IC 9476

INFORMATION CIRCULAR/2004

Department of Health and Human Services

Centers for Disease Control and Prevention

National Institute for Occupational Safety and Health

Analysis of Mine Fires for All

U.S. Metal/Nonmetal Mining

Categories, 1990--2001
Information Circular 9476

Analysis of Mine Fires for All U.S. Metal/Nonmetal Mining

Categories,1990–2001

By Maria I. De Rosa

U.S. DEPARTMENT OF HEALTH AND HUMAN SERVICES

Centers for Disease Control and Prevention

National Institute for Occupational Safety and Health

Pittsburgh Research Laboratory

Pittsburgh, PA

November 2004
This document is the public domain and may be freely copied or reprinted.

Disclaimer: Mention of any company or product does not constitute endorsement by NIOSH.

ORDERING INFORMATION

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documents and information

about occupational safety and health are available from

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 FAX: 513–533–8573

 Telephone: 1–800–35–NIOSH

(1–800–356–4674)

 E-mail: pubstaft@cdc.gov

 Web site: www.cdc.gov/niosh

DHHS (NIOSH) Publication No. 2005–105
CONTENTS

Page

Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Introduction ................................................................................... 2

Methodologies ................................................................................. 2

Fire data analysis for all metal/nonmetal mining categories ............................................... 3

Underground metal/nonmetal and stone mine fires ................................................... 3

Ignition source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Method of detection ........................................................................ 3

Suppression method ........................................................................ 8

Equipment involved ........................................................................ 9

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Burning materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Fire injuries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Surface of underground metal/nonmetal and stone mine fires ........................................... 9

Ignition source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Method of detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Suppression method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Equipment involved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Burning materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fire injuries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Surface metal/nonmetal mine fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Ignition source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Method of detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Suppression method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Equipment involved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Burning materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fire injuries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Surface sand and gravel mine fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Ignition source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Method of detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Suppression method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Equipment involved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Burning materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Fire injuries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Surface stone mine fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Ignition source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Method of detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Suppression method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Equipment involved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Burning materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Fire injuries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Metal/nonmetal mill fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Ignition source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Method of detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Suppression method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Equipment involved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Burning materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Fire injuries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Stone mill fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Ignition source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Method of detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Suppression method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Equipment involved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CONTENTS–Continued

Page

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Burning materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Fire injuries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Summary of major fire and fire injury findings for all metal/nonmetal mining categories . . . . . . . . . . . . . . . . . . . . . . . . 44

Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Acknowledgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

ILLUSTRATIONS

1. Number of fires and fire injuries for underground metal/nonmetal and stone mines by state, 1990–2001 ...... 7

2. Number of fires, fire injuries, risk rates, and employees' working hours for underground metal/nonmetal and 

stone mines by time period, 1990–2001 ...................................................... 7

3. Major variables for underground metal/nonmetal and stone mine fires, 1990–2001 ....................... 8

4. Number of fires and fire injuries for surface of underground metal/nonmetal and stone mines by state, 

1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5. Number of fires, fire injuries, risk rates, and employees' working hours for surface of underground

 metal/nonmetal and stone mines by time period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6. Major variables for surface of underground metal/nonmetal and stone mine fires, 1990–2001 . . . . . . . . . . . . . . 13

7. Number of fires and fire injuries for surface metal/nonmetal mines by state, 1990–2001 . . . . . . . . . . . . . . . . . . . 19

8. Number of fires, fire injuries, risk rates, and employees' working hours for surface metal/nonmetal mines by 

time period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

9. Major variables for surface metal/nonmetal mine fires, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

10. Number of fires and fire injuries for surface sand and gravel mines by state, 1990–2001 . . . . . . . . . . . . . . . . . . 24

11. Number of fires, fire injuries, risk rates, and employees' working hours for surface sand and gravel mines by 

time period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

12. Major variables for surface sand and gravel mine fires, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

13. Number of fires and fire injuries for surface stone mines by state, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

14. Number of fires, fire injuries, risk rates, and employees' working hours for surface stone mines by time period, 

1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

15. Major variables for surface stone mine fires, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

16. Number of fires and fire injuries for metal/nonmetal mills by state, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . 34

17. Number of fires, fire injuries, risk rates, and employees' working hours for metal/nonmetal mills by time period, 

1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

18. Major variables for metal/nonmetal mill fires, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

19. Number of fires and fire injuries for stone mills by state, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

20. Number of fires, fire injuries, risk rates, and employees' working hours for stone mills by time period, 

1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

21. Major variables for stone mill fires, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

22. Number of fires, fire injuries, risk rates, and employees' working hours for all metal/nonmetal mining 

categories by time period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

TABLES

1. Number of fires, fire injuries, and risk rates for underground metal/nonmetal and stone mines by state, 

employees' working hours, and lost workdays, 1990–2001 ....................................... 4

2. Number of fires, fire injuries, and risk rates for underground metal/nonmetal and stone mines by time period,

employees' working hours, and lost workdays, 1990–2001 ....................................... 4

3. Number of fires for underground metal/nonmetal and stone mines by ignition source and time period, 

1990–2001 ............................................................................ 4

4. Number of fires for underground metal/nonmetal and stone mines by method of detection and time period, 

1990–2001 ............................................................................ 5

5. Number of fires for underground metal/nonmetal and stone mines by suppression method and time period, 

1990–2001 ............................................................................ 5
TABLES–Continued

Page

6. Number of fires for underground metal/nonmetal and stone mines by equipment involved and time period, 

1990–2001 ............................................................................ 5

7. Number of fires for underground metal/nonmetal and stone mines by location and time period, 1990–2001 .... 6

8. Number of fires for underground metal/nonmetal and stone mines by burning material and time period, 

1990–2001 ............................................................................ 6

9. Number of fire injuries per number of fires causing injuries and total fires for underground metal/nonmetal 

and stone mines by year, ignition source, equipment involved, and location, 1990–2001 ................ 6

10. Number of fires, fire injuries, and risk rates for surface of underground metal/nonmetal and stone mines by state,

employees' working hours, and lost workdays, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

11. Number of fires, fire injuries, and risk rates for surface of underground metal/nonmetal and stone mines by 

time period, employees' working hours, and lost workdays, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

12. Number of fires for surface of underground metal/nonmetal and stone mines by ignition source and time period,

 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

13. Number of fires for surface of underground metal/nonmetal and stone mines by method of detection and time 

period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

14. Number of fires for surface of underground metal/nonmetal and stone mines by suppression method and time 

period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

15. Number of fires for surface of underground metal/nonmetal and stone mines by equipment involved and time 

period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

16. Number of fires for surface of underground metal/nonmetal and stone mines by location and time period, 

1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

17. Number of fires for surface of underground metal/nonmetal and stone mines by burning material and time period,

 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

18. Number of fire injuries per number of fires causing injuries and total fires for surface of underground 

metal/nonmetal and stone mines by year, ignition source, equipment involved, and location, 1990–2001 . . . 12

19. Number of fires, fire injuries, and risk rates for surface metal/nonmetal mines by state, employees' working

hours, and lost workdays, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

20. Number of fires, fire injuries, fire fatalities, and risk rates for surface metal/nonmetal mines by time period, 

employees' working hours, and lost workdays, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

21. Number of fires for surface metal/nonmetal mines by ignition source and time period, 1990–2001 . . . . . . . . . . . 15

22. Number of fires for surface metal/nonmetal mines by method of detection and time period, 1990–2001 . . . . . . . 16

23. Number of fires for surface metal/nonmetal mines by suppression method and time period, 1990–2001 . . . . . . . 16

24. Number of fires for surface metal/nonmetal mines by equipment involved and time period, 1990–2001 . . . . . . . 16

25. Number of fires for surface metal/nonmetal mines by location and time period, 1990–2001 . . . . . . . . . . . . . . . . 16

26. Number of fires for surface metal/nonmetal mines by burning material and time period, 1990–2001 . . . . . . . . . 17

27. Number of fire injuries per number of fires causing injuries and total fires for surface metal/nonmetal mines

 by year, ignition source, equipment involved, and location, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

28. Number of fires, fire injuries, and risk rates for surface sand and gravel mines by state, employees' working 

hours, and lost workdays, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

29. Number of fires, fire injuries, and risk rates for surface sand and gravel mines by time period, employees' 

working hours, and lost workdays, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

30. Number of fires for surface sand and gravel mines by ignition source and time period, 1990–2001 . . . . . . . . . . 21

31. Number of fires for surface sand and gravel mines by method of detection and time period, 1990–2001 . . . . . . 22

32. Number of fires for surface sand and gravel mines by suppression method and time period, 1990–2001 . . . . . . 22

33. Number of fires for surface sand and gravel mines by equipment involved and time period, 1990–2001 . . . . . . 22

34. Number of fires for surface sand and gravel mines by location and time period, 1990–2001 . . . . . . . . . . . . . . . . 22

35. Number of fires for surface sand and gravel mines by burning material and time period, 1990–2001 . . . . . . . . . 23

36. Number of fire injuries per number of fires causing injuries and total fires for surface sand and gravel mines 

by year, ignition source, equipment involved, and location, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

37. Number of fires, fire injuries, and risk rates for surface stone mines by state, employees' working hours, 

and lost workdays, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

38. Number of fires, fire injuries, fire fatalities, and risk rates for surface stone mines by time period, employees' 

working hours, and lost workdays, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

39. Number of fires for surface stone mines by ignition source and time period, 1990–2001 . . . . . . . . . . . . . . . . . . . 30

40. Number of fires for surface stone mines by method of detection and time period, 1990–2001 . . . . . . . . . . . . . . . 30
TABLES–Continued

Page

41. Number of fires for surface stone mines by suppression method and time period, 1990–2001 . . . . . . . . . . . . . . . 30

42. Number of fires for surface stone mines by equipment involved and time period, 1990–2001 . . . . . . . . . . . . . . . 31

43. Number of fires for surface stone mines by location and time period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . 31

44. Number of fires for surface stone mines by burning material and time period, 1990–2001 . . . . . . . . . . . . . . . . . 31

45. Number of fire injuries per number of fires causing injuries and total fires for surface stone mines by year, 

ignition source, equipment involved, and location, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

46. Number of fires, fire injuries, and risk rates for metal/nonmetal mills by state, employees' working hours, 

and lost workdays, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

47. Number of fires, fire injuries, fire fatalities, and risk rates for metal/nonmetal mills by time period, employees'

 working hours, and lost workdays, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

48. Number of fires for metal/nonmetal mills by ignition source and time period, 1990–2001 . . . . . . . . . . . . . . . . . 36

49. Number of fires for metal/nonmetal mills by method of detection and time period, 1990–2001 . . . . . . . . . . . . . . 37

50. Number of fires for metal/nonmetal mills by suppression method and time period, 1990–2001 . . . . . . . . . . . . . . 37

51. Number of fires for metal/nonmetal mills by equipment involved and time period, 1990–2001 . . . . . . . . . . . . . . 37

52. Number of fires for metal/nonmetal mills by location and time period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . 38

53. Number of fires for metal/nonmetal mills by burning material and time period, 1990–2001 . . . . . . . . . . . . . . . . 38

54. Number of fire injuries per number of fires causing injuries and total fires for metal/nonmetal mills by year, 

ignition source, equipment involved, and location, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

55. Number of fires, fire injuries, and risk rates for stone mills by state, employees' working hours, and lost 

workdays, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

56. Number of fires, fire injuries, and risk rates for stone mills by time period, employees' working hours, and 

lost workdays, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

57. Number of fires for stone mills by ignition source and time period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . 43

58. Number of fires for stone mills by method of detection and time period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . 43

59. Number of fires for stone mills by suppression method and time period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . 43

60. Number of fires for stone mills by equipment involved and time period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . 43

61. Number of fires for stone mills by location and time period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

62. Number of fires for stone mills by burning material and time period, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . 44

63. Number of fire injuries per number of fires causing injuries and total fires for stone mills by year, ignition 

source, equipment involved, and location, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

64. Major fire findings for all metal/nonmetal mining categories, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

65. Major fire injury findings for all metal/nonmetal mining categories, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . 47

66. Number of fires, fire injuries, fire fatalities, and risk rates for all metal/nonmetal mining categories by time 

period, employees' working hours, and lost workdays, 1990–2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

UNIT OF MEASURE ABBREVIATIONS USED IN THIS REPORT

hr hour(s) st short tons

min minute(s)
ANALYSIS OF MINE FIRES FOR ALL U.S. METAL/NONMETAL 

MINING CATEGORIES, 1990–2001

By Maria I. De Rosa1

ABSTRACT

 This report analyzes mine fires for all U.S. underground and surface metal/nonmetal mining categories

during 1990–2001 by state and six successive 2-year time periods. Injury risk rates are derived, and ignition

source, methods of detection and suppression, and other variables are examined. Fires involving contractors

are also included in the analysis. The data were derived from Mine Safety and Health Administration (MSHA)

mine fire accident publications and verbal communications with mine personnel. The analysis will provide the

National Institute for Occupational Safety and Health, MSHA, and the mining industry with a better

understanding of the causes and hazards associated with mine fires and an increased awareness aimed at

preventing and reducing fire hazards. It will also form a basis for future fire research programs.

1

Industrial hygienist, Pittsburgh Research Laboratory, National Institute for Occupational Safety and Health, Pittsburgh, PA.
2

INTRODUCTION

Mine fires pose a constant danger to the safety of miners and

to their livelihood. Underground mine fires pose an added hazard

because of the confined environment with remote exits. Enactment of safety regulations [30 CFR2

 56, 57] for underground and

surface metal/nonmetal operations has greatly improved the safety

of miners. However, mine fires and fire injuries remain serious

hazards for all underground and surface mines.

This report analyzes mine fires and fire injuries for all U.S.

metal/nonmetal mining categories, including sand and gravel

and stone operations, during 1990–2001. Fires involving contractors are also included in the analysis. A similar analysis of

fire incidents in metal/nonmetal mines during 1950–1984 was

done by the former U.S. Bureau of Mines (USBM) [Butani and

Pomroy 1987]. Detailed analyses of mobile equipment fires for

all underground and surface coal and metal/nonmetal mining

categories during 1990–1999 have recently been reported by

NIOSH [De Rosa 2004].

Injury risk rate (Irr) values for the 12-year time period

(1990–2001) and for six successive 2-year time periods within

the 12-year period are derived. Irr values for individual states

for the 12-year period are also derived. Other variables by state

and time period include employees' working hours and lost

workdays. The number of fire fatalities is reported by time

period. Variables such as ignition source, method of detection

and suppression, equipment involved, location, and burning

material are reported by six 2-year time periods only. Furthermore, the number of fire injuries per number of fires causing

injuries and total fires has been analyzed by year, ignition

source, equipment involved, and location. For comparison

purposes, the major fire and fire injury findings for all

metal/nonmetal mining categories have been reported.

The data in this report were derived from "Injury Experience"

publications [MSHA 1991a,b,c,d; 1992a,b,c,d; 1993a,b,c,d;

1994a,b,c,d; 1995a,b,c,d; 1996a,b,c,d; 1997a,b,c,d; 1998a,b,c,d;

1999a,b,c,d; 2000a,b,c,d; 2001a,b,c,d; 2002a,b,c,d], "Fire

Accident Reports" [MSHA 1993e; 1994e; 1995e; 1996e;

1997e,f; 2000e], MSHA "Fire Accident Abstracts" internal

publications, and verbal communications with mine personnel.

Mining companies are required by 30 CFR 50 to report to

MSHA all fires that result in injuries and fires that are not

extinguished within 30 min of discovery. A small number of

fires lasting <30 min without injuries reported in the "Fire

Accident Abstracts" have been included in this report. Also

included in this report are fires caused by explosions and

explosives.

The analysis in this report will provide the National Institute

for Occupational Safety and Health (NIOSH), the Mine Safety

and Health Administration (MSHA), and the mining industry

with a better understanding of the causes and hazards of mine

fires and fire injuries and an increased awareness aimed at

preventing and reducing fire hazards. It will also form a basis

for developing future fire research programs.

METHODOLOGIES

For all metal/nonmetal mining categories, data on mine fires

during 1990–2001 have been reported as actual numbers and

calculated values.

1. For each mining category, actual numbers include the

total number of fires, fire injuries, employees' working hours,

and lost workdays for a 12-year period (1990–2001) and for six

successive 2-year periods within the 12-year period. These

numbers have also been reported by state for the 12-year time

period. The actual number of fire fatalities has been reported by

time period. Furthermore, actual numbers of fires for the six

2-year periods have been reported by ignition source, method of

detection and suppression, equipment involved, location, and

burning material. Actual numbers of fire injuries per number of

fires causing injuries and total fires have been reported by year,

ignition source, equipment involved, and location.

2. For each mining category, the calculated values include the

injury risk rates during the 12-year period and the six 2-year

periods. The injury risk rate (Irr) values were calculated

according to the MSHA formula (incidence rate (IR) = number

2

Code of Federal Regulations. See CFR in references.

of fire injuries × 200,000 working hours divided by the total

employees' working hours) [MSHA 1991a,b,c,d; 1992a,b,c,d;

1993a,b,c,d; 1994a,b,c,d; 1995a,b,c,d; 1996a,b,c,d; 1997a,b,c,d;

1998a,b,c,d; 1999a,b,c,d; 2000a,b,c,d; 2001a,b,c,d; 2002a,b,c,d].

Also, injury risk rate values for individual states (12-year period)

were calculated according to this same formula.

For comparison purposes, only the injury risk rate values for

12-year and 2-year time periods and the injury risk rate values

for individual states (12-year time period) with the highest

number of fire injuries have been considered. The fatality risk

rate values have not been calculated because of the small

number of fatalities that occurred during the 12-year period.

3. Calculations of Irr values are as follows:

a. Injury risk rate (Irr) value: Number of fire injuries ×

200,000 working hours divided by total employees'

working hours. The Irr value is the average risk rate

value for the number of fire injuries per 200,000 working

hours for a given time period.

b. Total employees' working hour (Ewhr) value during

1990–2001: Sum of 12 yearly Ewhr values for all of the
3

states involved in fires. This value also includes the Ewhr

value reported for all other states not involved in fires. The

Ewhr value for each state (12-year time period) is the sum

of 12 yearly Ewhr values for that state.

c. Total employees' working hours (Ewhr) value for six

2-year time periods: Sum of two yearly Ewhr values for

all of the states involved and not involved in fires within

the 2-year period.

d. The lost workday (LWD) values were reported by state

and time period.

e. A lost workday value of 6,000, assigned by MSHA to

each fatality or permanent total disability, was reported.

FIRE DATA ANALYSIS FOR ALL METAL/NONMETAL MINING CATEGORIES

UNDERGROUND METAL/NONMETAL AND STONE

MINE FIRES

Table 1 and figure 1 show the number of fires and fire injuries

that occurred in underground metal/nonmetal and stone mines by

state during 1990–2001. Table 1 also shows the injury risk rates,

employees' working hours, and lost workdays. Overall, 65 fires

occurred in 20 states; these include 2 fires and no injuries for

contractors. Six of the fires caused nine injuries. The yearly average was 5.4 fires and 0.75 injury. Forty-one fires with 2 injuries

occurred in metal mines, 14 fires with 7 injuries occurred in

nonmetal mines, and 10 fires with no injuries occurred in stone

mines. The underground mine fires required 25 mine rescue team

interventions and 30 mine/section evacuations. The Ewhr value

was 260 × 106

 hr (Irr = 0.007), and the LWD value was 83.

Idaho had the most fires (eight fires and no injuries),

followed by Louisiana (seven fires and two injuries), Michigan

(six fires and six injuries), and Missouri (six fires and no

injuries). Of these states, Michigan had the highest injury risk

rate value (Irr = 0.146).

Table 2, partly illustrated in figure 2, shows the number of

fires, fire injuries, risk rates, employees' working hours, and lost

workdays by time period. The number of fires during the six time

periods show an increase during the fourth period followed by a

sharp decrease during the fifth period and a sharp increase in the

last period. The number of fire injuries show an increase followed

by a decrease during most of the periods, accompanied by a

decline in employees' working hours during most of the periods;

an increase is seen during the third and fourth periods. The Irr

values follow patterns similar to those shown by the injury values.

Tables 3–8 show the number of fires by ignition source,

method of detection and suppression, equipment involved,

location, and burning material by time period. Figure 3 shows

the major variables related to fires for 1990–2001. Table 9

shows the number of fire injuries per number of fires causing

injuries and total fires by year, ignition source, equipment

involved, and location.

Ignition Source

Table 3 shows the number of fires by ignition source for each

time period. The sources that caused most of the underground

metal/nonmetal and stone mine fires were hydraulic fluid/fuel

sprayed onto equipment hot surfaces (16 fires or 25%), flame

cutting/welding spark/slag/flame (13 fires or 20%), and

electrical short/arcing (12 fires or 19%).

Thirteen of the 16 mobile equipment hydraulic fluid/fuel fires

became large fires because of the continuous flow of fluids from

the pumps due to engine shutoff failure, lack of an emergency line

drainage system, or lack of effective and rapid local firefighting

response capabilities. In at least two instances during these fires,

the cab was suddenly engulfed in flames, probably due to the

ignition of flammable vapors and mists that penetrated the cab. Of

note is that the hydraulic fluid fires subsequently involved the fuel

system. Other ignition sources included engine/motor mechanical

malfunctions, spontaneous combustion (involving timber)/hot

material, conveyor belt/equipment friction, heat source (mostly

involving heaters), overheated oil, and explosion/ignition of

explosives. Fires caused by the spontaneous combustion/hot

material and electrical short/arcing ignition sources were usually

detected long after they had started due to lack of combustion

gas/smoke detection systems.

During the first period, the largest number of fires were caused

by hydraulic fluid/fuel sprayed onto equipment hot surfaces, flame

cutting/welding spark/slag/flame, and electrical short/arcing

sources. During the second period, the largest number of fires

were caused by flame cutting/welding spark/slag/flame and

electrical short/arcing sources. During the third period, the largest

number of fires were caused by conveyor belt/equipment friction.

During the fourth period, the largest number of fires were caused

by hydraulic fluid/fuel sprayed onto equipment hot surfaces.

During the fifth period, the largest number of fires were caused by

hydraulic fluid/fuel sprayed onto equipment hot surfaces and

flame cutting/welding spark/slag/flame. During the sixth period,

the largest number of fires were caused by hydraulic fluid/fuel.

