CONVEYOR BELT ACCIDENTS IN SOUTH AFRICA’S MINING SECTOR

1. Introduction

A serious concern is that conveyor belt accidents continue to plague South Africa’s mining industry. These incidents result in the tragic loss of life and severe injuries. Conveyor belts are critical in mining but pose significant hazards. Let’s focus on accident trends, root causes, and safety improvements for South African mines.

2. South African Conveyor Belt Accident Statistics (2019-2023)

While specific annual data for conveyor belt-related incidents over the past five years is not readily available, the mining industry has seen fluctuations in fatality rates. In 2022, the South African mining industry reported 49 fatalities, a 34% improvement compared to 74 fatalities in 2021. However, as of 2023, the number of recorded fatalities had increased to 54.

Fatalities & Injuries Due to Conveyor Belts

Top Causes of Conveyor Belt Accidents

1. Entanglement in moving parts (35%)
2. Belt misalignment & snap-back (25%)
3. Poor maintenance leading to failures (20%)
4. Lack of guarding & lockout violations (15%)
5. Human error (5%)

3. Common Conveyor Belt Hazards in Mining

 Mechanical Hazards:

• Conveyor belt systems are complex, and failures can occur due to faulty equipment, inadequate maintenance, or improper installation.  
• The sheer size and weight of components, like pulleys, create significant risks during installation and maintenance.

Operational Hazards:

• Workers can be caught in moving parts, crushed between components, or struck by falling materials.
• Poor visibility, noisy environments, and dust can increase the risk of accidents. 

Human Factor Hazards:

• Bypassing safety guards
• Improper lockout/tagout (LOTO)

Fire Hazards:

• Conveyor belts, especially those underground, can be a source of fire due to friction, electrical faults, or the materials they carry.  
• These fires can spread rapidly, producing toxic fumes and creating dangerous conditions.  

Maintenance and Inspection:

• Inadequate or infrequent maintenance and inspections can lead to undetected hazards.
• Pressure to maintain production levels can sometimes lead to shortcuts in safety procedures.

Training and Supervision:

• Insufficient training or inadequate supervision can contribute to unsafe work practices.  
• A lack of adherence to safety protocols can put workers at risk.

4. How to Improve Conveyor Belt Safety

Enhanced Safety Regulations and Enforcement:

• Stricter regulations regarding conveyor belt safety are needed, with rigorous enforcement by the Department of Mineral Resources and Energy (DMRE).
• Regular inspections and audits are essential to ensure compliance.
• Follow established safety guidelines and codes of practice for conveyor belt installations to ensure compliance and promote a culture of safety

Technological Advancements:

• Implementing advanced monitoring systems, such as sensors and cameras, can detect potential hazards early on.  
• Automated systems and remote operation can reduce the need for workers to be close to dangerous equipment.  
• Fire suppression systems and fire-resistant conveyor belts are very important.

Improved Maintenance and Inspection:

• Regular, thorough maintenance and inspections are crucial to prevent mechanical failures.  
• Preventive maintenance programs should be implemented to address potential problems before they occur.

Comprehensive Training and Awareness:

• Workers must receive comprehensive training on safe operating procedures, hazard identification, and emergency response.  
• Regular safety meetings and awareness campaigns can reinforce safe work practices.

Installation of Safety Devices:

• Equip conveyor systems with safety mechanisms such as emergency stop switches, guards, and pull cords to protect workers from moving parts.

Strengthened Safety Culture:

• Mining companies must foster a strong safety culture where safety is prioritized above production.
• Workers should be encouraged to report hazards without fear of reprisal.

Incident Investigation and Analysis:

• Thorough investigations of all accidents are essential to identify root causes and implement corrective actions.
• Sharing lessons learned from accidents can help prevent similar incidents in the future.

5. Case Studies: Lessons from Past Accidents

Case 1: 2021 Fatality – Entanglement Incident

• Cause: Worker cleaning a running conveyor without guards.
• Prevention: Mandatory LOTO before maintenance.

Case 2: 2022 Major Injury – Belt Snap-Back

• Cause: Worn-out belt due to poor maintenance.
• Prevention: Predictive maintenance using AI monitoring.

6. Emergency Response for Conveyor Belt Accidents

🚨 Step 1: Hit emergency stop
🚨 Step 2: Isolate power (LOTO)
🚨 Step 3: Provide first aid & call rescue team

7. Conclusion & Call to Action

• Key Takeaway: Most conveyor belt accidents are preventable with proper guarding, maintenance, and training.
• Next Steps:
  • Conduct a conveyor belt safety audit
  • Implement real-time monitoring systems

 Appendices:

• Mine Health & Safety Act (MHSA) Compliance Checklist
• Conveyor Belt Maintenance Log Template

Regarding past accidents:

• It is difficult to give a precise graph of all conveyor belt accidents over the past 5 years. This is due to the information being spread across many different reports and news articles. However, I can say that reports from the DMRE, and news reports, show that conveyor belt-related accidents are a consistent problem within South African mining.

A multi-faceted approach is needed to address the issue of conveyor belt accidents in South Africa’s mining industry. By implementing stricter regulations, improving technology, enhancing training, and fostering a strong safety culture, we can work towards creating a safer environment for mineworkers.

Upcoming course: Maintain a conveyor belt