Disclaimer: This document is to be used as a general guide, and it is not intended as a sole source of information, nor is it intended to provide legal advice. Users are encouraged to seek technical advice from equipment manufacturers, qualified professionals familiar with individual sites, safety programs, tasks, and company policies and procedures. Anyone using this document does so at their own risk. NSSGA is not responsible for any acts or omissions taken by any party using this document for reference.

• Take Control Program Guide
  •  Example Programs, Policies, Checklists and Forms
• 10 Activity-Specific Videos
  1. Working at Heights
  2. Confined Space Entry
  3. Working with Electricity or Stored Energy
  4. Operating or Working Around Mobile Equipment
  5. Lifting and Rigging
  6. Drilling and Blasting
  7. Working Around Water
  8. Working Around Highwalls
  9. Working Around Moving Machine Parts
  10. Contractors
• Take Control Posters
• Take Control Discussion Questions
• Relevant Fatalgrams

The stone, sand, and gravel industry is committed to the prevention of all injuries. However, industry experience suggests that there is a need to establish specific focus on the prevention of the mechanisms that result in serious injuries and fatalities (SIFs), which are injuries that are life altering, life threatening, or result in a fatality. The stone, sand, and gravel industry has and continues to experience a steady decline in reportable injuries, but the decline in serious injuries and fatalities has not been as quick by comparison, and has plateaued in recent years.

Image

Evidence shows that not all events have the potential to lead to a serious injury or fatality and the absence of reportable injuries does not indicate a company will not have an SIF event in the future. The strategy for reducing SIFs involves the identification of situations with a high potential to cause an SIF, identification of critical controls, monitoring of those controls, and review of SIF events for organizational learning and improvement. It is important to note that this process does not exclude existing injury prevention programs in the industry, but rather, provides increased clarity and focus on one part of injury management and prevention.

Organizational leaders must be committed to putting safety first and leading efforts to ensure employees are provided with safe workplaces. To best understand how to improve systems, organizations must intentionally collaborate with and engage workers at every level. Employees are the greatest source of intelligence within an organization and leaders should recognize the importance of employee input and work to enhance their engagement.

This guidance document has been created to help workers and organizational leaders recognize situations with the potential to cause an SIF and take proactive steps to prevent them from occurring. Through committed leadership and engaged employees, implementation of this program can help raise awareness of situations with high SIF-potential and ensure critical controls are in place before work begins.

Leaders must be relentless in the pursuit of providing workers with safe workplaces. This guidance along with input from boots on the ground workers can help build and support a workplace focused on eliminating serious injuries and fatalities. 

If an activity, task, or exposure involves one or more of these situations, then it should be considered to have a high SIF potential and critical controls must be identified and implemented.

Identify Critical Controls 

Critical controls are those controls that must be in place to prevent someone from being seriously or fatally injured. For example, a fall arrest system is a critical control for work being conducted at a height, and a completed confined space entry permit is a critical control when entering a confined space. The failure of a critical control could result in a serious injury or fatality. Critical controls are identified in this guide for each of the 10 high-SIF potential situations; however, because each task and operation is unique, there may be other controls that should be considered and implemented.  

A risk assessment is a proven way to manage the many hazards associated with mining, characterize the risks they present, and put controls in place to lower these risks to acceptable levels. Typically risk acceptability is characterized by managing risk to as-low-as is reasonably achievable (ALARA) or as-low-as is reasonably practicable (ALARP). A risk assessment is a systematic process conducted by a competent person or persons who evaluate the task, identify potential hazards, analyze risk, control those risks, and document the assessment and corrective actions taken. A risk assessment may also be called a Job Safety Analysis (JSA) or Job Hazard Analysis (JHA).