Method of Detection

Table 4 shows the number of fires by method of detection for

each time period. The most frequent methods were miners who

saw smoke long after the fire had started, operators who saw the

fires when they started as flames/flash fires, and miners who saw

smoke shortly after the fires had started. Other methods of detection were welders who saw sparks, miners who heard an

explosion or smelled smoke, and operators who experienced an

equipment power loss. One fire was detected by carbon

monoxide gas sampling, and two fires were undetected.

During the first period, the largest number of fires were

detected by operators as flames/flash fires. During the second

period, the largest number of fires were detected by welders as

sparks. During the third, fifth, and sixth periods, the largest

number of fires were detected by miners as smoke long after the

fires had started. During the fourth period, the largest number

of fires were detected visually as flames and sparks.
4

Table 1.—Number of fires, fire injuries, and risk rates for underground metal/nonmetal

and stone mines by state, employees' working hours, and lost workdays, 1990–2001

State1 No. fires1 No.

fire injuries1 LWD2 Ewhr,2

 106 hr Irr3

Alaska . . . . . . . . . . . . . 1 — — 2 —

Arizona . . . . . . . . . . . . 3 — — 28.3 —

Colorado . . . . . . . . . . . 3 — — 9.6 —

Idaho . . . . . . . . . . . . . . 8 — — 9.7 —

Illinois . . . . . . . . . . . . . 2 — — 0.5 —

Indiana . . . . . . . . . . . . 2 — — 2.1 —

Kansas . . . . . . . . . . . . 1 — — 1 —

Kentucky . . . . . . . . . . . 2 — — 11.3 —

Louisiana . . . . . . . . . . 7 2 24 7.4 0.054

Michigan . . . . . . . . . . . 6 6 52 8.2 0.146

Missouri . . . . . . . . . . . 6 — — 16.8 —

Montana . . . . . . . . . . . 2 — — 10.5 —

Nevada . . . . . . . . . . . . 3 — — 14 —

New Mexico . . . . . . . . 4 — — 22.8 —

New York . . . . . . . . . . 5 — — 9.4 —

Ohio . . . . . . . . . . . . . . 2 — — 5.7 —

South Dakota . . . . . . . 3 — — 12.1 —

Tennessee . . . . . . . . . 1 — — 14 —

Washington . . . . . . . . 1 — — 3 —

Wyoming . . . . . . . . . . . 3 1 7 24.5 0.008

All other states . . . . . . — — — 47 —

 Total . . . . . . . . . . . . 65 9 83 260 3

0.007 1

Derived from MSHA "Fire Accident Abstract" internal publications. 2

Derived from MSHA "Injury Experience in Mining" publications. 3

Calculated according to MSHA formula reported in the "Methodologies" section.

Table 2.—Number of fires, fire injuries, and risk rates for underground metal/nonmetal and stone mines

by time period, employees' working hours, and lost workdays, 1990–2001

Time period

90-91 92-93 94-95 96-97 98-99 00-01 1990-2001

Number of fires1 . . . . . . . . . 10 10 10 15 6 14 65

Number of fire injuries1 .... 1 3 — 5 — — 9

LWD2 . . . . . . . . . . . . . . . . . 2 31 — 50 — — 83

Ewhr,2

 106 hr . . . . . . . . . . . . 49 42 43 45 41 40 260

Irr3 . . . . . . . . . . . . . . . . . . . . 0.004 0.014 — 0.022 — — 3

0.007 1

Derived from MSHA "Fire Accident Abstract" internal publications. 2

Derived from MSHA "Injury Experience in Mining" publications. 3

Calculated according to MSHA formula reported in the "Methodologies" section.

Table 3.—Number of fires for underground metal/nonmetal and stone mines by ignition source and time period,

1990–2001

Ignition source

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Hydraulic fluid/fuel on equipment hot

 surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 2 4 2 4 16

Flame cutting/welding spark/slag/flame . . . . . 2 3 2 3 2 1 13

Electrical short/arcing . . . . . . . . . . . . . . . . . . . 2 3 1 1 1 4 12

Engine/motor malfunction . . . . . . . . . . . . . . . . — 1 — 3 — 1 5

Conveyor belt/equipment friction .......... — — 3 2 — — 5

Spontaneous combustion (involving timber)/

 hot material . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 — — — 3 5

Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . 1 — 1 — 1 1 4

Explosion/ignition-explosives . . . . . . . . . . . . . 1 — 1 — — — 2

Overheated oil ........................ — — — 2 — — 2

Unknown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ————— 1

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 10 10 15 6 14 65
5

Table 4.—Number of fires for underground metal/nonmetal and stone mines by method of detection

and time period, 1990–2001

Method of detection

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Visual:

 Late smoke detection . . . . . 1 2 4 2 3 6 18

 Flames/flash fires . . . . . . . . 3 2 3 3 2 4 17

 Sparks . . . . . . . . . . . . . . . . 2 3 1 3 1 — 10

Heard explosion . . . . . . . . . . . 1 — 1 — — — 3

Smelled smoke . . . . . . . . . . . . — 1 — — — 1 2

Power loss . . . . . . . . . . . . . . . — 1 ———— 1

CO gas sampling . . . . . . . . . . — 1 ———— 1

Undetected ............... 2 ————— 2

 Total . . . . . . . . . . . . . . . . . 10 10 10 15 6 14 65

Table 5.—Number of fires for underground metal/nonmetal and stone mines by suppression method

and time period, 1990–2001

Suppression method

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

FE-DCP-foam-water . . . . . . . . 2 4 2 3 3 9 23

Water . . . . . . . . . . . . . . . . . . . 3 3 2 4 3 3 18

Portable fire extinguisher .... 3 2 1 6 — 2 14

FSS-DCP-foam-water . . . . . . . — 1 1 — — — 2

FSS-HD1 ................. — — 1 1 — — 2

Manual with FE2 ........... — — 1 — — — 1

Destroyed/HD3 ............ 2 — 2 1 — — 5

 Total . . . . . . . . . . . . . . . . . . 10 10 10 15 6 14 65

DCP Dry chemical powder.

FE Portable fire extinguisher.

FSS Machine fire suppression system.

HD Heavily damaged.

1

Heavy damage to equipment due to FSS activation failure or late activation. 2

Method used by welders to extinguish clothing and oxyfuel/grease fires. 3

Usually due to failure of other firefighting methods, late fire detection, undetected fires, or fire size.

Table 6.—Number of fires for underground metal/nonmetal and stone mines by equipment involved

and time period, 1990–2001

Equipment

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Mobile equipment1 ............... 3 5 4 9 3 7 31

Oxyfuel torch2 ................... 2 3 1 2 2 — 10

Beltline . . . . . . . . . . . . . . . . . . . . . . . . — — 3 1 — 1 5

Electrical system/battery/charger . . . . 1 1 — — — 3 5

Heater/cutting saw . . . . . . . . . . . . . . . 1 — — 1 1 1 4

Explosive box . . . . . . . . . . . . . . . . . . . 1 — 1 — — — 2

Air compressor . . . . . . . . . . . . . . . . . . — — — 2 — — 2

Other3 ......................... 2 1 1 — — 2 6

 Total . . . . . . . . . . . . . . . . . . . . . . . . 10 10 10 15 6 14 65

1

Includes golf and ore carts, locomotives, loaders, scoops, tractors, shuttle cars, power scalers, trolleys, trucks, and drills. 2

At times, electrical arc welding equipment was used.

3

Did not involve equipment.
6

Table 7.—Number of fires for underground metal/nonmetal and stone mines by location and time period, 1990–2001

Location

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Mobile equipment working areas1 ....... 3 4 2 6 1 4 20

Flame cutting/welding areas2 .......... 2 3 2 3 2 1 13

Mine face/section/crosscut/drift areas . . . 2 2 — 2 — 1 7

Battery/motor barn/pipeline areas . . . . . . 1 — 11126

Belt entry . . . . . . . . . . . . . . . . . . . . . . . . . — — 3 1 — 1 5

Shop/refuse/maintenance areas ....... 1 — — — 1 2 4

Chute/crusher/air compressor areas . . . . — — 1 1 — 1 3

Decline slopes ..................... — 1 — — 1 1 3

Gobline/abandoned areas ............ 1 ———— 1 2

Panel/tunnel areas .................. — — 1 1 — — 2

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 10 10 15 6 14 65

1

Includes haulage, loading, mucking, transportation, and drilling areas. 2

Includes shops, mainways, boreholes, shafts, stations, slusher buckets and chute areas, and mobile equipment maintenance areas.

Table 8.—Number of fires for underground metal/nonmetal and stone mines by burning material and time period,

1990–2001

Burning material

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Hydraulic fluid/fuel . . . . . . . . . . . . . . . . . . 2 2 2 4 2 4 16

Electrical cord/cables/wires/batteries . . . . 3 3 1 1 1 4 13

Oxyfuel/clothing/grease/other1 ......... 2 3 2 3 2 1 13

Belt material . . . . . . . . . . . . . . . . . . . . . . . — — 3 2 — 1 6

Refueling fuel/flammable liquid/oil/

 grease/refuse . . . . . . . . . . . . . . . . . . . . 2 — 1 2 1 — 6

Timber/pipeline/chute liner . . . . . . . . . . . . — 1 — — — 3 4

Equipment mechanical components .... — 1 — 3 — — 4

Detonated explosives ................ 1 — 1 — — — 2

Shop/content ...................... ————— 1 1

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . 10 10 10 15 6 14 65

1

Includes rubber tires and hoses, refuse, chute liner, hydraulic fluid, shop, wood, and shaft material.

Table 9.—Number of fire injuries per number of fires causing injuries and total fires for underground metal/nonmetal and stone mines

by year, ignition source, equipment involved, and location, 1990–2001

Year

No.

total

fires

No. fires

causing

injuries

No.

fire

injuries

Ignition source Equipment Location

1990 . . . . 3 1 1 Hydraulic fluid/fuel on equipment hot surfaces . . . Ore cart . . . . . . . . . Transportation area.

1991 .... 7 — — — — —

1992 . . . . 6 2 1 Flame cutting/welding spark/slag/flame . . . . . . . . Oxyfuel torch . . . . Flame cutting/welding areas.

1 Overheated oil . . . . . . . . . . . . . . . . . . . . . . . . . . . Scoop . . . . . . . . . . Mining area.

1993 . . . . 4 1 1 Flame cutting/welding spark/slag/flame . . . . . . . . Oxyfuel torch . . . . Flame cutting/welding areas.

1994 .... 8 — — — — —

1995 .... 2 — — — — —

1996 . . . . 6 1 1 Overheated oil . . . . . . . . . . . . . . . . . . . . . . . . . . . Air compressor . . . Drilling area.

1997 . . . . 9 1 4 Hydraulic fluid/fuel on equipment hot surfaces . . . Scoop . . . . . . . . . . Mining area.

1998 .... 3 — — — — —

1999 .... 3 — — — — —

2000 .... 8 — — — — —

2001 .... 6 — — — — —

Total . . . . 65 6 9
7

Figure 1.—Number of fires and fire injuries for underground metal/nonmetal and stone mines by state, 1990–2001.

Figure 2.—Number of fires, fire injuries, risk rates, and employees' working hours for underground metal/nonmetal and stone mines

by time period, 1990–2001.
8

Suppression Method

Table 5 shows the number of fires by suppression method for

each time period. Usually more than one agent was used to

fight a fire. The most common methods were portable fire

extinguishers with dry chemical powder, foam, and water,

followed by water or portable fire extinguishers alone. Other

suppression methods included machine fire suppression systems

with dry chemical powder, foam, and water and manual

techniques with or without portable fire extinguishers (welders'

method to extinguish clothing and oxyfuel/grease fires). Four

of the 16 pieces of mobile equipment involved in hydraulic

fluid/fuel fires had machine fire suppression systems. Dual

activations (two activations) of machine fire suppression and

engine shutoff systems succeeded in temporarily abating the

fires; however, the flames reignited, fueled by the flow of

pressurized fluids entrapped in the lines. On one occasion the

fire suppression system failed to activate, and in another

instance the system was activated late.

Portable fire extinguishers, used upon discovery of the fires,

were successful in extinguishing small fires involving oxyfuel/

grease, oil, refueling fuel, and electrical wires, cables and

batteries. Mine rescue teams (required 25 times), upon mine/

section evacuation (performed 30 times), fought the fires

(including 12 mobile equipment fires) with dry chemical powder

and water; in one instance, foam was also used. However,

seven fires destroyed or heavily damaged equipment (including

four pieces of mobile equipment) because of failure of

firefighting methods, late fire detection, undetected fires, or fire

size. Other factors that determined the success of fire

suppression efforts were the time lapse between detection and

application of extinguishing agents and effective and rapid local

firefighting response capabilities.

During the first period, the largest number of fires were

suppressed with portable fire extinguishers or water alone.

During the second and sixth periods, the largest number of fires

were suppressed with portable fire extinguishers together with dry

chemical powder, foam, and water. During the third and fifth

periods, the largest number of fires were suppressed with water

alone and portable fire extinguishers with dry chemical powder,

foam, and water. During the fourth period, the largest number of

fires were suppressed with portable fire extinguishers alone.

Figure 3.—Major variables for underground metal/nonmetal and stone mine fires, 1990–2001. (FE = portable fire extinguisher)
9

Equipment Involved

Table 6 shows the number of fires by equipment involved for

each time period. The equipment most often involved was

mobile equipment (golf and ore carts, locomotives, shuttle cars,

loaders, power scalers, scoops, tractors, trolleys, trucks, and

drills), followed by oxyfuel torches (at times electrical arc

welding equipment was used). Other equipment included beltlines, electrical systems, batteries, chargers, heaters, cutting

saws, explosive boxes, and air compressors. Six fires did not

involve equipment. During all of the periods, the largest

number of fires involved mobile equipment.

Location

Table 7 shows the number of fires by location for each time

period. The most common locations were mobile equipment

working areas (haulage, loading, mucking, transportation and

drilling areas, decline slopes), followed by flame cutting/

welding areas (at shops, mainways, boreholes, shafts, stations,

slusher bucket and chute areas, and maintenance areas), and

mine face, section, crosscut, and drift areas. Other fire locations

were battery and pipeline areas, motor barns, belt entries, shops,

refuse and maintenance areas, decline slopes, chute and crusher

areas, panel and tunnel areas, and goblines and abandoned areas.

During the first, second, fourth, and sixth periods, the largest

number of fires occurred at mobile equipment working areas.

During the third period, the largest number of fires occurred at

belt entries. During the fifth period, the largest number of fires

occurred at flame cutting/welding areas.

Burning Materials

Table 8 shows the number of fires by burning material for

each time period. The materials most often involved were

hydraulic fluid/fuel, electrical cord, cables, wires, batteries,

oxyfuel/clothing/grease, and materials such as rubber tires and

hoses, hydraulic fluid, shop, refuse, wood, chute liner, and shaft

material. Other burning materials included belt material, refueling fuel, flammable liquids, oil, grease, refuse, timber, pipelines, chute liners, equipment mechanical components, detonated explosives, and shops and their content.

During the first period, the largest number of fires involved

electrical cord, cables, wires, and batteries. During the second

period, the largest number of fires involved oxyfuel, clothing/

grease, and other materials and electrical cord, cables, wires, and

batteries. During the third period, the largest number of fires

involved belt materials. During the fourth period, the largest number of fires involved hydraulic fluid/fuel. During the fifth period,

the largest number of fires involved hydraulic fluid/fuel and

oxyfuel. During the sixth period, the largest number of fires

involved hydraulic fluid/fuel and electrical materials.

Fire Injuries

Table 9 shows the number of fire injuries per number of fires

causing injuries and total fires by year, ignition source,

equipment involved, and location during 1990–2001. Overall,

there were nine injuries caused by six fires. The greatest

number of fire injuries occurred in 1997 (four injuries caused by

one fire). The ignition sources that caused the fire injuries were

hydraulic fluid/fuel sprayed onto equipment hot surfaces, flame

cutting/welding spark/slag/flame, and overheated oil. The

equipment involved in fire injuries included mobile equipment,

oxyfuel torches, and air compressors. The locations where the

fire injuries occurred were mobile equipment working areas,

flame cutting/welding areas, and mining areas.

SURFACE OF UNDERGROUND METAL/NONMETAL

AND STONE MINE FIRES

Table 10 and figure 4 show the number of fires and fire

injuries occurring at the surface of underground metal/nonmetal

and stone mines by state during 1990–2001. Table 10 also

shows the injury risk rates, employees' working hours, and lost

workdays.

A total of 12 fires occurred in 11 states; 5 of the fires caused

5 injuries. The yearly average was one fire and 0.42 injury.

Five fires with two injuries occurred at metal mines, five fires

with two injuries occurred at nonmetal mines, and two fires with

one injury occurred at stone mines. None of the fires involved

contractors. The Ewhr value was 58 × 106

 hr (Irr = 0.017), and

the LWD value was 75.

Nevada had the most fires (two fires and no injuries). Ohio,

New Mexico, Missouri, South Dakota, and Idaho each had one

fire with one injury. Of these states, Missouri had the highest

injury risk rate value (Irr = 0.25).

Table 11, partly illustrated in figure 5, shows the number of

fires, fire injuries, risk rates, employees' working hours, and lost

workdays by time period. The number of fires decreased during

most of the six time periods. The number of fire injuries and

employees' working hours decreased during all of the periods.

The Irr values follow patterns similar to those shown by the

injury values.

Tables 12–17 show the number of fires by ignition source,

method of detection and suppression, equipment involved,

location, and burning material by time period. Figure 6 shows

the major variables related to fires for 1990–2001. Table 18

shows the number of fire injuries per number of fires causing

injuries and total fires by year, ignition source, equipment

involved, and location.

Ignition Source

Table 12 shows the number of fires and fire injuries by

ignition source for each time period. The leading source was

flame cutting/welding spark/slag/flame (seven fires or 58%),

followed by electrical short/arcing and heat source (one fire for

each ignition). The ignition sources for three fires were

unknown.

During the first through third periods, the fires were caused

by the flame cutting/welding spark/slag/flame source. During

the fifth period, the fire was caused by a heat source. During the
10

sixth period, the fires were caused by flame cutting/welding

spark/slag/flame and electrical short/arcing sources. No fires

occurred during the fourth period.

Method of Detection

Table 13 shows the number of fires by method of detection

for each time period. The most frequent method was welders

who saw sparks. This was followed by miners who saw smoke

long after the fires had started and miners who saw smoke

shortly after the fires had started. Three fires were undetected.

During the first period, the largest number of fires were

detected by welders as sparks. During subsequent periods, the

fires were detected by welders as sparks (second period), by

miners as smoke shortly or long after the fires had started and by

welders as sparks (third period), by miners as smoke (fifth

period), and by welders and miners as sparks and as smoke

(sixth period).

Table 10.—Number of fires, fire injuries, and risk rates for surface of underground metal/nonmetal

and stone mines by state, employees' working hours, and lost workdays, 1990–2001

State1 No. fires1 No.

fire injuries1 LWD2 Ewhr,2

 106 hr Irr3

California . . . . . . . . . . 1 — — 0.7 —

Idaho . . . . . . . . . . . . . . 1 1 10 2.43 0.082

Kansas . . . . . . . . . . . . 1 — — 0.26 —

Kentucky . . . . . . . . . . . 1 — — 3.1 —

Missouri . . . . . . . . . . . 1 1 21 0.8 0.25

Montana . . . . . . . . . . . 1 — — 4 —

Nevada . . . . . . . . . . . . 2 — — 3.1 —

New Mexico . . . . . . . . 1 1 16 2.6 0.077

Ohio . . . . . . . . . . . . . . 1 1 15 2.1 0.095

South Dakota . . . . . . . 1 1 13 4 0.05

Utah . . . . . . . . . . . . . . 1 — — 0.7 —

All other states . . . . . . — — — 34.21 —

 Total . . . . . . . . . . . . 12 5 75 58 3

0.017 1

Derived from MSHA "Fire Accident Abstract" internal publications. 2

Derived from MSHA "Injury Experience in Mining" publications. 3

Calculated according to MSHA formula reported in the "Methodologies" section.

Table 11.—Number of fires, fire injuries, and risk rates for surface of underground metal/nonmetal and stone mines

by time period, employees' working hours, and lost workdays, 1990–2001

Time period

90-91 92-93 94-95 96-97 98-99 00-01 1990-2001

Number of fires1 . . . . . . . . . . . . . 3 2 3 — 2 2 12

Number of fire injuries1 ........ 2 1 1 — — 1 5

LWD2 . . . . . . . . . . . . . . . . . . . . . 16 — 56 — — 3 75

Ewhr,2

 106 hr . . . . . . . . . . . . . . . . 12 11 10 9 8 8 58

Irr3 . . . . . . . . . . . . . . . . . . . . . . . . 0.033 0.018 0.02 — — 0.025 3

0.017 1

Derived from MSHA "Fire Accident Abstract" internal publications. 2

Derived from MSHA "Injury Experience in Mining" publications. 3

Calculated according to MSHA formula reported in the "Methodologies" section.

Table 12.—Number of fires for surface of underground metal/nonmetal and stone mines by ignition source

and time period, 1990–2001

Ignition source

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Flame cutting/welding spark/slag/flame . . . . 2 1 3 — — 1 7

Electrical short/arcing . . . . . . . . . . . . . . . . . . ————— 1 1

Heat source . . . . . . . . . . . . . . . . . . . . . . . . . ———— 1 — 1

Unknown . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 — — 1 — 3

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 3 — 2 2 12
11

Table 13.—Number of fires for surface of underground metal/nonmetal and stone mines by method of detection

and time period, 1990–2001

Method of detection

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Visual:

 Sparks . . . . . . . . . . . . . . . 2 1 1 — — 1 5

 Smoke . . . . . . . . . . . . . . . — — 1 — — 1 2

 Late smoke detection . . . . — — 1 — 1 — 2

Undetected .............. 1 1 — — 1 — 3

 Total . . . . . . . . . . . . . . . . 3 2 3 — 2 2 12

Table 14.—Number of fires for surface of underground metal/nonmetal and stone mines by suppression method

and time period, 1990–2001

Suppression method

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Water . . . . . . . . . . . . . . . . . . . . — — 2 — 1 1 4

Manual with or without FE1 .... 2 — 1 — — — 3

FE . . . . . . . . . . . . . . . . . . . . . . . — 1 — — — 1 2

Destroyed/HD2 ............. 1 1 — — 1 — 3

 Total . . . . . . . . . . . . . . . . . . . 3 2 3 — 2 2 12

FE Portable fire extinguisher.

