tensioned components to prevent a sudden release of energy before dismantling equipment. Position yourself only in areas where you will not be exposed to hazards resulting from a sudden release of energy. Train miners in safe work procedures and ensure they are familiar with manufacturer's recommendations before beginning

METAL/NONMETAL MINE FATALITY - On November 4, 2005, a 21-year old laborer with 5 weeks mining experience was fatally injured at a crushed stone operation. The victim was being task trained to operate a haul truck. While backing down a ramp, he lost control of the truck. The truck went through a berm, overturned, and fell to the bench below.

METAL/NONMETAL MINE FATALITY - On November 4, 2005, a 21-year old laborer with 5 weeks mining experience was fatally injured at a crushed stone operation. The victim was being task trained to operate a haul truck. While backing down a ramp, he lost control of the truck. The truck went through a berm, overturned, and fell to the bench below. Best Practices Task train new miners in all phases of mobile equipment operation at locations designated for training only. Provide classroom training that includes a thorough review of the Operator's Manual before hands-on training of operating mobile equipment. Experienced miners providing task training must be knowledgeable of all safety requirements and proficient in the safe operation of mobile equipment. Conduct pre-operational checks to identify any defects that may affect the safe operation of mobile equipment before placing it into service.

METAL/NONMETAL MINE FATALITY - On October 28, 2005, a 32-year old crusher foreman with 7 years mining experience was fatally injured at a sand and gravel operation. The victim and another miner were moving a radial stacking conveyor to a new position. The victim was positioned on the ground while a front-end loader was used to move the unit. He was caught by one of the wheels of the stacking conveyor.

METAL/NONMETAL MINE FATALITY - On October 28, 2005, a 32-year old crusher foreman with 7 years mining experience was fatally injured at a sand and gravel operation. The victim and another miner were moving a radial stacking conveyor to a new position. The victim was positioned on the ground while a front-end loader was used to move the unit. He was caught by one of the wheels of the stacking conveyor. Best Practices Stop, Look, Analyze, and Manage (SLAM) each task to identify all potential hazards. Prior to starting the task, jointly discuss steps that will be taken to safely perform the job. Ensure that miners communicate clearly with each other. Ensure that miners are not positioned in areas where they are exposed to hazards.

Most Frequently Cited Standards by Mine Type for Metal / Nonmetal Mines Mills – Metal Mills – Nonmetal Mills – Stone Sand and Gravel Surface Metal Surface Nonmetal Surface Stone Underground Metal Underground Nonmetal Underground stone Coal Mines Plants – Coal Surface Coal Underground Coal

Most Frequently Cited Standards 2004 Sand and Gravel Standard TitleNumber of Violations Percent (%) Standard Guarding of Moving Machine Parts2, (a) Horns and Backup Alarms (a) Safety Defects (b) Electrical Conductors Preparation and Submission of MSHA Report Form (a) Parking Brakes (a)(2) Berms or Guardrails (a) Guard Construction (b) Inspection and Cover Plates Insulation and Fittings for Power Wires and Cables Testing Grounding Systems Safe Access Housekeeping (a) Handrails and Toe Boards Warning Signs Inspection (a)(2) First Aid Workplace Safety Records (b) Correction of Dangerous Conditions Requirements for Container Labels (a)

MSHA's Accident Prevention Program: Tips and Ideas by Mine Type Surface Mines Coal Metal Nonmetal Stone Sand and Gravel

MSHA's Accident Prevention Program Safety Ideas and Tips By Mine Type Sand and Gravel Safety IdeasMiner's Tips Blocking Against Motion Chutes and Bins: Access Without Spillage Cleaning Equipment Steps Conveyor Belts Move Faster Than You Can Conveyor Belt Skirt Boards Conveyor Clean-up Conveyor Safety Features Should Not Be Options Dump Point Warning Light Effective Annual Refresher Training Electrically Insulated Matting Ask Someone Who Knows Avoid Dump-Point Hazards Battery Safety Bulk Truck Maintenance Buried Gas Line Hazards Conditioning Contractor Safety Creating Understanding Designate Someone Don’t Get Caught In A Moving Conveyor Downed Power Line Driller / Blaster Communications

MSHA's Occupational Illness and Injury Prevention Program MSHA's Occupational Illness and Injury Prevention Program Miner's Tips and Health Ideas by Category Confined Space Cold Stress Disease Dust Control General Safety Health Heat Stress Hygiene and Housekeeping Knee Injury Noise Personal Protective Equipment Remember Your Health Comes First!

Previous MSHA Webcasts Remember -- "Safety and Health are Values!" For 2004 Metal/Nonmetal Mine Safety and Health "SLAM" Stop - Look - Analyze - Manage" October 12, 2004 See Material Metal/Nonmetal Mine Safety and Health "Industry Needs U in the Middle to Reduce Fatalities" January 22, 2004 See Material

Stakeholder Best Practices Automated External Defibrillator (AED) Adding Pipeline on a Dredge Building A Safety Culture Can You See What You're Breathing? Changing Screening Cold Weather Hazards Contractors are Miners, Too Ensure A Healthy Workplace Fatigue Handling Caustic Soda * Handling Caustic Soda Haulage Road Housekeeping Heat Stress - Summer Alert Improving Your Pre-shift Inspection Is that Cell Phone conversation worth the Price? Keeping the Truck Driver in the Cab Maintaining the Bank Edge Mentoring Mounting and Dismounting Equipment Noise Reduction in the Cab Open Pit Traffic Control Oxygen-Acetylene Cutting Operations Plan Your Work and Work Your Plan Recognizing Work Zones Red Flags of Substance Abuse Reducing Silica Exposure Signs, Signs, Everywhere There's Signs Substance Abuse Support the IRS (Increased Roof Support) Suspended Loads Underground Air Quality Wellness Windshield Access Workboat Safety * Workboat Safety

Equipment Safety and Health Concerns Equipment Safety and Health Concerns Equipment Related Accidents The following pages contain equipment related accident data from Searches can be done for a particular year or by listed equipment type, which then are linked to fatalgrams and accident reports. Our goal is to educate equipment operators and the mining community about the hazards associated with operating a specific type of equipment.

SLAM Risks SLAM Risks Stop - Look - Analyze - Manage

The majority of fatal accidents have these common root causes Failure to identify hazards Failure to manage risks SLAM Risks the SMART Way! Miners: Stop Think through the task Look Identify the hazards for each job step Analyze Determine if you have the proper knowledge, training, and tools Manage Remove or control hazards and use proper equipment Stop Isolate each step in a task and identify past and potential accidents, injuries, and violations. Measure Evaluate the risks associated with the task and barriers that have allowed hazards to cause injuries Act Implement controls to minimize or eliminate any hazards that make the risk unacceptable Review Conduct frequent work site visits to observe work practices and audit accidents, injuries, and violations to identify root causes Train Develop a human factor-based action plan and then involve and train the miners Mine Operators:

When Miners & Mine Management are Risk SLAMMERS together they Make the RIGHT Decision and …