First, prior to a task being performed, hazards are identified and assessed for their level of risk. Next, the mine operator decides whether to eliminate, mitigate or tolerate these hazards. Typically, it is most effective to eliminate hazards early in the life of a mine or processing facility (i.e., during the planning stages), or when significant changes are being made to mine processes because these situations provide opportunities to eliminate hazards through design and engineering controls. Mitigation actions can take the form of equipment, tools, or other mechanisms to control hazards. If a hazard is tolerated, then administrative controls, specialized training, or recovery measures are used to minimize risk. As mitigation actions are taken, their effectiveness must be carefully monitored on a regularly scheduled basis and changes should be made as needed and documented. 

CRITICAL CONTROLS

–    Fall prevention devices (harness, positioning devices, anchor points, lanyards, connectors, etc.) are inspected for wear and tear before use.
–    Scaffolding and elevated platforms are equipped with guardrails and toe-boards.
–    Surface openings are barricaded, covered, or guarded. Caution tape is not a substitute for barricades. An exclusion zone is established beneath the work area.
–    Ladders are set on a firm base, correctly angled (4:1 ratio) and tied off.
–    100% tie off is used with full-body harness.
–    Anchor points are strong enough (i.e., they can support at least 5,000 pounds per person attached).
–    Anchor points are high enough so that a fall will clear any obstructions and limit free fall.
–    A plan is in place to quickly rescue fallen or suspended employee(s). All employees are familiar with the plan and know where to access it.

Discussion Questions | Poster | Fatalgrams

CRITICAL CONTROLS

–    A “Confined Space Entry Permit” is fully completed, and the entry supervisor has signed the permit certifying the space is safe for work prior to anyone entering the Permit Required Confined Space. Key aspects of an entry permit include: job details outlined including purpose of entry, pre-entry meeting and review is completed, including training verification of all involved, authorized entrant(s) have been identified and entry supervisor has reviewed/signed off, authorized attendant understands job duties and is not engaged in any other work, atmospheric monitoring is conducted and level(s) at which entry may occur have been identified and verified, communication procedures, methods, and equipment are identified and followed, including the emergency communication system, area is appropriately prepared for entry (e.g., area is flagged, barricaded, lit, etc.), necessary PPE is checked for wear, tear, damage, etc. (e.g., hi-visibility clothing, hardhat, eye protection, safety boots, respiratory protection, hearing protection, fall protection, etc.) and is worn during entry.
–    Rescue procedures are in place, which include entrants wearing a harness and having a lifeline or being tied off. 
–    Rescue and retrieval equipment is readily available. 

Discussion Questions | Poster | Fatalgrams

Discussion Questions | Poster | Fatalgrams

CRITICAL CONTROLS

–    Seatbelts are worn every single time anyone operates or rides in any vehicle.
–    Vehicle pedestrian segregation plans (see examples included in program) are implemented and posted/provided to non-employees who will interact with or work near mobile equipment.
–    Practices are established and followed to increase employee visibility (e.g., high-visibility clothing/PPE is worn).
–    Practices are established and followed to increase vehicle visibility (e.g., whip flags are installed on trucks and light support vehicles).
–    There is adequate communication between equipment operators (e.g., three-part or repeat-back communication is used).
–    Adequate signage and barriers are used onsite (e.g., barricades, flagging, berms).
–    Materials are dumped at a safe distance back from edges and pushed with a dozer.
–    People coming to pick up equipment or material stay in their vehicle.
–    Equipment is operated free of distractions (see distractions audit included in program). 
–    Vehicle safety features are working properly and routinely checked (e.g., lighting, cameras, backup sensors, mirror placement, etc.).
–    Operators sound the horn before movement.
–    Appropriate speed limits are set and followed.