HD Heavily damaged.

1

Method used by welders to extinguish clothing and oxyfuel/grease fires. 2

Usually due to failure of firefighting methods, undetected fires, or fire size.

Table 15.—Number of fires for surface of underground metal/nonmetal and stone mines by equipment involved

and time period, 1990–2001

Equipment 

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Oxyfuel torch1 ............ 2 1 3 — — 1 7

Facilities2 ............... 1 1 — — 1 1 3

Ventilation fan . . . . . . . . . . . ————— 1 1

Heater . . . . . . . . . . . . . . . . . . ———— 1 — 1

 Total . . . . . . . . . . . . . . . . . 3 2 3 — 2 2 12

1

At times, electrical arc welding equipment was used.

2

Considered equipment in this report.

Table 16.—Number of fires for surface of underground metal/nonmetal and stone mines by location and time period,

1990–2001

Location

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Flame cutting/welding areas1 ......... 2 1 3 — — 1 7

Facility/garage/trailer/storage areas .... 1 1 — — 2 — 4

Fan housing ...................... ————— 1 1

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 3 — 2 2 12

1

Includes shop, junction box, facilities, handrail, head frame, walkway, and maintenance areas.

Table 17.—Number of fires for surface of underground metal/nonmetal and stone mines by burning material

and time period, 1990–2001

Burning material

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Oxyfuel/clothing/grease/other1 .... 2 1 3 — — 1 7

Facility/content ................ 1 1 — — 1 — 3

Wood . . . . . . . . . . . . . . . . . . . . . . . ———— 1 1 2

 Total . . . . . . . . . . . . . . . . . . . . . . 3 2 3 — 2 2 12

1

Includes electrical junction boxes, handrails, grease, flammable liquids, rubber tires, and equipment mechanical components.
12

Table 18.—Number of fire injuries per number of fires causing injuries and total fires for surface of underground metal/nonmetal

and stone mines by year, ignition source, equipment involved, and location, 1990–2001

Year

No.

total

fires

No. fires

causing

injuries

No.

fire

injuries

Ignition source Equipment Location

1990 . . . . 2 1 1 Flame cutting/welding spark/slag/flame . . . . Oxyfuel torch . . . Flame cutting/welding areas.

1991 . . . . 1 1 1 Flame cutting/welding spark/slag/flame . . . . Oxyfuel torch . . . Flame cutting/welding areas.

1992 .... 1 — — — — —

1993 . . . . 1 1 1 Flame cutting/welding spark/slag/flame . . . . Oxyfuel torch . . . Flame cutting/welding areas.

1994 . . . . 2 1 1 Flame cutting/welding spark/slag/flame . . . . Oxyfuel torch . . . Flame cutting/welding areas.

1995 .... 1 — — — — —

1996 .... — — — — — —

1997 .... — — — — — —

1998 .... 1 — — — — —

1999 .... 1 — — — — —

2000 . . . . 2 1 1 Flame cutting/welding spark/slag/flame . . . . Oxyfuel torch . . . Flame cutting/welding areas.

2001 .... — — — — — —

Total . . . . 12 5 5

Figure 4.—Number of fires and fire injuries for surface of underground metal/nonmetal and stone mines by state, 1990–2001.
13

Figure 5.—Number of fires, fire injuries, risk rates, and employees' working hours for surface of underground

metal/nonmetal and stone mines by time period, 1990–2001.

Figure 6.—Major variables for surface of underground metal/nonmetal and stone mine fires, 1990–2001. (FE = portable fire extinguisher)
14

Suppression Method

Table 14 shows the number of fires by suppression method

for each time period. The most common method was water

alone, followed by manual techniques with or without portable

fire extinguishers and portable fire extinguishers alone. In three

instances the fires destroyed or heavily damaged facilities

because of failure of firefighting methods, undetected fire, or

fire size.

During the first period, the largest number of fires were

suppressed manually with or without portable fire extinguishers.

During subsequent periods, the fires were extinguished with

portable fire extinguishers alone (second period), water alone

(third and fifth periods), and portable fire extinguishers or water

alone (sixth period).

Equipment Involved

Table 15 shows the number of fires by equipment involved

for each time period. The equipment most often involved was

oxyfuel torches (at times electrical arc welding equipment was

used), followed by facilities (considered equipment in this

report), a heater, and a ventilation fan.

During the first and third periods, the largest number of fires

involved oxyfuel torches. During the other periods, the fires

involved oxyfuel torches and facilities (second period), facilities

and a heater (fifth period), and an oxyfuel torch and a ventilation

fan (sixth period).

Location

Table 16 shows the number of fires by location for each time

period. The most common locations were flame cutting/welding

areas (at shops, junction boxes, facilities, handrails, head frames,

walkways, and maintenance areas), followed by facilities,

garages, trailers and storage areas, and a ventilation fan housing.

During the first and third periods, the largest number of fires

occurred at the flame cutting/welding areas. During the other

periods, the fires occurred at flame cutting/welding areas and at

facility, garage, trailer, and storage areas (second period),

facilities (fifth period), and flame cutting/welding areas and fan

housing (sixth period).

Burning Materials

Table 17 shows the number of fires by burning material for

each time period. The materials most often involved were

oxyfuel/clothing/grease and other materials (including electrical

junction boxes, handrails, rubber tires, flammable liquids, and

equipment mechanical components). Other burning materials

involved facilities and their contents, and wood.

During the first and third periods, the largest number of fires

involved oxyfuel, clothing, grease, and other materials. During

the other periods, the fires involved oxyfuel and facilities and

their contents (second period), wood and facilities (fifth period),

and oxyfuel and wood (sixth period).

Fire Injuries

Table 18 shows the number of fire injuries per number of

fires causing injuries and total fires by year, ignition source,

equipment involved, and location during 1990–2001. In 1990,

1991, 1993, 1994, and 2000, there was one injury caused by one

fire for each year. The cause of these fires was the flame

cutting/welding spark/slag/flame ignition source.

SURFACE METAL/NONMETAL MINE FIRES

Table 19 and figure 7 show the number of fires and fire

injuries for surface metal/nonmetal mines by state during

1990–2001. Table 19 also shows the injury risk rates, employees' working hours, and lost workdays. A total of 79 fires

occurred in 16 states during 1990–2001 for these mines.

Forty-five of the fires caused 44 injuries and 2 fatalities

(including 9 fires and 7 injuries involving contractors). The

yearly average was 6.6 fires and 3.7 injuries. Sixty-five fires

with 31 injuries and 2 fatalities occurred at metal mines, and

14 fires with 13 injuries occurred at nonmetal mines. The Ewhr

value was 546 × 106

 hr (Irr = 0.016), and the LWD value was

13,134.

Nevada and Arizona had the most fires (19 fires, 10 injuries,

and 1 fatality; and 19 fires and 11 injuries, respectively). They

were followed by Minnesota (11 fires, 4 injuries, and 1 fatality)

and Alaska (6 fires and 4 injuries). Of these states, Alaska had

the highest injury risk rate value (Irr = 0.079).

Table 20, partly illustrated in figure 8, shows the number of

fires, fire injuries, fire fatalities, risk rates, employees' working

hours, and lost workdays by time period. The number of fires

increased during the second period, then decreased during most

of the remaining periods. The number of fire injuries decreased

during most of the periods (a small increase is seen during the

last period), accompanied by a decline in employees' working

hours during most of the periods (a small increase is seen during

the third and fourth periods). The Irr values follow patterns

similar to those shown by the number of fire injuries.

Tables 21–26 show the number of fires by ignition source,

method of detection and suppression, equipment involved,

location, and burning material by time period. Figure 9 shows

the major variables related to fires for 1990–2001. Table 27

shows the number of fire injuries per number of fires causing

injuries and total fires by year, ignition source, equipment

involved, and location.

Ignition Source

Table 21 shows the number of fires and fire injuries by

ignition source for each time period. The leading source was

hydraulic fluid/fuel sprayed onto equipment hot surfaces

(35 fires or 44%), followed by flame cutting/welding spark/

slag/flame (13 fires or 17%) and electrical short/arcing (8 fires

or 10%). Other sources were heat source-flammable liquid/

vapors, flammable liquid/combustible material/refueling fuel on

hot surfaces, overheated oil, hot material, and conveyor belt
15

friction. Three ignition sources were unknown. Twenty-two of

the 35 equipment hydraulic/fuel fires became large fires because

of continuous flow of fluids from the pumps due to engine

shutoff failure, difficulty in activating available emergency

systems at ground level, lack of an emergency line drainage

system, or lack of effective and rapid local firefighting response

capabilities. In at least five instances, the cab was suddenly

engulfed in flames, probably due to the ignition of flammable

vapors and mists that penetrated the cab. Of note is that the

hydraulic fluid fires subsequently involved the fuel system.

During the first through fourth and the sixth periods, the

largest number of fires were caused by hydraulic fluid/fuel

sprayed onto equipment hot surfaces. During the fifth period,

the largest number of fires were caused by flame

cutting/welding spark/slag/flame.

Table 19.—Number of fires, fire injuries, fire fatalities, and risk rates for surface metal/nonmetal mines

by state, employees' working hours, and lost workdays, 1990–2001

State1 No. fires1 No.

fire injuries1 LWD2 Ewhr,2

 106 hr Irr3

Alabama . . . . . . . . . . . . 1 1 — 1.6 0.125

Alaska . . . . . . . . . . . . . . 6 4 72 10.1 0.079

Arizona . . . . . . . . . . . . . 19 11 243 88.4 0.025

California . . . . . . . . . . . 5 1 — 25.7 0.008

Florida . . . . . . . . . . . . . . 3 3 52 42.4 0.014

Georgia . . . . . . . . . . . . . 3 4 17.6 15.4 0.052

Idaho . . . . . . . . . . . . . . . 2 1 — 7.7 0.026

Michigan . . . . . . . . . . . . 1 — — 7.3 —

Minnesota4 . . . . . . . . . . 11 4 6,236 12.3 0.065

Missouri . . . . . . . . . . . . 2 1 — 1 0.2

Nevada4 . . . . . . . . . . . . 19 10 6,419 109 0.018

New Mexico . . . . . . . . . 2 — — 21.2 —

North Carolina . . . . . . . 2 2 46 10.2 0.039

South Carolina . . . . . . . 1 1 36 2 0.1

Texas . . . . . . . . . . . . . . 1 1 12 6.4 0.031

Wyoming . . . . . . . . . . . . 1 — — 4.5 —

All other states . . . . . . . — — — 181 —

 Total . . . . . . . . . . . . . 79 44 13,134 546 3

0.016

 1

Derived from MSHA "Fire Accident Abstract" internal publications.

 2

Derived from MSHA "Injury Experience in Mining" publications.

 3

Calculated according to MSHA formula reported in the "Methodologies" section.

 4

Minnesota and Nevada each had a fire fatality. These were caused by hydraulic fluid/fuel fires involving a

dozer and a truck, respectively.

Table 20.—Number of fires, fire injuries, fire fatalities, and risk rates for surface metal/nonmetal mines

by time period, employees' working hours, and lost workdays, 1990–2001

Time period

90-91 92-93 94-95 96-97 98-99 00-01 1990-2001

Number of fires1 . . . . . . . . . 16 22 15 13 6 7 79

Number of fire injuries1 . . . . 11 10 8 5 4 6 44

Number of fatalities1 ...... — — 1 — — 1 2

LWD2 . . . . . . . . . . . . . . . . . 224 281 6,109 132 44 6,344 13,134

Ewhr,2

 106 hr . . . . . . . . . . . . 97 93 95 98 83 80 546

Irr3 . . . . . . . . . . . . . . . . . . . . 0.023 0.021 0.017 0.01 0.01 0.015 3

0.016 1

Derived from MSHA "Fire Accident Abstract" internal publications. 2

Derived from MSHA "Injury Experience in Mining" publications. 3

Calculated according to MSHA formula reported in the "Methodologies" section.

Table 21.—Number of fires for surface metal/nonmetal mines by ignition source and time period, 1990–2001

Ignition source

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires 

Hydraulic fluid/fuel/oil on equipment hot surfaces . . . 7 11 6 8 — 3 35

Flame cutting/welding spark/slag/flame . . . . . . . . . . . 3 4 2 — 2 2 13

Electrical short/arcing . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 2 1 — 1 8

Heat source-flammable liquid/vapors ............. 1 1 2 1 1 1 7

Flammable liquid/combustible material/refueling fuel

 on hot surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 2 — 1 — 7

Overheated oil .............................. 1 1 — — — — 2

Hot material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — — 1 1 — 2

Conveyor belt/equipment friction ................ — — 1 1 — — 2

Unknown/other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — 1 — 1 1 — 3

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 22 15 13 6 7 79
16

Table 22.—Number of fires for surface metal/nonmetal mines by method of detection and time period,

1990–2001

Method of detection

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Visual:

 Flames/flash fires . . . . . . . 6 11 8 7 1 4 37

 Smoke . . . . . . . . . . . . . . . 5 4 4 4 1 2 20

 Sparks . . . . . . . . . . . . . . . 3 3 2 — 2 1 11

 Late smoke detection . . . . 2 2 1 21 — 8

Undetected .............. — 2 — — 1 — 3

 Total . . . . . . . . . . . . . . . . 16 22 15 13 6 7 79

Table 23.—Number of fires for surface metal/nonmetal mines by suppression method and time period, 1990–2001

Suppression method 

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

FE-foam-DCP-water . . . . . . . . . . . 3 5 6 9 — 3 26

FE . . . . . . . . . . . . . . . . . . . . . . . . . 6 5 5 1 3 2 22

Manual with or without FE1 ...... 3 3 2 1 1 1 11

Water . . . . . . . . . . . . . . . . . . . . . . 2 2 — 1 1 1 7

FSS-DCP-water . . . . . . . . . . . . . . 1 1 2 — — — 4

FSS-HD2 .................... 1 ————— 1

Destroyed/HD3 ............... — 6 — 1 1 — 8

 Total . . . . . . . . . . . . . . . . . . . . . 16 22 15 13 6 7 79

DCP Dry chemical powder.

FE Portable fire extinguisher.

FSS Machine fire suppression system.

HD Heavily damaged.

1

Method used by welders to extinguish clothing and oxyfuel/grease fires. 2

Heavy damage to equipment due to FSS activation failure.

3

Usually due to failure of firefighting methods, late fire detection, undetected fires, or fire size.

Table 24.—Number of fires for surface metal/nonmetal mines by equipment involved and time period,

1990–2001

Equipment

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Mobile equipment1 . . . . . . . . 9 14 10 10 1 3 47

Oxyfuel torch2 . . . . . . . . . . . . 3 4 2 — 2 2 13

Heater . . . . . . . . . . . . . . . . . . 2 1 1 — 1 2 7

Maintenance equipment .... 1 1 1 — — — 3

Generator ............... 1 — 1 — — — 2

Facility3 ................. — 1 — — 1 — 2

Beltline . . . . . . . . . . . . . . . . . — — — 1 — — 1

Chute . . . . . . . . . . . . . . . . . . ————1 — 1

Sump . . . . . . . . . . . . . . . . . . — 1 — — — — 1

Other . . . . . . . . . . . . . . . . . . . — — — 2 — — 2

 Total . . . . . . . . . . . . . . . . . 16 22 15 13 6 7 79

1

Includes loaders, dozers, trucks, shovels, drills, and scrapers. 2

At times, electrical arc welding equipment was used.

3

Considered equipment in this report.

Table 25.—Number of fires for surface metal/nonmetal mines by location and time period, 1990–2001

Location

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Mobile equipment working areas1 . . . . . . . . . . . . . 8 13 10 10 — 3 44

Flame cutting/welding areas2 . . . . . . . . . . . . . . . . 3 4 2 — 2 2 13

Maintenance/storage/refuse areas . . . . . . . . . . . . 3 3 2 — 3 1 12

Facility/shop/roofing areas .................. 2 — — — 1 1 4

Generator housing/crusher/fire training areas . . . — — 1 2 — — 3

Waste dump/sump areas . . . . . . . . . . . . . . . . . . . — 2 — 1 — — 3

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 22 15 13 6 7 79

1

Includes mining, haulage, drilling, loading, and excavating areas. 2

Includes pipeline, dump rope, crowd platform, and maintenance areas.
17

Table 26.—Number of fires for surface metal/nonmetal mines by burning material and time period, 1990–2001

Burning material

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Hydraulic fluid/fuel/oil . . . . . . . . . . . . . . . . . 7 11 5 8 — 3 34

Oxyfuel/clothing/grease/other1 . . . . . . . . . . 3 4 2 — 2 2 13

Flammable liquid/combustible material . . . 2 2 3 1 2 1 11

Electrical wires/cables . . . . . . . . . . . . . . . . 2 2 2 1— 1 8

Refuse/wood/tires/chute liner . . . . . . . . . . . 1 1 — 2 1 — 5

Equipment mechanical components ..... 1 1 2 — — — 4

Facility/content ...................... — 1 — — 1 — 2

Belt material . . . . . . . . . . . . . . . . . . . . . . . . — — 1 1 — — 2

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 22 15 13 6 7 79

1

Includes rubber hoses, pipeline, dump rope cables, grease, screen liner, shaft material, and equipment mechanical components.

Table 27.—Number of fire injuries per number of fires causing injuries and total fires for surface metal/nonmetal mines by year,

ignition source, equipment involved, and location, 1990–2001

Year

No.

total

fires

No. fires

causing

injuries

No.

fire

injuries

Ignition source Equipment Location

1990 . . . . 5 3 1 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

1 Hydraulic fluid/fuel on equipment hot surfaces Truck . . . . . . . . . . . . . . . Haulage area.

1 Oil on hot surfaces . . . . . . . . . . . . . . . . . . . . . Truck . . . . . . . . . . . . . . . Haulage area.

1991 . . . . 11 7 2 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

1 Flammable liquid on hot surfaces . . . . . . . . . . Maintenance equipment Refuse pile area.

5 Hydraulic fluid/fuel on equipment hot surfaces Loader/truck/dozer .... Loading/haulage/mining areas.

1992 . . . . 13 5 2 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

1 Flammable liquid on hot surfaces . . . . . . . . . . Maintenance equipment Maintenance area.

1 Heat source-flammable vapors . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance area.

1 Hydraulic fluid/fuel on equipment hot surfaces Loader ............. Loading area.

1993 . . . . 9 5 1 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

1 Refueling fuel on hot surfaces . . . . . . . . . . . . Truck . . . . . . . . . . . . . . . Maintenance area.

2 Hydraulic fluid/fuel on equipment hot surfaces Scraper/loader . . . . . . . Mining/loading areas.

1 Electrical short/arcing . . . . . . . . . . . . . . . . . . . Truck . . . . . . . . . . . . . . . Haulage area.

1994 . . . . 10 4 1 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

1 Electrical short/arcing . . . . . . . . . . . . . . . . . . . Generator ........... Generator housing.

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance area.

1 Hydraulic fluid/fuel on equipment hot surfaces Truck . . . . . . . . . . . . . . . Haulage area.

19951 . . . 5 5 1 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

1 Flammable liquid on hot surfaces . . . . . . . . . . Maintenance equipment Storage facility.

2 Hydraulic fluid/fuel on equipment hot surfaces Truck . . . . . . . . . . . . . . . Haulage area.

1996 . . . . 6 4 3 Hydraulic fluid/fuel on equipment hot surfaces Truck . . . . . . . . . . . . . . . Haulage area.

1 Oil on hot surfaces . . . . . . . . . . . . . . . . . . . . . Truck . . . . . . . . . . . . . . . Dump area.

1997 . . . . 7 1 1 Heat source-flammable liquid . . . . . . . . . . . . . Matches . . . . . . . . . . . . Fire training facility.

1998 . . . . 1 1 1 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

1999 . . . . 5 3 1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance areas.

1 Flammable liquid on hot surfaces . . . . . . . . . . Truck . . . . . . . . . . . . . . . Maintenance area.

1 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

20001 . . . 5 5 1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance area.

2 Hydraulic fluid/fuel on equipment hot surfaces Truck . . . . . . . . . . . . . . . Haulage area.

1 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

2001 . . . . 2 2 2 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

Total . . . . 79 45 44

1

A fire fatality occurred in 1995 and 2000. These were caused by hydraulic fluid/fuel fires involving a truck and a dozer, respectively.

Method of Detection

Table 22 shows the number of fires by method of detection

for each time period. The most frequent methods were operators

who saw the fires when they started as flames/flash fires, miners

who saw smoke shortly after the fires had started, and welders

who saw sparks. Other methods of detection were miners who

saw smoke long after the fires had started. Three fires were

undetected. During the first through fourth and the sixth

periods, the largest number of fires were detected by operators

as flames/flash fires. During the fifth period, the largest number

of fires were detected by welders as sparks.

Suppression Method

Table 23 shows the number of fires by suppression method for

each time period. The most common methods were portable fire

extinguishers with foam, dry chemical powder, and water,

followed by portable fire extinguishers alone and manual techniques with or without portable fire extinguishers. Other methods
18

were water alone and machine fire suppression systems with dry

chemical powder, foam, and water. Five of the 35 pieces of mobile equipment involved in the hydraulic fluid/ fuel fires had machine fire suppression systems. Dual activation (one activaion) of

machine fire suppression and engine shutoff systems succeeded in

temporarily abating the fires; however, the flames reignited, fueled

by the flow of pressurized fluids entrapped in the lines. On three

other occasions (one of which resulted in a fatality), the fires raged

out of control because of machine fire suppression system failure.

In another instance the fire was detected late.

On at least five occasions, including one mobile equipment

fire, fire brigades and fire departments fought the fires with

foam, dry chemical powder, and water. However, eight fires

destroyed or heavily damaged equipment (including seven

pieces of mobile equipment) because of failure of firefighting

methods, late fire detection, undetected fires, or fire size.

During the first and fifth periods, the largest number of fires

were suppressed with portable fire extinguishers alone. During

the second period, the largest number of fires were suppressed

with portable fire extinguishers together with foam, dry chemical

powder, and water and with portable fire extinguishers alone.

During the third, fourth, and sixth periods, the largest number of

fires were suppressed with portable fire extinguishers, foam, dry

chemical powder, and water.

Equipment Involved

Table 24 shows the number of fires by equipment involved

for each time period. The equipment most often involved was

mobile equipment (trucks, dozers, loaders, shovels, drills, and

scrapers), followed by oxyfuel torches (at times electrical arc

welding equipment was used) and heaters. Other equipment

included maintenance equipment, beltlines, generators, chutes,

a sump, and facilities (considered equipment in this report).

During the first through fourth and the sixth periods, the

largest number of fires involved mobile equipment. During the

fifth period, the largest number of fires involved oxyfuel

torches.

Table 28.—Number of fires, fire injuries, and risk rates for surface sand and gravel mines by state,

employees' working hours, and lost workdays, 1990–2001

State1 No. fires1 No.

fire injuries1 LWD2 Ewhr,2

 106 hr Irr3

Arizona . . . . . . . . . . . 3 3 63 15 0.04

Arkansas . . . . . . . . . 1 1 — 10 0.02

California . . . . . . . . . 9 5 160 89.4 0.011

Colorado . . . . . . . . . . 2 2 6 24 0.017

Florida . . . . . . . . . . . . 2 2 — 15 0.027

Illinois . . . . . . . . . . . . 3 3 54 20.7 0.029

Indiana . . . . . . . . . . . 2 2 22 21.3 0.019

Kansas . . . . . . . . . . . 1 1 — 8 0.025

Kentucky . . . . . . . . . . 1 1 7 6 0.033

Louisiana . . . . . . . . . 4 4 29 15 0.053

Maryland . . . . . . . . . . 1 1 3 11.2 0.018

Michigan . . . . . . . . . . 6 6 69 33.5 0.036

Mississippi . . . . . . . . 3 3 54 6.3 0.095

Missouri . . . . . . . . . . 1 1 32 10 0.02

Nebraska . . . . . . . . . 2 2 34 11 0.036

New Hampshire . . . . 2 2 8 26.5 0.015

New York . . . . . . . . . 3 2 16 28 0.014

Ohio . . . . . . . . . . . . . 4 2 65 37 0.011

Oklahoma . . . . . . . . . 1 — — 10 —

Oregon . . . . . . . . . . . 1 1 16 13.7 0.015

Pennsylvania . . . . . . 5 5 76 19.3 0.052

South Carolina . . . . . 1 — — 10.2 —

South Dakota . . . . . . 2 2 35 5.8 0.069

Texas . . . . . . . . . . . . 1 1 30 60 0.003

Utah . . . . . . . . . . . . . 3 3 6,075 15.6 0.039

Virginia . . . . . . . . . . . 1 — — 10.4 —

Washington . . . . . . . 1 1 20 25 0.008

Wisconsin . . . . . . . . . 2 2 39 22 0.018

Wyoming . . . . . . . . . . 2 2 8 4.4 0.091

All other states . . . . . — — — 157 —

 Total . . . . . . . . . . . 70 60 6,921 741 3

0.016 1

Derived from MSHA "Fire Accident Abstract" internal publications. 2

Derived from MSHA "Injury Experience in Mining" publications. 3

Calculated according to MSHA formula reported in the "Methodologies" section.
19

Figure 7.—Number of fires and fire injuries for surface metal/nonmetal mines by state, 1990–2001.

Figure 8.—Number of fires, fire injuries, risk rates, and employees' working hours for surface metal/nonmetal

mines by time period, 1990–2001.
20

Location

Table 25 shows the number of fires by location for each time

period. The most common locations were mobile equipment

working areas (mining, haulage, loading, drilling, and excavating

areas). This was followed by flame cutting/welding areas (at pipeline, dump rope, crowd platform, and maintenance areas) and

maintenance, storage, and refuse areas. Other fire locations included facilities and roofing areas, waste dump and sump areas,

and generator housing, crusher, and fire training areas. During the

first through fourth and the sixth periods, the largest number of

fires occurred at mobile equipment working areas. During the

fifth period, the largest number of fires occurred at maintenance,

storage, and refuse areas.

Burning Materials

Table 26 shows the number of fires by burning material for

each time period. The material most often involved was hydraulic fluid/fuel, followed by oxyfuel/clothing/grease and other

materials (including rubber hoses, pipelines, grease, equipment

mechanical components, dump rope cables, screen liner, and

shaft material), flammable liquids, and combustible materials.

Other burning materials involved electrical wires and cables,

refuse, wood, tires and chute liner, equipment mechanical components, facilities and their content, and belt material. During

the first through fourth and the sixth periods, the largest number

of fires involved hydraulic fluid/fuel and oil. During the fifth

period, the largest number of fires involved oxyfuel, flammable

liquids, and combustible materials.

Fire Injuries

Table 27 shows the number of fire injuries per number of

fires causing injuries and total fires by year, ignition source,

equipment involved, and location for 1990–2001. Overall, there

were 44 injuries and 2 fatalities caused by 45 fires. The greatest

number of fire injuries occurred in 1991 (eight injuries caused by

seven fires). The ignition sources that caused most of the fire injuries were hydraulic fluid/fuel sprayed onto equipment hot

surfaces and flame cutting/welding spark/slag/flame. Other ignition sources causing injuries were flammable liquid/refueling

fuel on hot surfaces, heat source-vapors/flammable liquid, electrical short/arcing, and oil on hot surfaces. The equipment most

often involved in fire injuries included mobile equipment, oxyfuel torches, and maintenance equipment, followed by heaters,

electrical systems, and air compressors. The locations where the

fire injuries occurred were mobile equipment working areas,

Figure 9.—Major variables for surface metal/nonmetal mine fires, 1990–2001. (FE = portable fire extinguisher)
21

flame cutting/welding areas, maintenance and fire training areas,

and generator housing.

Nevada and Minnesota each had a fire fatality [MSHA 1995e,

2000e]. These were caused by hydraulic fluid/fuel fires involving a truck and a dozer, respectively. The victims were

severely burned while exiting the cab.

SURFACE SAND AND GRAVEL MINE FIRES

Table 28 and figure 10 show the number of fires and fire

injuries for surface sand and gravel mines by state during

1990–2001. Table 28 also shows the injury risk rates, employees' working hours, and lost workdays. At surface sand and

gravel mines, a total of 70 fires with 60 injuries occurred in 29

states during 1990–2001. Fifty-nine of the fires caused

60 injuries (none of the fires involved contractors). The yearly

average was 5.8 fires and five injuries. The Ewhr value was

741 × 106

 hr (Irr = 0.016), and the LWD value was 6,921.

California had the most fires (nine fires and five injuries), followed by Michigan (six fires and six injuries) and Pennsylvania

(five fires and five injuries). Of these states, Pennsylvania had

the highest injury risk rate value (Irr = 0.052).

Table 29, partly illustrated in figure 11, shows the number of

fires, fire injuries, risk rates, employees' working hours, and lost

workdays by time period. The number of fires and fire injuries

show an increase during the second period followed by a decrease

during the fourth period followed by a small increase during the

fifth period and a sharp decrease during the last period. Employees'

working hours increased during most of the periods. The Irr values

follow patterns similar to those shown by the injury values.

Tables 30–35 show the number of fires by ignition source,

method of detection and suppression, equipment involved, location, and burning material by time period. Figure 12 shows the

major variables related to fires for 1990–2001. Table 36 shows

the fire injuries per number of fires causing injuries and total fires

by year, ignition source, equipment involved, and location.

Ignition Source

Table 30 shows the number of fires by ignition source for each

time period. The leading source was flame cutting/welding spark/

slag/flame (29 fires or 41%), followed by heat source/explosion

(15 fires or 21%) involving pressurized cans and flammable

liquids and by hydraulic fluid/fuel sprayed onto equipment hot

surfaces (14 fires or 20%). Other ignition sources were flammable

liquid/gas/refueling fuel on hot surfaces/collision (in one instance,

the fuel ignited upon equipment collision) and electrical short/

arcing/explosion (involving a pump). Two ignition sources were

unknown. At least 5 of the 14 mobile equipment hydraulic fluid/

fuel fires became large fires because of the continuous flow of

fluids from the pumps due to engine shutoff failure, difficulty in

activating available emergency systems at ground level, lack of an

emergency drainage system, or lack of effective and rapid local

firefighting response capabilities. On two occasions, the cab was

suddenly engulfed in flames, probably due to the ignition of

flammable vapors and mists that penetrated the cab. Of note is

that the hydraulic fluid fires subsequently involved the fuel

system. During all of the periods, the largest number of fires were

caused by flame cutting/welding spark/slag/flame.

Table 29.—Number of fires, fire injuries, and risk rates for surface sand and gravel mines

by time period, employees' working hours, and lost workdays, 1990–2001

Time period

90-91 92-93 94-95 96-97 98-99 00-01 1990-2001

Number of fires1 . . . . . . . . . 8 16 16 11 13 6 70

Number of fire injuries1 . . . . 7 13 15 8 11 6 60

LWD2 . . . . . . . . . . . . . . . . . 73 193 218 6,089 234 114 6,921

Ewhr,2

 106 hr . . . . . . . . . . . . 115 112 118 122 134 140 741

Irr3 . . . . . . . . . . . . . . . . . . . . 0.012 0.023 0.025 0.013 0.016 0.009 3

0.016 1

Derived from MSHA "Fire Accident Abstract" internal publications. 2

Derived from MSHA "Injury Experience in Mining" publications. 3

Calculated according to MSHA formula reported in the "Methodologies" section.

Table 30.—Number of fires for surface sand and gravel mines by ignition source and time period, 1990–2001

Ignition source

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Flame cutting/welding spark/slag/flame . . . . . . . . . . 4 6 6 5 5 3 29

Heat source/explosion1 ....................... 2 3 5 2 1 2 15

Hydraulic fluid/fuel on equipment hot surfaces ..... — 5 4 2 2 1 14

Flammable liquid/gas/refueling fuel on hot surfaces/

 equipment collision ........................ 2 2 — 1 1 — 6

Electrical short/arcing/explosion2 ............... — — 1 1 2 — 4

Unknown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — — — 2 — 2

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 16 16 11 13 6 70

1

Involving pressurized cans and flammable liquid. 2

Involving a pump.
22

Table 31.—Number of fires for surface sand and gravel mines by method of detection and time period,

1990–2001

Method of detection

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Visual:

 Flames/flash fires . . . . . . . 2 5 3 3 4 4 21

 Sparks . . . . . . . . . . . . . . . 4 5 6 1 4 1 21

 Smoke . . . . . . . . . . . . . . . — 3 4 3 — 1 11

 Late smoke detection . . . . 1 2 — 3 2 — 8

Heard an explosion . . . . . . . . 1 — 2 — 1 — 4

Power loss . . . . . . . . . . . . . . — 1 — — — — 1

Undetected .............. — — 1 1 2 — 4

 Total . . . . . . . . . . . . . . . . 8 16 16 11 13 6 70

Table 32.—Number of fires for surface sand and gravel mines by suppression method and time period,

1990–2001

Suppression method

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Manual with or without FE1 ..... 4 5 6 2 4 3 24

FE-DCP-foam-water . . . . . . . . . . 1 6 4 4 4 1 20

Water . . . . . . . . . . . . . . . . . . . . . 1 4 5 3 1 2 16

FE . . . . . . . . . . . . . . . . . . . . . . . . 2 1 — 1 2 — 6

Destroyed/HD2 .............. — — 1 1 2 — 4

 Total . . . . . . . . . . . . . . . . . . . . 8 16 16 11 13 6 70

DCP Dry chemical powder.

FE Portable fire extinguisher.

HD Heavily damaged.

1

Method used by welders to extinguish clothing and oxyfuel/grease fires. 2

Usually due to failure of firefighting methods, late fire detection, undetected fires, or fire size.

Table 33.—Number of fires for surface sand and gravel mines by equipment involved and time period,

1990–2001

Equipment

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Oxyfuel torch1 ............ 4 6 6 5 5 3 29

Mobile equipment2 ........ 2 5 5 2 3 1 18

Heater/burner . . . . . . . . . . . . 2 3 5 2 1 2 15

Generator/pump .......... — — — 1 2 — 3

Maintenance equipment .... — 2 — 1 — — 3

Facility3 ................. — — — — 2— 2

 Total . . . . . . . . . . . . . . . . . 8 16 16 11 13 6 70

1

At times, electrical arc welding equipment was used.

2

Includes trucks, loaders, scrapers, dredges, backhoes, and buckets. 3

Considered equipment in this report.

Table 34.—Number of fires for surface sand and gravel mines by location and time period, 1990–2001

Location 90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Flame cutting/welding areas1 ................ 4 6 6 5 5 3 29

Maintenance areas ........................ 3 4 5 3 1 1 17

Mobile equipment working areas2 ............. — 5 4 3 3 1 16

Generator/pump/electrical control areas ....... — — 1 — 2 — 3

Facility area ............................. — — — — 2 — 2

Crusher/refuse areas . . . . . . . . . . . . . . . . . . . . . . 1 — — — —1 2

Beltline area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — 1 — — — — 1

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 16 16 11 13 6 70

1

Includes beltline, water pipelines, chute, crusher, hopper and compactor areas, washer plants, and maintenance areas. 2

Includes haulage, loading, mining, and dredging areas.
23

Table 35.—Number of fires for surface sand and gravel mines by burning material and time period, 1990–2001

Burning material 90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Oxyfuel/clothing/grease/other1 ............ 4 6 6 5 5 3 29

Hydraulic fluid/fuel . . . . . . . . . . . . . . . . . . . . . — 5 4 2 2 1 14

Refuse/rubber tires ..................... 1 2 4 1 — 1 9

Flammable liquid/gas/refueling fuel . . . . . . . . 2 2 1 2 11 9

Electrical control wires/cables . . . . . . . . . . . . — — 1 1 2 — 4

Belt material/crusher . . . . . . . . . . . . . . . . . . . 1 1 — — 1 — 3

Facility/content ........................ — — — — 2 — 2

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 16 16 11 13 6 70

1

Includes chute liner, washer plant, flammable liquids, shaker deck, belt material, crusher and hopper, and equipment mechanical components.

Table 36.—Number of fire injuries per number of fires causing injuries and total fires for surface sand and gravel mines by year,

ignition source, equipment involved, and location, 1990–2001

Year

No.

total

fires

No. fires

causing

injuries

No.

fire

injuries

Ignition source Equipment Location

1990 . . . . 4 3 1 Flame cutting/welding spark/slag/flame . . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

2 Refueling fuel on hot surfaces . . . . . . . . . . . . . Truck . . . . . . . . . . . . . . . Maintenance area.

1991 . . . . 4 4 3 Flame cutting/welding spark/slag/flame . . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Refuse area.

1992 . . . . 9 6 2 Flammable liquid on hot surfaces . . . . . . . . . . . Maintenance equipment Maintenance area.

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance area.

1 Flame cutting/welding spark/slag/flame . . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

2 Hydraulic fluid/fuel on equipment hot surfaces Truck . . . . . . . . . . . . . . . Haulage area.

1993 . . . . 7 7 4 Flame cutting/welding spark/slag/flame . . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Beltline areas.

2 Hydraulic fluid/fuel on equipment hot surfaces Dredge-loader . . . . . . . . Dredging/loading areas.

1994 . . . . 8 7 3 Flame cutting/welding spark/slag/flame . . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

3 Heat source-flammable liquid . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance area.

1 Electrical short/arcing . . . . . . . . . . . . . . . . . . . . Electrical system . . . . . Electrical control area.

1995 . . . . 8 8 3 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance area.

3 Flame cutting/welding spark/slag/flame . . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

2 Hydraulic fluid/fuel on equipment hot surfaces Loader/scraper ....... Loading/mining areas.

1996 . . . . 7 6 1 Flame cutting/welding spark/slag/flame . . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

2 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance area.

1 Flammable liquid on hot surfaces . . . . . . . . . . . Maintenance equipment Maintenance area.

1 Hydraulic fluid/fuel on equipment hot surfaces Loader ............. Loading area.

1 Electrical short/arcing . . . . . . . . . . . . . . . . . . . . Loader cab .......... Loading area.

1997 . . . . 4 2 2 Flame cutting/welding spark/slag/flame . . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

1998 . . . . 10 9 4 Flame cutting/welding spark/slag/flame . . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

3 Electrical short/arcing . . . . . . . . . . . . . . . . . . . . Pump/generator . . . . . . Pump/generator housing.

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance area.

2 Hydraulic fluid/fuel on equipment hot surfaces Truck/loader . . . . . . . . . Haulage/loading areas.

1999 . . . . 3 1 1 Flame cutting/welding spark/slag/flame . . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

2000 . . . . 3 3 2 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance/refuse areas.

1 Flame cutting/welding spark/slag/flame . . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

2001 . . . . 3 3 2 Flame cutting/welding spark/slag/flame . . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.

1 Hydraulic fluid/fuel . . . . . . . . . . . . . . . . . . . . . . Loader ............. Loading area.

Total . . . . 70 59 60

Method of Detection

Table 31 shows the number of fires by method of detection

for each time period. The most frequent methods were welders

who saw sparks and operators who saw the fires when they

started as flames/flash fires. Other methods of detection were

miners who heard an explosion and operators who experienced

an equipment power loss. Four fires were undetected.

During the first period, the largest number of fires were

detected by welders as sparks. During the second and fifth

periods, the largest number of fires were detected by operators

and welders as flames/flash fires and sparks. During the third

period, the largest number of fires were detected by welders as

sparks. During the fourth period, the largest number of fires

were detected by operators as flames/flash fires and by miners

as smoke shortly or long after the fires had started. During the

sixth period, the largest number of fires were detected by

operators as flames/flash fires.

Suppression Method

Table 32 shows the number of fires by suppression method

for each time period. The most frequent methods were manual

techniques with or without portable fire extinguishers, portable
24

Figure 10.—Number of fires and fire injuries for surface sand and gravel mines by state, 1990–2001.

Figure 11.—Number of fires, fire injuries, risk rates, and employees' working hours for surface sand and gravel mines by

time period, 1990–2001.
25

fire extinguishers with dry chemical powder, foam and water,

and water alone. Portable fire extinguishers alone were also

used to suppress the fires. None of the equipment involved in

fires had machine fire suppression systems. On at least three

occasions, including one mobile equipment fire, fire brigades

and fire departments fought the fires with foam, dry chemical

powder, and water. However, in four instances the fires destroyed or heavily damaged equipment (including two pieces of

mobile equipment) because of failure of other firefighting methods, late fire detection, undetected fires, or fire size.

During the first, third, and sixth periods, the largest number

of fires were suppressed manually with or without portable fire

extinguishers. During the second and fourth periods, the largest

number of fires were suppressed with portable fire extinguishers

together with dry chemical powder, foam, and water. During the

fifth period, the largest number of fires were extinguished manually with or without portable fire extinguishers and with

portable fire extinguishers, dry chemical powder, foam, and

water.

Equipment Involved

Table 33 shows the number of fires by equipment involved for

each time period. The equipment most often involved was oxyfuel

torches (at times electrical arc welding equipment was used),

followed by mobile equipment (loaders, trucks, scrapers, dredges,

backhoes, and buckets) and heaters/burners. Other equipment included maintenance equipment, generators and pumps, and

facilities (considered equipment in this report). During all of the

periods, the largest number of fires involved oxyfuel torches.

Location

Table 34 shows the number of fires by location for each time

period. The most common locations were flame cutting/welding

areas (at beltline, pipeline, chute, crusher, hopper, and compactor areas, washer plants, and maintenance areas), followed by

maintenance areas and mobile equipment working areas (loading, haulage, mining, and dredging areas). Other fire locations

included generator and pump housing, electrical control areas,

facility areas, crusher and refuse areas, and beltline areas.

During all of the periods, the largest number of fires occurred at

flame cutting/welding areas.

Burning Materials

Table 35 shows the number of fires by burning material for

each time period. The materials most often involved were

oxyfuel/clothing/grease and other materials (including chute

liner, washer plant, flammable liquids, equipment mechanical

components, shaker deck, crusher and hopper, and belt material).

Figure 12.—Major variables for surface sand and gravel mine fires, 1990–2001. (FE = portable fire extinguisher)
26

This was followed by hydraulic fluid/fuel and by flammable

liquids, gas, and refueling fuel. Other burning materials

included refuse and rubber tires, electrical control, wires and

cables, belt material and crusher, and facilities and their

contents. During all of the periods, the largest number of fires

involved oxyfuel/clothing/grease and other materials.

Fire Injuries

Table 36 shows the number of fire injuries per number of fires

causing injuries and total fires by year, ignition source, equipment

involved, and location during 1990–2001. Overall, there were

60 injuries caused by 59 fires. The greatest number of fire injuries

occurred in 1998 (10 injuries caused by 9 fires). The ignition

sources that caused most of the fire injuries were flame

cutting/welding spark/slag/flame, heat source, and hydraulic

fluid/fuel sprayed onto equipment hot surfaces. Other ignition

sources were flammable liquid/refueling fuel on hot surfaces and

electrical short/arcing. The equipment most often involved in fire

injuries included oxyfuel torches, heaters, and mobile equipment,

followed by maintenance equipment, electrical systems, pumps,

and generators. The locations where the fire injuries occurred

were flame cutting/welding areas, maintenance areas, mobile

equipment working areas, and pump and generator housing.

SURFACE STONE MINE FIRES

Table 37 and figure 13 show the number of fires and fire

injuries for surface stone mines by state during 1990–2001.

Table 37 also shows the injury risk rates, employees' working

hours, and lost workdays. In all, 96 fires occurred in 31 states

and 1 fire occurred in Puerto Rico. Sixty-eight of the fires

caused 67 injuries and 1 fatality (including 6 fires and 5 injuries

involving contractors). The yearly average was eight fires and

5.6 injuries. The Ewhr value was 689 × 106

 hr (Irr = 0.02), and

the LWD value was 7,399.

Indiana had the most fires (eight fires and four injuries),

followed by Georgia (seven fires and seven injuries) and

Pennsylvania (seven fires and five injuries). Of these states,

Georgia had the highest injury risk rate value (Irr = 0.058).

Table 38, partly illustrated in figure 14, shows the number of

fires, fire injuries, fire fatalities, risk rates, employees' working

hours, and lost workdays by time period. The number of fires and

fire injuries show an increase during the second period followed

by a decrease during most of the remaining periods. Employees'

working hours increased during most of the periods. The Irr

values follow patterns similar to those shown by the injury values.

Tables 39–44 show the number of fires by ignition source,

method of detection and suppression, equipment involved, location,

and burning material by time period. Figure 15 shows the major

variables related to fires for 1990–2001. Table 45shows the

number of fire injuries per number of fires causing injuries and total

fires by year, ignition source, equipment involved, and location.