Discussion Questions | Poster | Fatalgrams

CRITICAL CONTROLS

–    Only qualified or certified crane operators, riggers and signalmen with the required experience are involved in the lift. 
–    All lifting devices and cranes are inspected prior to use.
–    A lift plan is conducted if the lift exceeds 75% of the rated capacity at the configuration used, requires the use of more than one crane, involves the lifting of personnel in a platform or basket, or presents special hazards or circumstances.
–    The weight of the load to be lifted is determined before selecting rigging equipment and rigging hardware.
–    Non-conductive tag lines are used to guide loads.
–    Proper clearance, to include crane’s full extension radius, is maintained when working near overhead power lines.
–    Pick-up, lay-down and crane operating areas are barricaded and secure.
–    There is proper space, ground conditions and outrigger deployment for mobile crane operations.
–    No one climbs on or walks under suspended loads.
–    One person is designated as the signaler; the crane operator only moves loads on signals from this signaler. 

Discussion Questions | Poster | Fatalgrams

CRITICAL CONTROLS

–    Manufacturers’ guidelines are followed for the storage, handling, transportation and use of explosive materials.
–    Explosive storage areas are kept clean, dry, and orderly.
–    Inventory of explosive materials is rotated, and oldest stock is used first.
–    All locations where explosives are stored or used are properly ventilated before miners enter.
–    Damaged or deteriorated explosive materials, including initiation (detonating) devices, boosters, dynamite and blasting agents are not used. The explosives manufacturer is contacted if damaged, deteriorated, or outdated explosives are discovered.
–    Technology such as face profilers and borehole probes are used to obtain details about areas of weak burden and potential borehole deviation.
–    There is adequate communication with the driller and understanding of the blast site’s geology.
–    A drill pattern appropriate for the location has been developed and stemming depth and/or decking is adjusted to maintain adequate burden for the blast.
–    Site-specific blast plans are reviewed and followed prior to loading any explosives. 
–    Blast area is established, and all persons are removed from the area before the blast is fired.
–    Access routes to blast area are guarded or barricaded to prevent people and vehicles from entering.
–    No open flames, matches, or cigarettes are allowed within 50 feet of the blast site.
–    Only the blast crew handles explosives, but anyone can stop the job. 
–    Anyone entering the blast site must have steel toed shoes, safety glasses, hard hat, high visibility vest/shirt, vest or jacket, gloves, and a hazard briefing from the Blaster. 
–    Before firing a blast, ample warning is given to allow all persons to be evacuated from the blast area. 
–    Absolutely no access is permitted into the blast area between the time the warning signal is sounded, and all clear signal is given.  
–    A post-blast inspection is conducted to be certain the blast area is safe before anyone re-enters.

Discussion Questions | Poster | Fatalgrams

CRITICAL CONTROLS
–    A means of escape from equipment is provided in case of an emergency (e.g., seatbelt cutter and window breaker).
–    A throwable life ring is accessible at areas of water where work takes place (e.g., pumps).
–    Electrical cables used around water are rated for use around water and have proper ground fault protection.
–    Equipment is kept a safe distance back from the water’s edge.
–    Handrails are provided around docks and work boats.
–    Roadways are properly bermed near water hazards.
–    Coast Guard approved Type I or Type V personal flotation devices (PFDs) are worn when working around water. 
–    Personal flotation devices are regularly inspected for wear, tear, and damage and expiration dates are checked for styles that expire (e.g., auto-inflate PFDs). 
–    PFDs are properly stored in a cool, dark, dry place with no heavy objects on them, which can crush or damage performance. 
–    Workers should avoid working alone, near, or over water. If someone must work alone near or over water, a communication plan is in place.

Discussion Questions | Poster | Fatalgrams

CRITICAL CONTROLS
– Know what work is occurring around you, including: drill and blast activity, heavy equipment operation above you, excavation work, mucking, installation of ground support (underground)
– Highwalls are inspected to ensure there are no signs of instability (loose rocks, etc.). Undercuts are evaluated before approaching crests, edges or drop-offs.
– Dump areas are approached via a clear line of sight and setbacks are established.
– Unsafe conditions are barricaded or blocked and posted with warning signs until the hazard has been addressed.
– Berms at the base of highwalls are a minimum distance from the base of the highwall of 25% of the highwall height.
– Workers do not stand or park equipment below an area where a rock fall could occur. 
– Workers do not stand or work between a highwall and mobile equipment. 
– No one enters barricaded areas without authorization.
– Workers regularly look and listen for signs of unstable ground before starting work and continuously while they are working.
– Slopes adjacent to road traffic are evaluated for stability issues.
– Workers involved in blasting operations close to the edge of a highwall use fall protection.