Ignition Source

Table 39 shows the number of fires and fire injuries by

ignition source for each time period. The leading sources were

flame cutting/welding spark/slag/flame (25 fires or 26%), heat

source/explosion-flammable liquid (24 fires or 25%), and hydraulic fluid/fuel sprayed onto equipment hot surfaces (16 fires

or 17%). At least 10 of the 16 mobile equipment hydraulic

fluid/fuel fires became large fires because of the continuous flow

of fluids from the pumps due to engine shutoff failure, difficulty

in activating available emergency systems at the ground level,

lack of an emergency line drainage system, or lack of effective

and rapid local firefighting response capabilities. On two

occasions, the cab was suddenly engulfed in flames, probably

due to the ignition of flammable vapors and mists that penetrated

the cab. Of note is that the hydraulic fluid fires subsequently

involved the fuel system. Other ignition sources were electrical

short/arcing, refueling fuel/flammable liquid on hot surfaces,

explosion/ignition of hazardous material, chemical and explosives, hot material, engine malfunction/mechanical friction,

and overheated oil. Nine ignition sources were unknown.

During the first, third, fourth, and fifth periods, the largest

number of fires were caused by heat source/explosion-flammable

liquid/gas. During the second period, the largest number of fires

were caused by flame cutting/welding spark/slag/flame. During

the sixth period, the largest number of fires were caused by

hydraulic fluid/fuel sprayed onto equipment hot surfaces.

Method of Detection

Table 40 shows the number of fires by method of detection

for each time period. The most frequent methods were operators

who saw the fires when they started as flames/flash fires,

welders who saw sparks, and miners who saw smoke shortly

after the fires had started. Other methods of detection were

miners who heard an explosion or touched a hot spot, miners

who saw smoke long after the fires had started, and operators

who saw a white mist. Eight fires were undetected.

During the first period, the largest number of fires were

detected by welders as sparks and by miners who heard an

explosion. During the second period, the largest number of fires

were detected by welders as sparks. During the third period, the

largest number of fires were detected by operators as

flames/flash fires and by welders as sparks. During the fourth

and fifth periods, the largest number of fires were detected by

miners as smoke. During the sixth period, the largest number of

fires were detected by operators as flames/flash fires.

Suppression Method

Table 41 shows the number of fires by suppression method

for each time period. The most common methods were manual

techniques with or without portable fire extinguishers or water

alone, portable fire extinguishers with dry chemical powder, and

foam and water. None of the equipment involved in fires had

machine fire suppression systems. On at least six occasions,

including one mobile equipment fire, fire brigades and fire

departments fought the fires with portable fire extinguishers,

foam, dry chemical powder, and water. However, 12 fires destroyed or heavily damaged equipment (including four pieces of

mobile equipment) because of failure of firefighting methods,

late fire detection, undetected fires, or fire size.

During the first and fifth periods, the largest number of fires

were suppressed with water alone. During the second period, the

largest number of fires were suppressed manually with or without

portable fire extinguishers. During the third period, the largest
27

number of fires were suppressed with portable fire extinguishers or

water alone and manually with or without portable fire

extinguishers. During the fourth period, the largest number of fires

were extinguished with portable fire extinguishers alone or together

with dry chemical powder, foam, and water. During the sixth

period, the largest number of fires were extinguished with portable

fire extinguishers, dry chemical powder, foam, and water.

Equipment Involved

Table 42 shows the number of fires by equipment involved

for each time period. The equipment most often involved was

mobile equipment (dozers, loaders, trucks, tankers, drills, and

shovels), oxyfuel torches (at times electrical arc welding

equipment was used), heaters and burners, and maintenance

equipment. Other equipment included facilities (considered

equipment in this report), chemical/flammable liquid/gas tanks,

beltlines, electrical control systems, a hopper, a crusher, a

preheat system, a generator, a product treatment pot, and an

explosive device. During the first, third, and fifth periods, the

largest number of fires involved heaters, burners, and

maintenance equipment. During the second period, the largest

number of fires involved oxyfuel torches. During the fourth and

sixth periods, the largest number of fires involved mobile

equipment.

Location

Table 43 shows the number of fires by location for each time

period. The most common locations were flame cutting/welding

areas, maintenance and refuse areas, and mobile equipment

working areas (haulage, loading, mining, drilling, transportation,

and crusher areas). Other fire locations included facility and

garage areas, raw mills, preheat and storage silo areas, product

treatment areas, beltline and hopper areas, and waste dump, pit,

crusher, screen, and deck areas. Electrical control and power

house areas, chemical and flammable liquid storage areas, and

generator housing were also affected by the fires. During the

first, third, and fifth periods, the largest number of fires occurred

at maintenance and refuse areas. During the second period, the

 largest number of fires occurred at flame cutting/welding areas.

During the fourth and sixth periods, the largest number of fires

occurred at mobile equipment working areas.

Burning Materials

Table 44 shows the number of fires by burning material for each

time period. The materials most often involved were oxyfuel/

Figure 13.—Number of fires and fire injuries for surface stone mines by state, 1990–2001.
28

Figure 14.—Number of fires, fire injuries, risk rates, and employees' working hours for surface stone mines by time period, 1990–2001.

Figure 15.—Major variables for surface stone mine fires, 1990–2001. (FE = portable fire extinguisher)
29

Table 37.—Number of fires, fire injuries, and risk rates for surface stone mines by state,1

employees' working hours, and lost workdays, 1990–2001

State2 No. fires2 No.

fire injuries2 LWD3 Ewhr,3

 106 hr Irr4

Arizona . . . . . . . . . . 4 3 26 5.8 0.014

Arkansas . . . . . . . . 3 3 52 14 0.043

California . . . . . . . . 3 2 20 21.6 0.019

Colorado . . . . . . . . . 1 1 12 8.2 0.024

Connecticut . . . . . . 2 1 — 5.3 0.038

Florida . . . . . . . . . . . 5 5 50 39.5 0.025

Georgia . . . . . . . . . . 7 7 115 24 0.058

Idaho . . . . . . . . . . . . 1 1 — 3.5 0.057

Illinois . . . . . . . . . . . 5 2 247 24.6 0.016

Indiana . . . . . . . . . . 8 4 64 17.6 0.046

Kentucky . . . . . . . . . 4 2 6 16.4 0.024

Louisiana . . . . . . . . 2 2 2 4.2 0.095

Massachusetts . . . . 1 — — 8.2 —

Michigan . . . . . . . . . 3 1 43 11.3 0.018

Missouri . . . . . . . . . 3 2 18 28 0.014

Nebraska . . . . . . . . 1 1 — 2 0.1

New Jersey . . . . . . . 2 2 150 10 0.04

New York . . . . . . . . 5 — 7 17 —

North Carolina . . . . 2 2 24 27 0.015

Ohio . . . . . . . . . . . . 5 3 49 22 0.027

Oklahoma . . . . . . . . 3 2 32 19.2 0.021

Oregon . . . . . . . . . . 3 3 38 14.7 0.041

Pennsylvania . . . . . 7 5 177 46 0.022

Puerto Rico . . . . . . . 1 1 30 11.4 0.018

South Carolina . . . . 1 1 24 7.5 0.027

South Dakota . . . . . 3 3 15 5.4 0.111

Tennessee5 . . . . . . . 3 1 6,152 18 0.011

Texas . . . . . . . . . . . 3 2 37 49 0.008

Virginia . . . . . . . . . . 2 2 — 21.7 0.018

Washington . . . . . . 2 1 — 5.2 0.039

West Virginia . . . . . 1 1 — 6 0.033

Wisconsin . . . . . . . . 1 1 9 18 0.011

All other states . . . . — — — 157 —

 Total . . . . . . . . . . 97 67 7,399 689 4

0.02 1

Includes Puerto Rico.

2

Derived from MSHA "Fire Accident Abstract" internal publications. 3

Derived from MSHA "Injury Experience in Mining" publications. 4

Calculated according to MSHA formula reported in the "Methodologies" section. 5

Tennessee had 1 fire fatality caused by a hydraulic fluid/fuel fire involving a truck.

clothing/grease and other materials (including screen shaft, crusher,

 hopper, stampler breaker materials, rubber hoses, gear boxes, bin

feeder, hydraulic fluid, and chute liner), hazardous materials, chemicals, oil, refuse, detonated explosives, and hydraulic fluid/fuel.

Other burning materials included flammable liquids and gas,

facilities and their contents, electrical wires and cables, belts and

hot materials, equipment mechanical components, and deck liner.

During the first and fifth periods, the largest number of fires

involved hazardous material, chemicals, refuse, oil, and detonated

explosives. During the second period, the largest number of fires

involved oxyfuel/clothing/grease and other materials. During the

third period, the largest number of fires involved oxyfuel and

hazardous materials. During the fourth and sixth periods, the

largest number of fires involved hydraulic fluid/fuel.

Fire Injuries

Table 45 shows the number of fire injuries per number of

fires causing injuries and total fires by year, ignition source,

equipment involved, and location for 1990–2001. Overall, there

were 67 injuries and 1 fatality caused by 68 fires. The greatest

number of fire injuries occurred in 1993 (11 injuries and

1 fatality caused by 12 fires). The ignition sources that caused

the greatest number of fire injuries were flame cutting/welding

spark/slag/flame, heat source, and hydraulic fluid/fuel sprayed

onto equipment hot surfaces. Other ignition sources were flammable liquid/refueling fuel on hot surfaces, electrical short/

arcing, overheated oil, hot material, and mechanical friction.

The equipment involved in fire injuries included oxyfuel torches,

heaters, mobile equipment, maintenance equipment, electrical

systems, air compressors, beltline, and kiln. The locations where

most of the fire injuries occurred were flame cutting/welding

areas, maintenance and refuse areas, and mobile equipment

working areas. Other fire locations were generator housing,

beltlines, and kiln areas.

A fatality occurred in Tennessee [MSHA 1993e], which

was caused by a hydraulic fluid fire involving a truck. The

victim was severely burned in the cab, probably due to the

sudden ignition of flammable vapors and mists that penetrated

the cab.
30

Table 38.—Number of fires, fire injuries, fire fatalities, and risk rates for surface stone mines

by time period, employees' working hours, and lost workdays, 1990–2001

Time period

90-91 92-93 94-95 96-97 98-99 00-01 1990-2001

Number of fires1 . . . . . . . . . . 12 24 20 19 10 12 97

Number of fire injuries1 . . . . . 9 18 15 15 5 5 67

Number of fire fatalities1 .... — 1 — — — — 1

LWD2 . . . . . . . . . . . . . . . . . . 191 6,133 784 155 57 79 7,399

Ewhr,2

 106 hr . . . . . . . . . . . . . 103 110 116 116 124 120 689

Irr3 . . . . . . . . . . . . . . . . . . . . . 0.018 0.033 0.026 0.026 0.008 0.008 3

0.02 1

Derived from MSHA "Fire Accident Abstract" internal publications. 2

Derived from MSHA "Injury Experience in Mining" publications. 3

Calculated according to MSHA formula reported in the "Methodologies" section.

Table 39.—Number of fires for surface stone mines by ignition source and time period, 1990–2001

Ignition source

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Flame cutting/welding spark/slag/flame . . . . . . . . . . 3 10 5 3 2 2 25

Heat source/explosion-flammable liquid/gas . . . . . . 5 4 6 4 4 1 24

Hydraulic fluid/fuel on equipment hot surfaces . . . . . 2 4 2 3 — 5 16

Electrical short/arcing . . . . . . . . . . . . . . . . . . . . . . . . — — 2 4 — 1 7

Refueling fuel/flammable liquid on hot surfaces . . . . — 1 2 — 2 — 5

Explosion/ignition-hazardous material/chemical/

 explosives/flammable gas . . . . . . . . . . . . . . . . . . — 1 1 1 1— 4

Hot material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 1 1 1 — 3

Overheated oil ............................. — 1 — 1 — — 2

Engine malfunction/mechanical friction .......... — — — 1 — 1 2

Unknown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3 1 1 — 2 9

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 24 20 19 10 12 97

Table 40.—Number of fires for surface stone mines by method of detection and time period,

1990–2001

Method of detection

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Visual:

 Flames/flash fires . . . . . . . 2 5 5 3 3 6 24

 Sparks . . . . . . . . . . . . . . . 3 10 5 3 2 1 24

 Smoke . . . . . . . . . . . . . . . — 3 4 6 4 2 19

 Late smoke detection . . . . — 2 — 2 — — 4

 White mist . . . . . . . . . . . . . ————— 1 1

Heard an explosion . . . . . . . . 3 1 2 2 1— 9

Touched a hot spot ........ 2 1 3 2—— 8

Undetected .............. 2 2 1 1— 2 8

 Total . . . . . . . . . . . . . . . . 12 24 20 19 10 12 97

Table 41.—Number of fires for surface stone mines by suppression method and time period,

1990–2001

Suppression method

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Manual with or without FE1 .... 3 10 5 3 2 — 23

Water . . . . . . . . . . . . . . . . . . . . 4 4 5 4 4 1 22

FE-DCP-foam-water . . . . . . . . . 2 5 4 5 2 4 22

FE . . . . . . . . . . . . . . . . . . . . . . . 1 2 5 5 2 3 18

Destroyed/HD2 ............. 2 3 1 2 — 4 12

 Total . . . . . . . . . . . . . . . . . . . 12 24 20 19 10 12 97

DCP Dry chemical powder.

FE Portable fire extinguisher.

HD Heavily damaged.

1

Method used by welders to extinguish clothing and oxyfuel/grease fires. 2

Usually due to failure of firefighting methods, late fire detection, undetected fires, or fire size.
31

Table 42.—Number of fires for surface stone mines by equipment involved and time period, 1990–2001

Equipment

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Mobile equipment1 ....................... 2 5 5 7 3 7 29

Oxyfuel torch2 ........................... 3 10 5 3 2 2 25

Heater/maintenance equipment/burner ....... 4 4 6 4 4 1 23

Facilities3 .............................. 2 3 1 1—— 7

Chemical/flammable liquid/gas tanks . . . . . . . . . — — 1 1 1 — 3

Hopper/crusher/preheat system ............. — — — 2 1 — 3

Generator/product treatment pot ............ 1 — — 1 — — 2

Beltlines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — 1 — — 1 1 2

Electrical control system . . . . . . . . . . . . . . . . . . . — — 1 — — 1 2

Explosive device . . . . . . . . . . . . . . . . . . . . . . . . . — 1 ———— 1

Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 1 — — — 1

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 24 20 19 10 12 97

1

Includes dozers, loaders, trucks, drills, shovels, and tankers. 2

At times, electrical arc welding equipment was used.

3

Considered equipment in this report.

Table 43.—Number of fires for surface stone mines by location and time period, 1990–2001

Location

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Flame cutting/welding areas1 ...................... 3 10 5 3 2 2 25

Maintenance/refuse areas ........................ 4 4 7 4 5 — 24

Mobile equipment working areas2 ................... 2 4 3 6 1 5 21

Facility/garage areas ............................ 2 3 1 — — 3 9

Raw mill/preheat/silo/product treatment areas ......... 1 — 2 1 1 — 5

Waste dump/pit/crusher/screen deck areas ........... — 2 — 1 — 1 4

Beltline/hopper areas ............................ — 1 1 1 — 1 4

Chemical/flammable liquid storage areas ............ — — — 1 1 — 2

Electrical control/power house areas ................ — — 1 1 — — 2

Generator housing .............................. — — — 1 — — 1

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 24 20 19 10 12 97

1

Includes generator housing, chute, deck, bin feeder, crusher, hopper, shop, stampler breaker and screen shaft areas, and maintenance areas. 2

Includes haulage, loading, mining, drilling, transportation, and crusher areas.

Table 44.—Number of fires for surface stone mines by burning material and time period, 1990–2001

Burning material

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Oxyfuel/clothing/grease/other1 ............. 3 10 5 3 2 2 25

Hazardous material/chemical/refuse/oil/

 detonated explosive ................... 4 5 5 3 4 — 21

Hydraulic fluid/fuel/oil . . . . . . . . . . . . . . . . . . . . 2 4 2 6 — 5 19

Flammable liquid/gas . . . . . . . . . . . . . . . . . . . . 1 1 4 1 3 — 10

Facility/content ......................... 2 3 1 — — 1 7

Electrical wires/cables . . . . . . . . . . . . . . . . . . . — — 2 4 — 1 7

Belt/hot material . . . . . . . . . . . . . . . . . . . . . . . . — 11111 5

Equipment mechanical components ........ — — — 1 — 1 2

Deck liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ————— 1 1

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 24 20 19 10 12 97

 1

Includes screen shaft, crusher and hopper, stampler breaker, chute liner, hydraulic fluid, rubber hoses, gear boxes, and

bin feeder.
32

Table 45.—Number of fire injuries per number of fires causing injuries and total fires for surface stone mines by year, ignition source,

equipment involved, and location, 1990–2001

Year

No.

total

fires

No. fires

causing

injuries

No.

fire

injuries

Ignition source Equipment Location

1990 . . . 6 4 2 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . Refuse pile area.

2 Flame cutting/welding spark/slag/flame . . . . . . . . Oxyfuel torch . . . . . . Flame cutting/welding areas.1

1991 . . . 6 5 2 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . Maintenance area.

1 Flame cutting/welding spark/slag/flame . . . . . . . . Oxyfuel torch . . . . . . Flame cutting/welding areas.1

1 Flammable gas explosion . . . . . . . . . . . . . . . . . . . Product treatment pot Product treatment areas.

1 Hydraulic fluid/fuel on equipment hot surfaces . . . Loader ........... Loading area.

1992 . . . 10 7 5 Flame cutting/welding spark/slag/flame . . . . . . . . Oxyfuel torch . . . . . . Flame cutting/welding areas.1

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . Maintenance area.

1 Overheated oil . . . . . . . . . . . . . . . . . . . . . . . . . . . Air compressor . . . . . Drilling area.

19932 . . 14 12 5 Flame cutting/welding spark/slag/flame . . . . . . . . Oxyfuel torch . . . . . . Flame cutting/welding areas.1

3 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . Beltline/refuse pile areas.

2 Hydraulic fluid/fuel on equipment hot surfaces . . . Truck/dozer . . . . . . . . Crusher/mining areas.

1 Refueling fuel on hot surfaces . . . . . . . . . . . . . . . Truck . . . . . . . . . . . . . Maintenance area.

1994 . . . 9 6 3 Flame cutting/welding spark/slag/flame . . . . . . . . Oxyfuel torch . . . . . . Flame cutting/welding areas.1

2 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . Maintenance area.

1 Hydraulic fluid/fuel on equipment hot surfaces . . . Loader ........... Loading area.

1995 . . . 11 9 4 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . Hopper belt/maintenance areas.

2 Flame cutting/welding spark/slag/flame . . . . . . . . Oxyfuel torch . . . . . . Flame cutting/welding areas.1

2 Flammable liquid on hot surfaces . . . . . . . . . . . . . Truck/loader . . . . . . . Maintenance area.

1 Electrical short/arcing . . . . . . . . . . . . . . . . . . . . . . Dozer cab . . . . . . . . . Mining area.

1996 . . . 12 9 2 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . Maintenance area.

2 Electrical short/arcing . . . . . . . . . . . . . . . . . . . . . . Generator/truck ..... Generator housing/haulage area.

1 Flame cutting/welding spark/slag . . . . . . . . . . . . . Oxyfuel torch . . . . . . Flame cutting/welding areas.1

3 Hydraulic fluid/fuel on equipment hot surfaces . . . Dozer/truck . . . . . . . . Mining/haulage areas.

1 Oil on hot surfaces . . . . . . . . . . . . . . . . . . . . . . . . Truck . . . . . . . . . . . . . —

1997 . . . 7 6 1 Mechanical friction ........................ Loader ........... Loading area.

2 Flame cutting/welding spark/slag/flame . . . . . . . . Oxyfuel torch . . . . . . Flame cutting/welding areas.1

2 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . Maintenance/working areas.

1 Hot material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hopper belt ........ Hopper area.

1998 . . . 4 4 1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . Maintenance area.

1 Flammable liquid on hot surfaces . . . . . . . . . . . . . Truck . . . . . . . . . . . . . Preheat tower.

1 Hot material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kiln . . . . . . . . . . . . . . Kiln area.

1 Flame cutting/welding spark/slag/flame . . . . . . . . Oxyfuel torch . . . . . . Flame cutting/welding areas.1

1999 . . . 6 1 1 Fuel on hot surfaces . . . . . . . . . . . . . . . . . . . . . . . — Storage shed.

2000 . . . 4 3 1 Hydraulic fluid/fuel on equipment hot surfaces . . . Truck . . . . . . . . . . . . . Haulage area.

1 Flame cutting/welding spark/slag/flame . . . . . . . . Shovel . . . . . . . . . . . Flame cutting/welding areas.1

1 Electrical short/arcing . . . . . . . . . . . . . . . . . . . . . . Loader ........... Loading area.

2001 . . . 8 2 1 Flame cutting/welding spark/slag/flame . . . . . . . . Oxyfuel/torch . . . . . . Flame cutting/welding areas.1

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas heater . . . . . . . . Screen deck.

Total . . . 97 68 67

1

Includes crusher, ball chain, bin feeder, screen shaft, stamper breaker and beltline areas, and mobile equipment maintenance areas. 2

In 1993, there was 1 fire fatality, which was caused by a hydraulic fluid/fuel fire involving a truck.

METAL/NONMETAL MILL FIRES

Table 46 and figure 16 show the number of fires and fire

injuries for metal/nonmetal mills by state during 1990–2001.

Table 46 also shows the injury risk rates, employees' working

hours, and lost workdays. In all, 77 fires occurred in 26 states.

Thirty-seven of the fires caused 41 injuries and 1 fatality

(including 5 fires and 3 injuries involving contractors). The

yearly average was 6.4 fires and 3.4 injuries. Fifty-four fires

with 26 injuries and 1 fatality occurred at metal mills; 23 fires

with 15 injuries occurred at nonmetal mills. The Ewhr value

was 845 × 106

 hr (Irr = 0.01), and the LWD value was 6,681.

Minnesota had the most fires (16 fires and 5 injuries),

followed by Arizona (9 fires and 3 injuries), Wyoming (8 fires

and 3 injuries), Nevada (7 fires, 4 injuries, and 1 fatality), and

Texas (4 fires and 7 injuries). Of these states, Texas had the

highest injury risk rate value (Irr = 0.033).

Table 47, partly illustrated in figure 17, shows the number of

fires, fire injuries, fire fatalities, risk rates, employees' working

hours, and lost workdays by time period. The number of fires

increased slightly during the second period, then decreased

during the remaining periods. The number of fire injuries show

a decrease during most of the periods (an increase is seen during

the third period), accompanied by a decline in employees’

working hours during most of the periods. The Irr values follow

patterns similar to those shown by the injury values.

Tables 48–53 show the number of fires by ignition source,

method of detection and suppression, equipment involved,

location, and burning material by time period. Figure 18 shows

the major variables related to fires for 1990–2001. Table 54

shows the number of fire injuries per number of fires causing

injuries and total fires by year, ignition source, equipment

involved, and location.
33

Ignition Source

Table 48 shows the number of fires and injuries by ignition

source for each time period. The leading sources were flame

cutting/welding spark/slag/flame (29 fires or 38%), hot material

(12 fires or 16%), and flammable liquid/oil/refueling fuel on hot

surfaces/explosion (9 fires or 11%). Other ignition sources were

electrical short/arcing, conveyor belt friction, overheated oil,

surface vaporized oil on hot surface, chemical explosion/

ignition, hydraulic fluid/fuel sprayed onto equipment hot

surfaces, and heat source. Two sources were unknown. At least

one of the three mobile equipment hydraulic fluid/fuel fires

became a large fire because of continuous flow of fluids from

the pump due to engine shutoff failure. In this instance, the cab

was suddenly engulfed in flames, probably due to the ignition of

flammable vapors and mists that penetrated the cab.

During the first, third, fourth, and fifth periods, the largest

number of fires were caused by flame cutting/welding spark/

slag/flame. During the second period, the largest number of fires

were caused by flammable liquid/oil/refueling fuel on hot

surfaces/explosion. During the sixth period, the largest number

of fires were caused by flame cutting/welding spark/slag/flame,

conveyor belt friction, and overheated oil.

Method of Detection

Table 49 shows the number of fires by method of detection

for each time period. The most frequent methods were workers

who saw smoke long after the fires had started, followed by

welders who saw sparks and operators who saw the fires when

they started as flames/flash fires. Other methods of detection

were workers who saw smoke shortly after the fires had started,

workers who heard an electric trip warning or an explosion,

workers who saw a smoldering fire, and an operator who saw

white smoke. Four fires were undetected.

During the first period, the largest number of fires were

detected by workers as smoke long after the fires had started, by

operators as flames/flash fires, and by welders as sparks. During

the second, fourth, and fifth periods, the largest number of fires

were detected by workers as smoke long after the fires had

started. During the third period, the largest number of fires were

detected by operators as flames/flash fires. During the sixth

period, the largest number of fires were detected by workers as

smoke.

Suppression Method

Table 50 shows the number of fires by suppression method

for each time period. The most common methods were water or

portable fire extinguishers alone and manual techniques with or

without portable fire extinguishers. None of the equipment

involved in fires had machine fire suppression systems. Other

suppression methods were portable fire extinguishers with foam,

dry chemical powder, and water. On at least five occasions, including one mobile equipment fire, fire brigades and fire

departments fought the fires with portable fire extinguishers

together with foam, dry chemical, and water. However, six fires

destroyed or heavily damaged equipment (including one piece

of mobile equipment) because of failure of firefighting methods,

late fire detection, undetected fires, or fire size.

During the first period, the largest number of fires were

suppressed with water or portable fire extinguishers alone and

manually with or without portable fire extinguishers. During the

second period, the largest number of fires were suppressed with

portable fire extinguishers alone. During the third through fifth

periods, the largest number of fires were extinguished with water

alone. During the sixth period, the largest number of fires were

extinguished with water or portable fire extinguishers.

Equipment Involved

Table 51 shows the number of fires by equipment involved

for each time period. The equipment most often involved was

oxyfuel torches (at times electrical arc welding equipment was

used). This was followed by dust collectors, air compressors,

chutes, dryers, crushers, liquor and refueling pumps, and oil

vaporizers. Other equipment included mobile equipment (trucks,

dozers, loaders, shovels, and forklifts), beltlines, and electrical

breakers, cathodes, and fixtures. Also involved in fires were

facilities (considered equipment in this report), heaters, sample

and chemical containers, a hydroprecipitator, kilns, product

cooling systems, and maintenance equipment.

During the first, third, fourth, and fifth periods, the largest

number of fires involved oxyfuel torches. During the second

period, the largest number of fires involved oxyfuel torches,

mobile equipment, dust collectors, air compressors, chutes,

crushers, and dryers. During the sixth period, the largest number

of fires involved oxyfuel torches and dust collectors.

Location

Table 52 shows the number of fires by location for each time

period. The most common locations were flame cutting/welding

areas, beltline areas, and maintenance areas. Other fire locations

included dust collectors, air compressors, chutes, crushers,

dryers, pelletizer building, baghouse, refinery, liquor pump

areas, storage silos, product cooling areas, boiler rooms, power

houses, and chemical storage areas. Mobile equipment working

areas (haulage, loading, and mining areas), facility and elevator

shaft, and a lab and shop were also affected by the fires. During

the first through fifth periods, the largest number of fires

occurred at flame cutting/welding areas. During the sixth

period, the largest number of fires occurred at flame

cutting/welding areas, dust collectors, and maintenance areas.

Burning Materials

Table 53 shows the number of fires by burning material for

each time period. The materials most often involved were

oxyfuel/clothing/grease and other materials (including liquor

pumps, belt material, pipelines, dust collector and chute liners,

flammable liquids, wood pallets, crusher and screen panel). This

was followed by belt and hot materials, flammable liquids,

refueling fuel, and vaporized oil. Other burning materials
34

included electrical wires and cables, facilities and their contents,

and oil, chemicals, refuse, and core samples. Dust collector and

chute liners, pipeline and crusher materials, equipment mechanical components, and hydraulic fluid/fuel were also

involved in the fires.

During the first, third, fourth, and fifth periods, the largest

number of fires involved oxyfuel/clothing/grease and other

materials. During the second period, the largest number of fires

involved oxyfuel and flammable liquids, refueling fuel, and

vaporized oil. During the sixth period, the largest number of fires

involved oxyfuel, flammable liquids, and facilities and their

content.

Fire Injuries

Table 54 shows the number of fire injuries per number of

fires causing injuries and total fires by year, ignition source,

equipment involved, and location for 1990–2001. Overall, there

were 41 injuries and 1 fatality caused by 37 fires.

The greatest number of fire injuries occurred in 1990 (eight

injuries caused by eight fires) and 1994 (seven injuries and one

fatality caused by six fires). The ignition sources that caused the

injuries were flame cutting/welding spark/slag/flame, flammable

liquid/refueling fuel on hot surfaces/explosion, and hot material.

Other ignition sources were chemical ignition, electrical short/

arcing, overheated oil, conveyor belt friction, heat source, and hydraulic fluid/fuel sprayed onto equipment hot surfaces. The equipment involved in fire injuries included oxyfuel torches,

maintenance equipment, refueling and liquor pumps, and product

cooling systems. Other equipment included chemical containers,

electrical systems, air compressors, mobile equipment, heaters, and

beltline. The location where most of the fire injuries occurred were

the flame cutting/welding areas, maintenance areas, pump housing,

liquor pump and refinery areas, and product cooling area. Other

fire locations were lab and storage areas, crusher and pelletizer

building, beltline, maintenance areas, and mobile equipment

working areas.

A fatality occurred in Nevada [MSHA 1994e]. The victim,

equipped with firefighting gear and self-contained breathing

apparatus, was fighting a refinery electrical fire. The victim was

found unconscious on the floor.

Figure 16.—Number of fires and fire injuries for metal/nonmetal mills by state, 1990–2001.
35

Figure 18.—Major variables for metal/nonmetal mill fires, 1990–2001. (FE = portable fire extinguisher)

Figure 17.—Number of fires, fire injuries, risk rates, and employees' working hours for metal/nonmetal mills by time

period, 1990–2001.
36

Table 46.—Number of fires, fire injuries, and risk rates for metal/nonmetal mills by state,

employees' working hours, and lost workdays, 1990–2001

State1 No. fires1 No.

fire injuries1 LWD2 Ewhr,2

 106 hr Irr3

Alaska . . . . . . . . . . . 1 1 7 7.1 0.028

Arizona . . . . . . . . . . 9 3 56 78.5 0.008

Arkansas . . . . . . . . 1 — — 18.5 —

California . . . . . . . . 2 — — 44.72 —

Georgia . . . . . . . . . . 3 3 6 102 0.006

Idaho . . . . . . . . . . . . 1 1 — 7 0.029

Kansas . . . . . . . . . . 1 1 33 4.5 0.044

Louisiana . . . . . . . . 1 1 50 16.5 0.012

Michigan . . . . . . . . . 4 1 11 27 0.007

Minnesota . . . . . . . . 16 5 26 75 0.013

Missouri . . . . . . . . . 1 — — 4.8 —

Montana . . . . . . . . . 2 1 — 33.5 0.006

Nevada4 . . . . . . . . . 7 4 6,058 86 0.009

New Jersey . . . . . . . 2 1 — 0.65 0.308

New Mexico . . . . . . 1 — — 11.4 —

New York . . . . . . . . 1 1 18 1.2 0.17

North Carolina . . . . 3 3 — 16.4 0.037

Oregon . . . . . . . . . . 1 1 — 1.84 0.109

Pennsylvania ..... 1 — — 2 —

Texas . . . . . . . . . . . 4 7 385 42 0.033

Utah . . . . . . . . . . . . 3 1 — 26.4 0.008

Vermont . . . . . . . . . 1 1 9 1.63 0.123

Virginia . . . . . . . . . . 1 1 — 7.9 0.025

West Virginia . . . . . 1 1 — 0.6 0.333

Wisconsin . . . . . . . . 1 — — 0.2 —

Wyoming . . . . . . . . . 8 3 22 46.1 0.013

All other states . . . . — — — 182 —

 Total . . . . . . . . . . 77 41 6,681 845 3

0.01 1

Derived from MSHA "Fire Accident Abstract" internal publications. 2

Derived from MSHA "Injury Experience in Mining" publications. 3

Calculated according to MSHA formula reported in the "Methodologies" section. 4

Nevada had 1 fire fatality.

Table 47.—Number of fires, fire injuries, fire fatalities, and risk rates for metal/nonmetal mills

by time period, employees' working hours, and lost workdays, 1990–2001

Time period

90-91 92-93 94-95 96-97 98-99 00-01 1990-2001

Number of fires1 . . . . . . . . . . 16 17 15 13 8 8 77

Number of fire injuries1 . . . . . 10 7 9 6 6 3 41

Number of fire fatalities1 .... — — 1 — — — 1

LWD2 . . . . . . . . . . . . . . . . . . 58 78 6,033 50 411 51 6,681

Ewhr,2

 106 hr . . . . . . . . . . . . . 151 143 139 141 131 140 845

Irr3 . . . . . . . . . . . . . . . . . . . . . 0.013 0.010 0.013 0.009 0.009 0.004 3

0.01 1

Derived from MSHA "Fire Accident Abstract" internal publications. 2

Derived from MSHA "Injury Experience in Mining" publications. 3

Calculated according to MSHA formula reported in the "Methodologies" section.

Table 48.—Number of fires for metal/nonmetal mills by ignition source and time period, 1990–2001

Ignition source

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Flame cutting/welding spark/slag/flame . . . . . . . . . . . . . . 7 4 8 5 3 2 29

Hot material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 3 3 2 — 12

Flammable liquid/refueling fuel/oil on hot surfaces/

 explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 — — — 1 9

Electrical short/arcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 1 12 — 8

Conveyor belt friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 — 2 — 2 7

Overheated/vaporized oil on hot surface ............. 1 1 — — — 2 4

Hydraulic fluid/fuel on equipment hot surfaces ......... — 1 — 1 — — 2

Chemical explosion/ignition . . . . . . . . . . . . . . . . . . . . . . . — — 1 — 1 — 2

Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 1 — — 1 2

Unknown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 1 1 — — 2

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 17 15 13 8 8 77
37

Table 49.—Number of fires for metal/nonmetal mills by method of detection and time period, 1990–2001

Method of detection

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Visual:

 Late smoke detection . . . . . . . . . . . . . 5 7 3 5 3 3 26

 Sparks . . . . . . . . . . . . . . . . . . . . . . . . 5 3 3 2 2 1 16

 Flames/flash fires . . . . . . . . . . . . . . . . 5 3 4 2 1 — 15

 Smoke . . . . . . . . . . . . . . . . . . . . . . . . — 1 1 2 1 4 9

 White smoke . . . . . . . . . . . . . . . . . . . . 1 — — — — — 1

 Smoldering fire . . . . . . . . . . . . . . . . . . — — — 1 — — 1

Heard an electrical trip warning . . . . . . . — 2 2 — — — 4

Heard an explosion . . . . . . . . . . . . . . . . . — 1 — — — — 1

Undetected ....................... — — 2 1 1 — 4

 Total . . . . . . . . . . . . . . . . . . . . . . . . . 16 17 15 13 8 8 77

Table 50.—Number of fires for metal/nonmetal mills by suppression method and time period, 1990–2001

Suppression method

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Water . . . . . . . . . . . . . . . . . . . . 5 5 6 7 3 3 29

FE . . . . . . . . . . . . . . . . . . . . . . . 5 8 2 1 2 3 21

Manual with or without FE1 .... 5 2 3 3 2 1 16

FE-DCP-foam-water . . . . . . . . . — 2 2 1 — — 5

Destroyed/HD2 ............. 1 — 21116

 Total . . . . . . . . . . . . . . . . . . . 16 17 15 13 8 8 77

DCP Dry chemical powder.

FE Portable fire extinguisher.

HD Heavily damaged.

1

Method used by welders to extinguish clothing and oxyfuel/grease fires. 2

Usually due to failure of firefighting methods, late fire detection, undetected fires, or fire size.

Table 51.—Number of fires for metal/nonmetal mills by equipment involved and time period, 1990–2001

Equipment

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Oxyfuel torch1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4 7 5 3 2 27

Dust collector/air compressor/chute/dryer/crusher . . . . . . . . 2 4 1 1 — 2 10

Liquor/refueling pump/oil vaporizer ................... 2 3 1 — 1 — 7

Electrical cathode/breaker/fixture ..................... 2 — 1 1 2 — 6

Beltline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 — 2 1 1 6

Mobile equipment2 ................................ — 4 — 1 — 1 6

Facility3 ......................................... — — 2 2 1 — 5

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — 1 1 — — 1 3

Sample/chemical containers/hydroprecipitator . . . . . . . . . . . 1 — 2 — — — 3

Maintenance equipment ............................ 2 — — — — — 2

Kiln/product cooling system ......................... — — — 1 — 1 2

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 17 15 13 8 8 77

1

At times, electrical arc welding equipment was used.

2

Includes shovels, forklifts, dozers, loaders, and trucks. 3

Considered equipment in this report.
38

Table 52.—Number of fires for metal/nonmetal mills by location and time period, 1990–2001

Location

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Flame cutting/welding areas1 .......................... 7 4 8 5 3 2 29

Beltline areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 — 3 1 1 9

Dust collector/air compressor/chute/crusher/dryer areas . . . . . 2 3 1 — — 2 8

Maintenance areas .................................. 3 3 — — — 2 8

Pelletizer/baghouse/refinery/liquor pump areas ............ 2 2 1 1— — 6

Storage silos ....................................... — — 2 2 — — 4

Product cooling area/boiler room/power house/chemical storage — — 1 — 2 1 4

Mobile equipment working areas2 ....................... — 2 — 1 — — 3

Facility/elevator shaft ................................ — — 1 1 1 — 3

Laboratory/shop .................................... — — 1 — 1 — 2

Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 — — — — — 1

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 17 15 13 8 8 77

 1

Includes dust collector, chute and hopper areas, bin feeder, baghouse, pelletizer building, pipeline, elevator shaft, liquor pump, shops, beltline

area, and maintenance areas.

 2

Includes haulage, loading, and mining areas.

Table 53.—Number of fires for metal/nonmetal mills by burning material and time period, 1990–2001

Burning material

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Oxyfuel/clothing/grease/other1 ....................... 7 4 8 5 3 2 29

Belt/hot material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 1 3 2 1 11

Flammable liquid/refueling fuel/vaporized oil ............ 3 4 — — — 2 9

Electrical wires/cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31112 — 8

Oil/chemicals/refuse/core samples . . . . . . . . . . . . . . . . . . . . 1 1 2 1— — 5

Facility/content ................................... — — 2 1 1 2 6

Dust collector/chute liners/pipeline/crusher material . . . . . . 1 1 1 1— — 4

Hydraulic fluid/fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — 1 — 1 — — 2

Equipment mechanical components .................. — 2 — — — 1 3

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 17 15 13 8 8 77

1

Includes liquor pumps, belt material, pipelines, flammable liquids, dust collector and chute liners, wood pallets, crusher, and screen panel.

Table 54.—Number of fire injuries per number of fires causing injuries and total fires for metal/nonmetal mills by year, ignition source,

equipment involved, and location, 1990–2001

Year

No.

total

fires

No. fires

causing

injuries

No.

fire

injuries

Ignition source Equipment Location

1990 . . 12 8 4 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . . . . Flame cutting/welding areas.

2 Electrical short/arcing . . . . . . . . . . . . . . . . . . . Electrical system . . . . . . . . Crusher/pelletizer building.

2 Flammable liquid on hot surfaces . . . . . . . . . . Maintenance equipment . . . Maintenance area.

1991 . . 4 2 1 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . . . . Flame cutting/welding areas.

1 Refueling fuel on hot surfaces . . . . . . . . . . . . Refueling pump . . . . . . . . . Pump housing.

1992 . . 8 2 1 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . . . . Flame cutting/welding areas.

1 Overheated oil . . . . . . . . . . . . . . . . . . . . . . . . Air compressor . . . . . . . . . . Mining area.

1993 . . 9 5 2 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . . . . Flame cutting/welding areas.

3 Flammable liquid/refueling fuel on hot sur-

 faces/explosion.

Liquor pump/heater/forklift . Maintenance area/liquor pump

 area.

19941 10 6 3 Chemical ignition . . . . . . . . . . . . . . . . . . . . . . Chemical samples . . . . . . . Storage/laboratory.

1 Electrical short/arcing . . . . . . . . . . . . . . . . . . . Electrical system . . . . . . . . Refinery building.

3 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . . . . Flame cutting/welding areas.

1995 . . 5 2 2 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . . . . Flame cutting/welding areas.

1996 . . 8 3 1 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . . . . Flame cutting/welding areas.

1 Conveyor belt friction . . . . . . . . . . . . . . . . . . . Beltline . . . . . . . . . . . . . . . . Beltline areas.

1 Hydraulic fluid/fuel on equipment hot surfaces Loader ................ Loading area.

1997 . . 5 3 3 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . . . . Flame cutting/welding areas.

1998 . . 5 1 1 Chemical ignition . . . . . . . . . . . . . . . . . . . . . . Chemical samples container Laboratory.

1999 . . 3 2 1 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . . . . Flame cutting/welding areas.

4 Hot material . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling system . . . . . . . . . . Product cooling area.

2000 . . 4 1 1 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . . . . Flame cutting/welding areas.

2001 . . 4 2 1 Oil on hot surfaces . . . . . . . . . . . . . . . . . . . . . Oil cooler . . . . . . . . . . . . . . Power house.

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . . . . Working area.

Total . . 77 37 41

1

In 1994, there was 1 fire fatality, which was caused by a refinery electrical fire.
39

STONE MILL FIRES

Table 55 and figure 19 show the number of fires and fire

injuries for stone mills by state during 1990–2001. Table 55

also shows the injury risk rates, employees' working hours, and

lost workdays. In all, 118 fires occurred in 33 states. Seventysix of the fires caused 82 injuries (including 8 fires and 6 injuries

involving contractors). The yearly average was 9.8 fires and 6.8

injuries. The Ewhr value was 873 × 106

 hr (Irr = 0.019), and the

LWD value was 1,911. Missouri had the most fires (16 fires and

9 injuries), followed by Pennsylvania (15 fires and 14 injuries),

Michigan (9 fires and 5 injuries), and Virginia (7 fires and 5

injuries). Of these states, Virginia had the highest injury risk

rate value (Irr = 0.091).

Table 56, partly illustrated in figure 20, shows the number of

fires, fire injuries, risk rates, employees' working hours, and lost

workdays by time period. The number of fires and fire injuries

decreased during most of the periods, with a sharp increase

during the last period. The number of employees' working hours

increased throughout the periods. The Irr values follow patterns

similar to those shown by the injury values.

Tables 57–63 show the number of fires by ignition source,

method of detection and suppression, equipment involved,

location, and burning material by time period. Figure 21 shows

the major variables related to fires for 1990–2001. Table 63

shows the fire injuries per number of fires causing injuries and

total fires by year, ignition source, equipment involved, and

location.

Ignition Source

Table 57 shows the number of fires and fire injuries by

ignition source for each time period. The leading sources were

flame cutting/welding spark/slag/flame (53 fires or 45%), hot

material (24 fires or 20%), and electrical short/arcing (11 fires or

9%). Other ignition sources were refueling fuel/flammable

liquid/gas on hot surfaces/collision, heat source, hydraulic

fluid/fuel sprayed onto equipment hot surfaces, conveyor belt

friction, and overheated oil. One ignition source was unknown.

At least four of the five mobile equipment hydraulic fluid/fuel

fires became large fires because of the continuous flow of fluids

from the pumps due to engine shutoff failure, difficulty in

activating available emergency systems at ground level, lack of

an emergency line drainage system, or lack of effective and

rapid local firefighting response capabilities. In at least one

instance, the cab was suddenly engulfed in flames, probably due

to the ignition of flammable vapors and mists that penetrated the

cab. Of note is that the hydraulic fluid fires subsequently

involved the fuel system.

During the first, second, and fourth periods, the largest

number of fires were caused by flame cutting/welding

spark/slag/flame. During the third and sixth periods, the largest

number of fires were caused by hot material. During the fifth

period, the largest number of fires were caused by hot material

and electrical short/arcing.

Method of Detection

Table 58 shows the number of fires by method of detection

for each time period. The most frequent methods were welders

who saw sparks, workers who saw smoke shortly and long after

the fires had started, and operators who saw the fires when they

started as flames/flash fires. Other methods of detection were

workers who heard an explosion and workers who saw a glow

or a smoldering fire. Six fires were undetected. The hot

material fires were detected long after they had started due to

lack of combustion smoke/gas detection systems.