Discussion Questions | Poster | Fatalgrams

CRITICAL CONTROLS
– All moving machine parts within seven feet of a walking or working surface are properly guarded while machinery is being operated. 
– Guards are sufficiently constructed so miners cannot circumvent or bypass the guard (i.e., a miner cannot get their hand around the guard and reach the moving part). 
– Prior to work beginning, guards are inspected for damage and to ensure any removed guards have been replaced.  
– Guards are only removed when testing machinery, conducting maintenance, or replacing a guard and lock-out tag-out procedures are followed.  
– Guards are immediately replaced and resecured after they have been removed to test machinery, conduct maintenance, etc.
– Guarding materials and fastening methods are securely installed and able to withstand wear, corrosion, vibration, and shock of normal operations. 
– If a drive belt fails inside a guard, the whipping action of the broken belt will be contained. 
– Workers do not walk on, across, or over conveyor belts without the belts being properly locked and tagged out, secured from movement, and proper fall protection being used. 
– Emergency stop cords are equipped on unguarded conveyors next to travel ways. Stop cords are routinely inspected and maintained to keep adequate tension and function. 

Discussion Questions | Poster | Fatalgrams

CRITICAL CONTROLS
– A “Questions to Ask your Contractors” (see examples in this program) checklist is used before hiring.
– Contractors have appropriate pre-qualifications including:
– Proper licensing, training/qualification/expertise, work history, etc.
– Contractors have been given site specific training and have appropriate up-to-date task training.
– A pre-job walk is performed that includes outlining a clear scope of work and job hazard analysis (JHA) prior to contractors beginning work. 
– Contractor work is isolated from active operations when possible. 
– Appropriate contractor permit systems or workplans are in place. 
– A site/safety person or persons are designated and assigned to do work approvals, spot checks, work verifications, etc. with contractors. 
– Contractors are involved in pre-work daily meetings when onsite.

Discussion Questions | Poster | Fatalgrams

Example Risk Assessments

• Tasks that Kill 
• Work Hazard Assessment
• Work Plan

Example Confined Space Entry Programs and Permits

• Confined Space Entry Permit 
• Confined Space Program 
• Confined Space Program, Matrix, and Permit
• Confined Space Entry Permit (2)

Example Energy Isolation Programs and Permits

• Energy Isolation Program
• Energy Isolation Electrical Permit 
• Lock Out Tag Out Try Out Procedure
• Lockout/Tag-Out Procedure

Example Vehicle Isolation Plans and Segregation Assessment Tools

• Vehicle Segregation Assessment Tool 
• Vehicle Pedestrian Segregation Policy
• Fatality Prevention Assessment – Interaction of Equipment and/or People
• Operation of Equipment Expectations

Example Lifting and Rigging Plans and Checklists

• Crane Lift Plan 
• Hoisting and Rigging Plan
• Inspection & Maintenance Checklist for Overhead Hoists
• Lifting and Rigging Expectations
• Crane Safety Policy 

Example Drilling and Blasting Plans and Checklists

• Pre-Blast Review Form; Site Specific Drilling & Blasting Procedure Form; Drill Log Template; Pre-Blast Site Safety Meeting Example Topics
• Drilling and Blasting Expectations
• Standard Blasting Policy 

Example Contractor Plans and Questionnaires

• Contractor Safety Program
• Contractor Pre-Job Meeting and Pre-Qualification Questionnaire
• Suggested Documents for Independent Contractor to Keep in “Onsite Binder”

Distractions Audit

• Addressing Distractions on Mine Sites: A Facility Self-Audit Guide