During the first, second, and fourth periods, the largest

number of fires were detected by welders as sparks. During the

third and fifth periods, the largest number of fires were detected

by workers as smoke long after the fires had started. During the

sixth period, the largest number of fires were detected by

operators as flames/flash fires.

Suppression Method

Table 59 shows the number of fires by suppression method

for each time period. The most common methods were manual

techniques with or without portable fire extinguishers, followed

by water or portable fire extinguishers alone. Other suppression

methods were portable fire extinguishers with foam, dry

chemical powder, and water. One piece of mobile equipment

involved in a fire had a machine fire suppression system, whose

activation together with the engine shutoff system succeeded in

temporarily abating the fire.

In at least 11 instances, including 2 mobiles equipment fires,

fire brigades and fire departments fought the fires with portable

fire extinguishers together with foam, dry chemical powder, and

water. However, seven fires destroyed or heavily damaged

equipment (including one piece of mobile equipment) because

of failure of firefighting methods, late fire detection, undetected

fires, or fire size.

During the first, second, and fourth periods, the largest

number of fires were suppressed manually with or without

portable fire extinguishers. During the third period, the largest

number of fires were suppressed manually with or without

portable fire extinguishers or water alone. During the fifth

period, the largest number of fires were extinguished with water

alone. During the sixth period, the largest number of fires were

extinguished with water alone and portable fire extinguishers

with foam, dry chemical powder, and water.

Equipment Involved

Table 60 shows the number of fires by equipment involved

for each time period. The equipment most often involved were

oxyfuel torches (at times electrical arc welding equipment was

used), followed by kilns, preheat and cooling systems, and

mobile equipment (loaders, trucks, drills, and locomotives).

Other equipment included electrical systems, heaters, barrels,

refueling pumps, beltlines, chutes, crushers, waste fuel tanks,
40

dust collectors, and storage bins. Maintenance equipment and

facilities (considered equipment in this report) were also involved in the fires.

During the first through fourth periods, the largest number of

fires involved oxyfuel torches. During the fifth period, the

largest number of fires involved electrical systems. During the

sixth period, the largest number of fires involved oxyfuel

torches, kilns, and preheat and cooling systems.

Location

Table 61 shows the number of fires by location for each time

period. The most common locations were flame cutting/welding

areas (at hopper, crusher, elevator shaft, chute and kiln areas,

and maintenance areas). This was followed by kilns, hoppers,

chutes, storage silo areas, mobile equipment working areas (shop

and crusher areas, drilling, loading, haulage, transportation, and

fuel preparation room), and beltline areas. Other fire locations

included maintenance areas, pump and bagging stations, preheat

and cooling areas, pit and bin areas, waste fuel areas, electrical

control rooms, shops, and substation areas. Dust collector,

crusher, chute, and facility areas were also affected by the fires.

During the first, second, and fourth periods, the largest

number of fires occurred at flame cutting/welding areas. During

the third period, the largest number of fires occurred at flame

cutting/welding areas, kilns, chutes, hoppers, and storage silo

areas. During the fifth period, the largest number of fires

occurred at beltline areas. During the sixth period, the largest

number of fires occurred at kiln areas.

Burning Materials

Table 62 shows the number of fires by burning material for

each time period. The materials most often involved were

oxyfuels/ clothing/grease and other materials (including rubber

hoses, pipelines, dust collector and chute liners, and shaft and kiln

materials). This was followed by belt and kiln/clinker hot

materials, flammable liquids/oil/refueling fuel, electrical wires/

cables/ transformers/ batteries, and rubber tires/refuse/waste fuel.

Other materials involved in fires were hydraulic fluid/fuel, chute

and dust collector liners and hoppers, and facilities and their

content.

During the first, second, and fourth periods, the largest

number of fires involved oxyfuel/clothing/grease and other materials. During the third period, the largest number of fires involved oxyfuel and belt and kiln/clinker hot materials. During

the sixth period, the largest number of fires involved oxyfuel and

flammable liquids, oil, and refueling fuel.

Fire Injuries

Table 63 shows the number of fire injuries per number of

fires causing injuries and total fires by year, ignition source,

Figure 19.—Number of fires and fire injuries for stone mills by state, 1990–2001.
41

Figure 20.—Number of fires, fire injuries, risk rates, and employees' working hours for stone mills by time period, 1990–2001.

Figure 21.–Major variables for stone mill fires, 1990-2001. (FE = portable fire extinguisher)
42

equipment involved, and location for 1990–2001. Overall, there

were 82 injuries caused by 76 fires. The greatest number of fire

injuries occurred in 1990 (15 injuries caused by 15 fires). The

ignition sources that caused most of the fire injuries were flame

cutting/welding spark/slag/flame, hot material, and flammable

liquid/refueling fuel on hot surfaces. Other ignition sources

were heat source, hydraulic fluid/fuel sprayed onto equipment

hot surfaces, mechanical friction, and electrical short/arcing.

The equipment involved in fire injuries included oxyfuel torches,

kilns, beltlines, chutes, refueling pumps, and maintenance

equipment. Other equipment included heaters, mobile equipment, maintenance equipment, kiln, and electrical systems. The

locations where the fire injuries occurred were flame cutting/

welding areas, beltlines, kiln and chute areas, and maintenance

areas, followed by mobile equipment working areas and

transportation areas. Other fire locations were pump stations

and beltline areas.

Table 55.—Number of fires, fire injuries, and risk rates for stone mills by state,

employees' working hours, and lost workdays, 1990–2001

State1 No. fires1 No.

fire injuries1 LWD2 Ewhr,2

 106 hr Irr3

Alabama . . . . . . . . . 2 2 249 38.4 0.01

California . . . . . . . . 3 1 10 38.6 0.005

Colorado . . . . . . . . . 3 2 58 8.5 0.047

Connecticut . . . . . . 1 1 4 5.2 0.039

Florida . . . . . . . . . . . 2 2 56 28.6 0.014

Georgia . . . . . . . . . . 1 1 10 31.2 0.006

Idaho . . . . . . . . . . . . 1 1 13 2.2 0.091

Illinois . . . . . . . . . . . 5 2 63 36.5 0.011

Indiana . . . . . . . . . . 1 1 — 27.6 0.007

Kansas . . . . . . . . . . 3 3 104 13.5 0.044

Kentucky . . . . . . . . . 3 7 158 24 0.058

Louisiana . . . . . . . . 2 1 102 1.1 0.182

Maryland . . . . . . . . . 3 — — 17 —

Michigan . . . . . . . . . 9 5 95 20.2 0.05

Missouri . . . . . . . . . 16 9 155 56 0.032

Montana . . . . . . . . . 1 1 16 3.7 0.054

Nebraska . . . . . . . . 1 1 39 5.9 0.034

Nevada . . . . . . . . . . 1 1 20 6 0.033

New Jersey . . . . . . . 1 1 27 8 0.025

New York . . . . . . . . 7 5 4 25.5 0.039

North Carolina . . . . 1 1 48 23.7 0.008

Ohio . . . . . . . . . . . . 9 3 58 35 0.017

Oklahoma . . . . . . . . 1 — — 15.6 —

Pennsylvania . . . . . 15 14 218 67 0.042

South Carolina . . . . 3 1 14 16.2 0.012

South Dakota . . . . . 1 1 16 5.7 0.035

Tennessee . . . . . . . 1 — 66 21.4 —

Texas . . . . . . . . . . . 7 4 24 54 0.015

Utah . . . . . . . . . . . . 1 — — 5.2 0.03

Virginia . . . . . . . . . . 7 5 153 11 0.091

West Virginia . . . . . 1 2 90 13.1 0.031

Wisconsin . . . . . . . . 4 3 41 11 0.055

Wyoming . . . . . . . . . 1 1 — 10 0.02

All other states . . . . — — — 186 —

 Total . . . . . . . . . . 118 82 1,911 873 3

0.019 1

Derived from MSHA "Fire Accident Abstract" internal publications. 2

Derived from MSHA "Injury Experience in Mining" publications. 3

Calculated according to MSHA formula reported in the "Methodologies" section.

Table 56.—Number of fires, fire injuries, and risk rates for stone mills by time period,

employees' working hours, and lost workdays, 1990–2001

Time period

90-91 92-93 94-95 96-97 98-99 00-01 1990-2001

Number of fires1 . . . . . . . . . 27 24 21 22 9 15 118

Number of fire injuries1 . . . . 22 17 13 14 2 14 82

LWD2 . . . . . . . . . . . . . . . . . 377 298 310 388 280 258 1,911

Ewhr,2

 106 hr . . . . . . . . . . . . 125 139 143 150 156 160 873

Irr3 . . . . . . . . . . . . . . . . . . . . 0.035 0.024 0.018 0.019 0.003 0.018 3

0.019 1

Derived from MSHA "Fire Accident Abstract" internal publications. 2

Derived from MSHA "Injury Experience in Mining" publications. 3

Calculated according to MSHA formula reported in the "Methodologies" section.
43

Table 57.—Number of fires for stone mills by ignition source and time period, 1990–2001

Ignition source

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Flame cutting/welding spark/slag/flame1 . . . . . . . . . . . . . . . . 14 13 6 14 2 4 53

Hot material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 7 3 3 5 24

Electrical short/arcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 2 — 3 — 11

Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3211—2 9

Refueling fuel/flammable liquid/gas on hot surfaces/ collision 2211 1 2 9

Hydraulic fluid/fuel on equipment hot surfaces ............ 3 — 1 1 — 1 6

Conveyor belt friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 1 1 — — 3

Overheated oil .................................... — — 1 1 — — 2

Unknown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — 1 — — — 1

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 24 21 22 9 15 118

1

This source caused explosions of pressurized cans and oxyfuel.

Table 58.—Number of fires for stone mills by method of detection and time period, 1990–2001

Method of detection 

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Visual:

 Sparks . . . . . . . . . . . . . . . 9 9 4 10 1 3 36

 Smoke . . . . . . . . . . . . . . . 5 2 4 6 2 4 23

 Late smoke detection . . . . 3 8 7 5 6 2 31

 Flames/flash fires . . . . . . . 7 2 2 1 — 5 17

 Smoldering fire/glow . . . . . — — 1 — — 1 1

Heard an explosion . . . . . . . . 2 1 ———— 3

Undetected .............. 1 2 3 — — — 6

 Total . . . . . . . . . . . . . . . . 27 24 21 22 9 15 118

Table 59.—Number of fires for stone mills by suppression method and time period, 1990–2001

Suppression method

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Manual with or without FE1 . . . . 12 12 6 12 2 3 47

Water . . . . . . . . . . . . . . . . . . . . 3 5 6 5 3 4 26

FE . . . . . . . . . . . . . . . . . . . . . . . 6 3 3 2 2 3 19

FE-foam-DCP-water2 ........ 4 3 3 3 1 4 18

FSS-foam-water . . . . . . . . . . . . 1 — — — — — 1

Destroyed/HD3 ............. 1 1 3 — 1 1 7

 Total . . . . . . . . . . . . . . . . . . . 27 24 21 22 9 15 118

DCP Dry chemical powder.

FE Portable fire extinguisher.

FSS Machine fire suppression system.

HD Heavily damaged.

1

Method used by welders to extinguish clothing and oxyfuel/grease fires. 2

In two instances, fire emergency foam suppression systems were used. 3

Usually due to failure of firefighting methods, late fire detection, undetected fires, or fire size. 

Table 60.—Number of fires for stone mills by equipment involved and time period, 1990–2001

Equipment 

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Oxyfuel torch1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 13 6 14 2 4 53

Kiln/preheat/cooling systems . . . . . . . . . . . . . . . . . . . . — 4 5 2 2 4 17

Mobile equipment2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 3 3 — 2 14

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 2 — 3 — 10

Heater/barrel/refueling pump . . . . . . . . . . . . . . . . . . . . 3 1 1 1 — 1 7

Beltline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — 1 1 2 1 1 6

Chute/crusher/waste fuel tank/bin feeder/dust collector 1 1 2 — 1 1 6

Facility3 ..................................... — — 1 — — — 1

Maintenance equipment ........................ 1 1 — — — — 2

Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — — — — — 2 2

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 24 21 22 9 15 118

1

At times, electrical arc welding equipment was used.

2

Includes loaders, trucks, drills, and locomotives.

3

Considered equipment in this report.
44

Table 61.—Number of fires for stone mills by location and time period, 1990–2001

Location

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Flame cutting/welding areas1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 13 6 14 2 4 53

Kiln/chute/hopper/silo areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . — 3 6 1 1 5 16

Mobile equipment working areas2 . . . . . . . . . . . . . . . . . . . . . . . . 4 — 3 3 1 1 12

Beltline areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — 2 1 2 3 2 10

Maintenance areas/pump station ........................ 3 3 1 — — 1 8

Preheat/cooling areas/bagging station/pit/bin/waste fuel areas . — 2 2 1 1 1 7

Electrical control room/shop/substation ................... 4 — 1 — 1 — 6

Dust collector/chute/crusher areas . . . . . . . . . . . . . . . . . . . . . . . 1 1 — 1 — 1 4

Facility areas ....................................... 1 — 1 — — — 2

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 24 21 22 9 15 118

1

Includes hopper, crusher, elevator shaft, chute and kiln areas, and maintenance areas. 2

Includes pumping station, shop and crusher areas, drilling, loading, haulage, transportation, and fuel preparation areas.

Table 62.—Number of fires for stone mills by burning material and time period, 1990–2001

Burning material

Time period

90-91

No. fires

92-93

No. fires

94-95

No. fires

96-97

No. fires

98-99

No. fires

00-01

No. fires

1990-2001

No. fires

Oxyfuel/clothing/grease/other1 . . . . . . . . . . . . . 14 13 6 14 2 4 53

Belt/kiln/clinker hot materials . . . . . . . . . . . . . . — 4 6 3 3 3 19

Flammable liquid/oil/refueling fuel . . . . . . . . . . 3 3 1 1 — 4 12

Rubber tires/refuse/waste fuel ............. 2 1 3 3 1 1 11

Electrical wires/cables/transformer/battery . . . . 4 2 1 — 3 1 11

Hydraulic fluid/fuel . . . . . . . . . . . . . . . . . . . . . . 3 — 1 1 — 1 6

Chute/dust collector liners/hopper .......... — 1 2 — — 1 4

Facility/content ......................... 1 — 1 — — — 2

 Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 24 21 22 9 15 118

1

Includes rubber hoses, pipelines, dust collector and chute liners, and kiln and shaft materials.

SUMMARY OF MAJOR FIRE AND FIRE INJURY FINDINGS

FOR ALL METAL/NONMETAL MINING CATEGORIES

The major fire and fire injury findings for all metal/nonmetal

mining categories for 1990–2001 are shown in tables 64–65.

Table 66, partly illustrated in figure 22, shows the number of

fires, fire injuries, fire fatalities, risk rates, employees' working

hours, and lost workdays for all metal/nonmetal mining categories by time period.

For all metal/nonmetal operations (including stone and sand

and gravel), a total of 518 fires occurred during 1990–2001; 296

of those fires caused 308 injuries and 4 fatalities (Ewhr = 4,012 ×

106

 hr, Irr = 0.015, LWD = 36,204). Thirty fires and 26 injuries

involved contractors. The greatest number of fires and fire injuries

occurred at surface operations; the highest risk rate values were

also calculated for surface operations. The number of fires

increased during the first four 2-year time periods (1990–1991,

1992–1993, 1994–1995, and 1996–1997), then decreased during

the last two periods (1998–1999 and 2000–2001). The number of

injuries showed a decrease throughout the periods, accompanied

by an increase in employees' working hours.

Twenty-five firefighting interventions by mine rescue teams

in underground mines and at least 30 interventions at surface

operations were required to combat these fires. However,

45 fires destroyed or heavily damaged facilities and equipment

(including 19 pieces of mobile equipment) because of failure of

firefighting methods, late fire detection, undetected fires, or fire

size. Ninety-seven fires were detected late, and 30 fires were

undetected.

The ignition sources that caused the greatest number of fires

were flame cutting/welding spark/slag/flame (169 fires or 33%

with 137 injuries), hydraulic fluid/fuel sprayed onto equipment

hot surfaces (89 fires or 17% with 46 injuries and 3 fatalities),

heat source/explosion and flammable liquids/ gas/refueling fuel

on hot surfaces (98 fires or 19% with 73 injuries), electrical

short/arcing (51 fires or 10% with 16 injuries), and spontaneous

combustion/hot material (46 fires or 9% with 17 injuries).

The flame cutting/welding spark/slag/flame source caused

fires usually involving welders' clothing or oxyfuel/grease and

other materials (including chute and dust collector liners,

flammable liquids, belt material, crusher, hopper and shaker

deck materials, washer plants, equipment mechanical components, stampler breaker, hydraulic fluid, rubber tires and hoses,

gear boxes, bin feeder, dump rope cables, screen liner and screen

panel, kiln and shaft material, pipelines, liquor pumps, wood

pallets, electrical junction boxes, handrails, grease, refuse, shop

and wood). The spontaneous combustion/hot material and

electrical fires were usually detected late due to lack of

combustion gas/smoke detection systems. At least 55 of the

89 mobile equipment hydraulic fluid/fuel fires became large fires

(requiring 12 mine rescue team interventions in underground
45

mines and at least 6 interventions at surface operations) because

of the continuous flow of fluid/fuel from the pumps due to

engine shutoff failure, lack of an emergency hydraulic line

drainage system, difficulty in activating available emergency

systems at the ground level, or lack of effective and rapid local

firefighting response capabilities. Ten pieces of mobile equipment involved in fires had machine fire suppression systems.

Dual activations (two activations) of machine fire suppression

and engine shutoff systems succeeded in temporarily abating the

fires, which reignited, fueled by the flow of pressurized fluids

entrapped in the lines. In at least 13 instances the cab was

suddenly engulfed in flames, forcing the operators to make an

unsafe exit, probably due to the ignition of flammable vapors

and mists that penetrated the cab. Of note is that the hydraulic

fluid fires subsequently involved the fuel system.

The major findings for each metal/nonmetal mining category

are discussed below.

1. In underground metal/nonmetal and stone mines, 65 fires

occurred; 6 of the fires caused 9 injuries (Ewhr = 260 × 106

 hr,

Irr = 0.007, LWD = 83). The leading ignition sources were

hydraulic fluid/fuel sprayed onto equipment hot surfaces

(16 fires or 25%), flame cutting/welding spark/slag/flame (13

fires or 20%), and electrical short/arcing (12 fires or 19%). The

flame cutting/welding spark/slag/flame source caused fires

involving oxyfuel/clothing/grease and other materials (including

rubber tires and hoses, hydraulic fluid, shop, refuse, wood, chute

liner, and shaft material). The electrical fires were usually

detected long after the fires had started due to lack of

combustion gas/smoke detection systems. Thirteen of the 16

mobile equipment hydraulic fluid/fuel fires became large fires

(requiring 12 mine rescue team interventions) because of the

continuous flow of fluids from the pumps due to engine shutoff

failure, lack of an emergency hydraulic line drainage system,

difficulty in activating available emergency systems at ground

level, or lack of effective and rapid local firefighting response

capabilities. In two instances during these fires, the cab was

suddenly engulfed in flames, probably due to the ignition of

flammable vapors and mists that penetrated the cab. Four pieces

of equipment involved in fires had machine fire suppression

systems. Dual activations (two activations) of machine fire suppression and engine shutoff systems succeeded in temporarily

abating the fires; however, the flames reignited, fueled by the

pressurized fluids entrapped in the lines.

Table 63.—Number of fire injuries per number of fires causing injuries and total fires for stone mills by year, ignition source,

equipment involved, and location, 1990–2001

Year

No.

total

fires

No. fires

causing

injuries

No.

fire

injuries

Ignition source Equipment Location

1990 . . . . 19 15 11 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.1

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance area.

1 Flammable liquid on hot surfaces . . . . . . . . . Refueling pump . . . . . . Pump station.

2 Hydraulic fluid/fuel on equipment hot surfaces Truck . . . . . . . . . . . . . . . Haulage area.

1991 . . . . 8 6 2 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.1

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance area.

2 Flammable liquid on hot surfaces . . . . . . . . . Maintenance equipment Maintenance area.

1 Hydraulic fluid/fuel on equipment hot surfaces Loader .............. Loading area.

1 Electrical short/arcing . . . . . . . . . . . . . . . . . . Locomotive . . . . . . . . . . Transportation area.

1992 . . . . 10 7 5 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.1

1 Hot material . . . . . . . . . . . . . . . . . . . . . . . . . . Chute . . . . . . . . . . . . . . Chute area.

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Hopper area.

1993 . . . . 14 10 6 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.1

2 Flammable liquid on hot surfaces . . . . . . . . . Maintenance equipment Maintenance area.

1 Hot material . . . . . . . . . . . . . . . . . . . . . . . . . . Preheat system . . . . . . Preheat tower.

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance area.

1994 . . . . 9 8 6 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.1

1 Hot material . . . . . . . . . . . . . . . . . . . . . . . . . . Beltline . . . . . . . . . . . . . Beltline areas.

1 Hydraulic fluid/fuel on equipment hot surfaces Truck . . . . . . . . . . . . . . . Haulage area.

1995 . . . . 12 5 1 Electrical short/arcing . . . . . . . . . . . . . . . . . . Electrical system . . . . . Electrical control room.

2 Hot material . . . . . . . . . . . . . . . . . . . . . . . . . . Hopper/kiln-chute ..... Hopper/kiln chute/loading areas.

1 Refueling fuel on hot surfaces . . . . . . . . . . . . Kiln . . . . . . . . . . . . . . . . Kiln area.

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance area.

1996 . . . . 14 10 9 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.1

1 Hydraulic fluid/fuel on equipment hot surfaces Truck . . . . . . . . . . . . . . . Haulage area.

1997 . . . . 8 4 4 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.1

1998 .... 6 — — — — —

1999 . . . . 3 2 2 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.1

2000 . . . . 6 4 3 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.1

1 Mechanical friction . . . . . . . . . . . . . . . . . . . . . Kiln . . . . . . . . . . . . . . . . Kiln area.

2001 . . . . 9 5 2 Refueling fuel on hot surfaces . . . . . . . . . . . . Kiln . . . . . . . . . . . . . . . . Kiln area.

1 Flame cutting/welding spark/slag/flame . . . . . Oxyfuel torch . . . . . . . . Flame cutting/welding areas.1

6 Hot material . . . . . . . . . . . . . . . . . . . . . . . . . . Beltline . . . . . . . . . . . . . Kiln/beltline areas.

1 Heat source . . . . . . . . . . . . . . . . . . . . . . . . . . Heater . . . . . . . . . . . . . . Maintenance area.

Total . . . . 118 76 82

1

Includes hopper, shaft, piping, chute and kiln areas, and mobile equipment maintenance areas.
46

Table 64.—Major fire findings for all metal/nonmetal mining categories, 1990–2001

Variables

Underground

metal/nonmetal and

stone mines

Surface of underground

metal/nonmetal and

stone mines

Surface metal/nonmetal

mines

Surface

sand and gravel mines Surface stone mines Metal/non

GT: No. fires:

No. fires causing injuries:LWD:

519296

36,204

No. fires:No. fires causing injuries:LWD:

65

6

83

No. fires:No. fires causing injuries:LWD:

12

5

75

No. fires:No. fires causing injuries:LWD:

7945

13,134

No. fires:No. fires causing injuries:LWD:

7159

6,921

No. fires:No. fires causing injuries:LWD:

9768

7,399

No. fires:No. fires causing injuries:LWD:

Ignition source . . . . . . . . Hydraulic fluid/fuel on

 equipment hot surfacesFlame cutting/welding spark/slag/flameElectrical short/arcing

Flame cutting/welding spark/slag/flameElectrical short/arcingHeat source

Hydraulic fluid/fuel on equipment hot surfacesFlame cutting/welding spark/slag/flameElectrical short/arcing

Flame cutting/welding spark/slag/flameHeat sourceHydraulic fluid/fuel on equipment hot surfaces

Flame cutting/welding spark/slag/flameHeat source- flammable liquidHydraulic fluid/fuel on equipment hot surfaces

Flame cutt spark/slaSpontaneo tion/hot mElectrical s

Method of detection . . . . Visual-late smoke

 detectionVisual-flames/flash firesVisual-smoke

Visual-sparksVisual-smoke/fumesVisual-late smoke detection 

Visual-flames/flash firesVisual-smokeVisual-sparks

Visual-flames/flash firesVisual-sparksVisual-smoke 

Visual-flames/flash firesVisual-sparksVisual-smoke

Visual-late  detectionVisual-spaVisual-flam fires

Suppression method . . . FE-DCP/foam/water

WaterFE

WaterManual with or without FEFE

FE-foam/DCP/waterFEManual with or without FE

Manual/FEFE-foam/DCP/waterWater

Manual with or without FEWaterFE-DCP/foam/water

WaterFEManual wit without F

Equipment . . . . . . . . . . . Mobile equipment1

Oxyfuel torchBeltline/drive/pulley

Oxyfuel torchFacilitiesHeater

Mobile equipment1

Oxyfuel torchHeater

Oxyfuel torchMobile equipment1

Heater/burner

Mobile equipment1

Heater/maintenance equipment/burnerOxyfuel torch

Oxyfuel torDust collecPump/oil va

Location . . . . . . . . . . . . Mobile equipment

 working areas2

Flame cutting/welding areas3Mine face/other areas

Flame cutting/welding areas3

Facility/garage/otherFan housing

Mobile equipment working areas2

Flame cutting/welding areas3Maintenance areas/ other

Flame cutting/welding areas3

Maintenance areasMobile equipment working areas2

Maintenance areas/ otherFlame cutting/welding areas3Mobile equipment working areas2

Flame cutt areas3Dust collec areasMaintenanc

Burning material . . . . . . Hydraulic fluid

Oxyfuel/clothing/ grease/otherElectrical cord/wire/ cable/battery

Oxyfuel/clothing/ grease/otherFacility/contentWood

Hydraulic fluid/fuel/oilOxyfuel/clothing/ grease/otherFlammable liquid/ material

Oxyfuel/clothing/ grease/otherHydraulic fluid/fuelFlammable liquid/gas

Oxyfuel/clothing/ grease/otherHazardous material/ chemical/otherHydraulic fluid/fuel

Oxyfuel/clo grease/oBelt materiFlammable  refueling 

 DCP Dry chemical powder. FE Portable fire extinguisher. GT Grand total.

1Includes golf and ore carts, locomotives, loaders, scoops, shuttle cars, power scalers, trolleys, trucks, drills, dozers, shovels, scrapers, dredges, buckets, tankers, a2Includes haulage, loading, mucking, decline slopes, panel and tunnel areas, transportation, drilling, mining, excavating areas, pumping stations, shop and crusher a

areas.

3Includes shops, mainways, boreholes, shafts, stations, slusher bucket, chute, dust collector, hopper, crusher and kiln areas, maintenance areas, junction boxes, fac

walkways, pipeline, dump rope, crowd platform, storage bin, baghouse, pelletizer building, liquor pump, beltline, generator housing, deck and bin feeder, stampler brea

areas, and washer plants.  NOTE.—Variables are listed in descending order of occurrence.
Table 65.—Major fire injury findings for all metal/nonmetal mining categories, 1990–2001

Variables

Underground

metal/nonmetal and

stone mines

Surface of underground

metal/nonmetal and

stone mines

Surface metal/nonmetal

mines

Surface

sand and gravel mines Surface stone mines Metal/non

GT: No. fire

 injuries:No. fire fatalities:Ewhr, 106 hr:

Irr:

308

4

4,0120.015

No. fire injuries: Ewhr, 106 hr:

Irr:

9

260

0.007

No. fire injuries:Ewhr, 106 hr:

Irr:

5

58

0.017

No. fire injuries:No. fire fatalities:Ewhr, 106 hr:

Irr:

44

2

546

0.016

No. fire injuries:Ewhr, 106 hr:

Irr:

60

741

0.016

No. fire injuries:No. fire fatalities:Ewhr, 106 hr:

Irr:

67

1

689

0.02

No. fire injuries:No. fire fatalities:Ewhr, 106 h

Irr:

Ignition source . . . . . . . . Hydraulic fluid/fuel on

 equipment hot surfacesFlame cutting/welding spark/slag/flameOverheated oil on hot surfaces

Flame cutting/welding/ spark/slag/flame

Hydraulic fluid/fuel on equipment hot surfacesFlame cutting/welding spark/slag/flameFlammable liquid/ refueling fuel/oil on hot surfaces

Flame cutting/welding spark/slag/flameHeat sourceHydraulic fluid/fuel on equipment hot surfaces

Flame cutting/welding spark/slag/flameHeat sourceHydraulic fluid/fuel on equipment hot surfaces

Flame cutt spark/slaFlammable  refueling  surfaces/Hot materia

Method of detection . . . . Visual-flames/flash

 firesVisual-sparksVisual-smoke

Visual-sparks Visual-flames/flash

 firesVisual-sparksVisual-smoke

Visual-sparksVisual-smokeVisual-flames/flash fires

Visual-sparksVisual-smokeVisual flames/flash fires

Visual-spaVisual-flamVisual-late  detection

Suppression method . . . FE-DCP/foam/water

Manual with or without FEFE

Manual with or without FE

FE-foam/DCP/waterManual with or without FEFE

Manual with or without FEWaterFE-foam/DCP/water

Manual with or without FEFEFE-foam/DCP/water

Manual wit without FFEWater

Equipment . . . . . . . . . . . Mobile equipment

Oxyfuel torchAir compressors/ mobile equipment

Oxyfuel torch Mobile equipment

Oxyfuel torchMaintenance equipment/mobile equipment

Oxyfuel torchHeaterMobile equipment

Oxyfuel torchHeaterMobile equipment

Oxyfuel torMaintenanc ment/liquProduct co system

Location . . . . . . . . . . . . Mobile equipment

 working areasFlame cutting/welding areasMine face/panel section

Flame cutting/welding area

Mobile equipment working areasFlame cutting/welding areasMaintenance areas

Flame cutting/welding areasMaintenance/refuse/ beltline areasMobile equipment working areas

Flame cutting/welding areasBeltline/maintenance/ working areasMobile equipment working areas

Flame cutt areasMaintenanc pump/refiProduct co

Burning material . . . . . . Hydraulic fluid/fuel

Oxyfuel/clothing/ grease/otherOil

Oxyfuel/clothing/ grease/other

Hydraulic fluid/fuelOxyfuel/clothing/ grease/otherFlammable liquid/ refueling fuel/oil

Oxyfuel/clothing/ grease/otherRefuseHydraulic fluid/fuel

Oxyfuel/clothing/ grease/otherRefuse/hazardous materialHydraulic fluid/fuel

Oxyfuel/clo greaseFlammable  refueling Material/be

DCP Dry chemical powder.FE Portable fire extinguisher.GT Grand total.NOTE.—Variables are listed in descending order of occurrence.
48

Table 66.—Number of fires, fire injuries, fire fatalities, and risk rates for all metal/nonmetal mining categories

by time period, employees' working hours, and lost workdays, 1990–2001

Time period

90-91 92-93 94-95 96-97 98-99 00-01 1990-2001

Number of fires1 . . . . . . . . . . . 92 115 100 93 54 64 518

Number of fire injuries1 . . . . . . 62 69 61 53 28 35 308

Number of fire fatalities1 ..... — 1 2 — — 1 4

LWD2 . . . . . . . . . . . . . . . . . . . 941 7,014 13,510 6,864 1,026 6,849 36,204

Ewhr,2

 106 hr . . . . . . . . . . . . . . 652 650 664 681 677 688 4,012

Irr3 . . . . . . . . . . . . . . . . . . . . . . 0.019 0.02 0.018 0.016 0.008 0.01 3

0.015

1

Derived from MSHA "Fire Accident Abstract" internal publications. 2

Derived from MSHA "Injury Experience in Mining" publications. 3

Calculated according to MSHA formula reported in the "Methodologies" section.

Upon mine/section evacuation (required 30 times), mine

rescue teams (required 25 times), often hindered by dense smoke

in reaching the fire location, fought the fires (including

12 mobile equipment fires) with dry chemical powder, rock dust,

and water; in one instance, foam was also used. However, five

fires destroyed or heavily damaged equipment (including four

pieces of mobile equipment) because of failure of firefighting

methods, late fire detection, undetected fires, or fire size.

Eighteen fires were detected late, and two were undetected.

The ignition sources that caused the underground fire

injuries were hydraulic fluid/fuel sprayed onto equipment hot

surfaces, flame cutting/welding spark/slag/flame, and overheated

oil. The equipment involved in fire injuries included mobile

equipment, oxyfuel torches, and air compressors. The locations

where fire injuries occurred were mobile equipment working

areas, flame cutting/welding areas, and mine face and panel

section.

2. At surface of underground metal/nonmetal and stone

mines, 12 fires occurred; 5 of the fires caused 5 injuries (Ewhr

= 58 × 106

 hr, Irr = 0.017, LWD = 75). The leading ignition

source was flame cutting/welding spark/slag/flame (7 fires or

58%), followed by electrical short/arcing and heat source. The

flame cutting/welding spark/slag/flame source caused fires

involving oxyfuel/clothing/grease and other materials (including

electrical junction boxes, handrails, grease, flammable liquids,

rubber tires, and equipment mechanical components). In all,

three fires destroyed or heavily damaged equipment. Two fires

were detected late, and three fires were undetected. The ignition

source that caused the fire injuries was flame cutting/welding

spark/slag/flame.

3. At surface metal/nonmetal mines, 79 fires occurred; 45 of

the fires caused 44 injuries and 2 fatalities (Ewhr = 546 × 106

 hr,

Irr = 0.016, LWD = 13,134). The leading ignition source was

hydraulic fluid/fuel sprayed onto equipment hot surfaces (35

fires or 44%), followed by flame cutting/welding spark/

slag/flame (13 fires or 17%) and electrical short/arcing (8 fires

or 10%). The flame cutting/welding spark/slag/flame source

caused fires involving oxyfuel/clothing/grease and other

Figure 22.—Number of fires, fire injuries, risk rates, and employees' working hours for all metal/nonmetal mining categories

by time period, 1990–2001.
49

materials (involving rubber hoses, grease, equipment mechanical

components, dump rope cables, screen liner, and shaft materials). Twenty-two of the 35 mobile equipment hydraulic

fluid/ fuel fires became large fires because of the continuous

flow of fluid/fuel from the pumps due to engine shutoff failure,

lack of an emergency line drainage system, difficulty in

activating available emergency systems at ground level, or lack

of effective and rapid local firefighting response capabilities. In

at least five instances the cab was suddenly engulfed in flames,

probably due to the ignition of flammable vapors and mists that

penetrated the cabs. Five pieces of mobile equipment involved

in fires had machine fire suppression systems. Dual activation

(one activation) of machine fire suppression and engine shutoff

systems succeeded in temporarily abating the fires; however, the

flames reignited, fueled by the flow of fluids entrapped in the

lines.

In at least five instances, including one mobile equipment

fire, fire brigades and fire departments fought the fires with

foam, dry chemical powder, and water. However, nine fires

destroyed or heavily damaged equipment (including seven

pieces of mobile equipment) because of failure of firefighting

methods, late fire detection, undetected fires, or fire size. Eight

fires were detected late, and three fires were undetected.

The ignition sources that caused most of the fire injuries were

hydraulic fluid/fuel sprayed onto equipment hot surfaces, flame

cutting/welding spark/slag/flame, and flammable liquid/refueling

fuel/oil on hot surfaces. The equipment most often involved in

fire injuries included mobile equipment, oxyfuel torches, and

maintenance equipment. The locations where most of the fire injuries occurred were mobile equipment working areas, flame

cutting/ welding areas, and maintenance areas.

4. At surface sand and gravel mines, 70 fires occurred; 59 of

the fires caused 60 injuries (Ewhr = 741 × 106

 hr, Irr = 0.016,

LWD = 6,921). The leading ignition sources were flame cutting/

welding spark/slag/flame (29 fires or 41%), heat source/ explosion

(15 fires or 21%), and hydraulic fluid/fuel sprayed onto equipment

hot surfaces (14 fires or 20%). The flame cutting/welding spark/

slag/flame source caused fires involving oxyfuel/clothing/ grease

and other materials (including chute liners, washer plant, crusher,

hopper and shaker deck, flammable liquids, equipment mechanical

components, and belt materials). Five of the 14 mobile equipment

hydraulic fluid/fuel fires became large fires because of the continuous flow of fluid/fuel from the pumps due to engine shutoff

failure, lack of an emergency line drainage system, difficulty in

activating available emergency systems at ground level, or lack of

effective and rapid local fire response capabilities. In two instances the cab was suddenly engulfed in flames, probably due to

the ignition of flammable vapors and mists that penetrated the cab.

None of the equipment involved in fires had machine fire

suppression systems.

On at least three occasions, including one mobile equipment

fire, fire brigades and fire departments fought the fires with

foam, dry chemical powder, and water. However, four fires

destroyed or heavily damaged equipment (including two pieces

of mobile equipment) because of failure of firefighting methods,

late fire detection, undetected fires, or fire size. Eight fires were

detected late, and four fires were undetected.

The ignition sources that caused most of the fire injuries

were flame cutting/welding spark/slag/flame, heat source, and

hydraulic fluid/fuel sprayed onto equipment hot surfaces. The

equipment most often involved in fire injuries included oxyfuel

torches, heaters, and mobile equipment. The locations where

most of the fire injuries occurred were flame cutting/welding

areas, maintenance areas, and mobile equipment working areas.

5. At surface stone mines, 97 fires occurred; 68 of the fires

caused 67 injuries and 1 fatality (Ewhr = 689 × 106

 hr, Irr = 0.02,

LWD = 7,399). The leading ignition sources were flame cutting/

welding spark/slag/flame (25 fires or 26%), heat

source/explosion-flammable liquid/gas (24 fire or 25%), and hydraulic fluid/fuel sprayed onto equipment hot surfaces (16 fires

or 17%). The flame cutting/welding spark/slag/flame source

caused fires involving oxyfuel/clothing/grease and other

materials (including screen panel and chute liner, crusher and

hopper, stampler breaker, rubber hoses, gear boxes, bin feeder,

hydraulic fluid, and shaft material). None of the mobile

equipment involved in fires had machine fire suppression systems. Ten of the 16 mobile equipment hydraulic fluid/fuel fires

became large fires because of the continuous flow of fluid/fuel

from the pumps due to engine shutoff failure, lack of an emergency line drainage system, or lack of effective and rapid local

firefighting response capabilities. In two instances the cab was

suddenly engulfed in flames, probably due to the ignition of

flammable vapors and mists that penetrated the cab.

In at least six instances, including one mobile equipment fire,

fire brigades and fire departments fought the fires with foam, dry

chemical powder, and water. However, 12 fires destroyed or

heavily damaged equipment (including four pieces of mobile

equipment) because of failure of firefighting methods, late fire

detection, undetected fires, or fire size. Four fires were detected

late; eight were undetected fires.

The ignition sources that caused most of the fire injuries were

flame cutting/welding spark/slag/flame, heat source, and hydraulic fluid/fuel sprayed onto equipment hot surfaces. The

equipment most often involved in fire injuries included oxyfuel

torches, heaters, and mobile equipment. The locations where

most of the fire injuries occurred were flame cutting/welding

areas, maintenance areas, refuse and fire pot areas, and mobile

equipment working areas.

6. At metal/nonmetal mills, 77 fires occurred; 37 of the fires

caused 41 injuries and 1 fatality (Ewhr = 845 × 106

 hr, Irr = 0.01,

LWD = 6,681). The leading ignition sources were flame cutting/

welding spark/slag/flame (29 fires or 38%), hot material (12 fires

or 16%), and flammable liquid/refueling fuel/oil on hot surfaces

(9 fires or 12%). The flame cutting/welding spark/ slag/ flame

source caused fires involving oxyfuel/clothing/grease and other

materials (including liquor pumps, belt material, pipelines,

flammable liquids, dust collector and chute liners, wood pallets,

crusher, and screen panel). The hot material fires and electrical

fires were usually detected long after they had started due to lack

of combustion gas/smoke detection systems. One of the three

mobile equipment hydraulic fluid/fuel fires became a large pump

fire because of the continuous flow of fluid from the pump due
50

to engine shutoff failure. In this instance the cab was suddenly

engulfed in flames, probably due to the ignition of flammable

vapors and mists that penetrated the cab.

In at least five instances, including one mobile equipment

fire, fire brigades and fire department fought the fires with foam,

dry chemical powder, and water. However, six fires destroyed

or heavily damaged equipment (including one piece of mobile

equipment) because of failure of firefighting methods, late fire

detection, undetected fires, or fire size. Twenty-six fires were

detected late, and four were undetected.

The ignition sources that caused most of the fire injuries were

flame cutting/welding spark/slag/flame, flammable liquids/

refueling fuel on hot surfaces/explosion, and hot material. The

equipment involved in fire injuries included oxyfuel torches,

maintenance equipment, refueling and liquor pumps, and product

cooling system. The locations where the fire injuries occurred

were flame cutting/welding areas, maintenance areas, pump

housing and liquor pump areas, and product cooling area.

7. At stone mills, 118 fires occurred; 76 of the fires caused

82 injuries (Ewhr = 873 × 106

 hr, Irr = 0.019, LWD = 1,911).

The leading ignition sources were flame cutting/welding

spark/slag/flame (53 fires or 45%), hot material (24 fires or

20%), and electrical short/arcing (11 fires or 9%).

The flame cutting/welding spark/slag/flame source caused

fires involving oxyfuel/clothing/grease and other materials

(including rubber hoses, pipelines, dust collector and chute

liners, and shaft and kiln materials). Four of the five hydraulic

fluid/fuel fires became large fires because of the continuous flow

of fluids from the pumps due to engine shutoff failure, lack of an

emergency line drainage system, difficulty in activating emergency systems at ground level, or lack of effective and rapid

local firefighting response capabilities. In one instance the cab

was suddenly engulfed in flames, probably due to the ignition of

flammable vapors and mists that penetrated the cab. Of the six

pieces of mobile equipment involved in fires, one had a machine

fire suppression system, which, upon activation with the engine

shutoff system, succeeded in temporarily abating the fire.

In at least 11 instances, including 2 mobile equipment fires,

fire brigades and fire departments fought the fires with foam, dry

chemical powder, and water. In two instances, emergency foam

fire suppression systems were used. However, seven fires

destroyed or heavily damaged equipment (including one piece

of mobile equipment) because of failure of firefighting methods.

Thirty-one fires were detected late, and six fires were

undetected.

The ignition sources that caused most of the fire injuries

were flame cutting/welding spark/slag/flame, hot material, and

flammable liquid/gas/refueling fuel on hot surfaces. The

equipment most often involved in fires included oxyfuel

torches, kilns, beltlines, chute, preheat system, and maintenance

equipment. Most of the fire injuries occurred at flame cutting/

welding areas, kiln, beltline and chute areas, preheat areas, and

maintenance areas.

CONCLUSIONS

During 1990–2001, a total of 518 fires occurred in all metal/

nonmetal mining categories; 296 of those fires caused 308 injuries and 4 fatalities. Surface operations had the most fires and

the highest injury risk rate values. Forty-five fires destroyed or

heavily damaged facilities and equipment (including 19 pieces

of mobile equipment) because of failure of firefighting methods,

late fire detection, undetected fires, or fire size.

In the future, many of these fires and injuries might be

prevented or detected and extinguished at their earliest stage by

improving current fire safety procedures, adopting existing/

improved fire detection and suppression technologies, and/or developing new technologies. Several strategies for reducing and/or

preventing the number of fires and fire injuries follow.

1. Increase vigilance, improve safety procedures, and develop new technologies in order to prevent fires and injuries

caused by flame cutting and welding operations.

2. Improve equipment hydraulic/fuel/electrical systems inspection programs; adopt fire-resistant hydraulic fluids and

electrically powered motors for use in underground mines;

develop new technologies (equipment/cab rapid fire detection/

prevention/suppression systems, emergency line drainage systems, and fire barriers); adopt an optimal ground level location

for the activation of emergency systems; improve operator's fire

preparedness training programs; and develop effective and

rapid local firefighting response capabilities.

3. Adopt existing/improved systems for continuous and early

detection of combustion gases and smoke along beltlines.

4. Adopt existing/improved technologies for monitoring

equipment (beltlines) operational functions.

5. Increase vigilance and adopt improved safety procedures

for handling flammable liquids and refueling fuel in the vicinity

of heat sources.

ACKNOWLEDGMENT

The author thanks Kimberly A. Mitchell, Program Operations Assistant, NIOSH Pittsburgh Research Laboratory, for computerizing

the tables and figures in this report.
51

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