COAL MINE SAFETY ACHIEVEMENTS IN THE USA AND THE 

CONTRIBUTION OF NIOSH RESEARCH
 

Dr G.S.Esterhuizen 

Dr R.G. Gürtunca 

National Institute for Occupational Safety and Health 

ABSTRACT 

Over the past century coal miner safety and health has seen tremendous improvements, 

the fatality and injury rates continue to decrease while productivity continues to 

increase. Many of the hazards that plagued miners in the past, such as coal bumps, 

methane and coal dust explosions, ground fall accidents and health issues have been 

significantly reduced. The contribution of NIOSH research includes products for 

prevention and survival of mine fires, methane control measures, design procedure for 

underground coal mines, methods for excavation surface controls, methods and 

procedures for blasting, laser usage in underground mines and prevention of 

electrocution from overhead power lines that have reduced accidents and injuries in 

underground coal mines. Health research has produced products such as the personal 

dust monitor, noise abating technologies and ergonomic solutions for equipment 

operators. Research priorities at NIOSH are set by considering surveillance statistics, 

stakeholder inputs and loss control principles. Future research in coal mining is directed 

towards respiratory diseases, noise induced hearing loss, repetitive musculoskeletal 

injuries, traumatic injuries, falls of ground and mine disasters. The recent spate of 

accidents in coal mines resulted in the Miner Act of 2006 which includes a specific role 

for NIOSH in future mine safety research and development. The mine safety 

achievements in the USA reflect the commitment of industry, labour, government and 

research organizations to improving the safety of the mine worker. 

1.1 INTRODUCTION 

The United States’ coal mining industry employs about 75,000 persons, producing more 

than 1.1 billion short tons of coal per year, approximately 60% is from surface mines 

and 40% from underground mines. Coal mining operations are concentrated in the 

eastern United States (Figure 1), with more than 70% of all operations located in 

Kentucky, West Virginia and Pennsylvania. Approximately 780 underground coal 

mines employ about 37,000 persons (excluding office workers). Safety and health in the 

mines is regulated through the Federal Mine Safety and Health Act of 1977. The Mine 

Safety and Health Administration (MSHA) is charged with enforcing the act, while 

many states have their own state enforcement offices. 

Page 1 
Figure 1. Coal mining operations in the USA. 

Miner safety and health in the United States has seen continuous improvement despite 

significant increases in productivity, more adverse mining conditions, and changes in 

mining methods and equipment. However, mining remains one of the high risk 

industries in the U.S. with injury and fatality rates that exceed the national average. The 

societal expectation of ‘zero accidents’ maintains a continuous demand for further 

improvements (Kohler, 2005). The achievements in mineworker safety have been the 

result of concerted efforts of industry, government agencies, employee organizations, 

researchers and manufactures. 

The National Institute for Occupational Safety and Health (NIOSH) has an extensive 

research program in coal mining safety and health which is coordinated through the 

Office of Mining and Construction Safety and Health Research in Washington D.C. 

(NIOSH, 2006). The two main centers for mining research are the Pittsburgh Research 

Laboratory (PRL) in Pennsylvania and the Spokane Research Laboratory (SRL) in the 

state of Washington. Both the PRL and SLR were formerly U.S. Bureau of Mines 

(USBM) research centers that were transferred to NIOSH in 1996, after closure of the 

USBM. This paper presents the contribution of NIOSH research to coal mine worker 

safety achievements since 1995, and includes a brief summary of NIOSH health related 

research outputs. 

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2.1 SAFETY ACHIEVEMENTS OF THE U.S. COAL MINES 

A series of mine disasters in coal mines during the 1900’s focused the public’s attention 

on the loss of life in the mining industry. In 1907 alone, more than 3,000 lives were lost 

in coal mining disasters. Mine worker safety has seen significant improvements since 

1911 when regular statistics were collected on a nationwide basis. Statistics presented 

in this paper were all retrieved from internet sources (Bureau of Labor Statistics, 2005, 

2006a/b; MSHA, 2006, Department of Energy, 2006). Figure 2 shows the historical 

trends in the aggregate number of fatalities and fatality rates in U.S. coal and metal/nonmetal (MNM) mines (MSHA, 2006). 

Figure 2. Trend in mine fatalities and rates (5 year aggregates) in the U.S. mining industry by
 

commodity, 1911-2005. 

The chart also shows some of the major impacting 

factors on the statistics. The introduction of the Federal Coal Mine Health and Safety 

Act of 1969, which mandated federal safety enforcement and called for expanded health 

and safety research, had a major impact on the safety achievements. 

The historical reduction in mine accidents has made U.S. mines some of the safest in 

the world. However, the fatality rate in the mining industry exceeds the national 

industrial rate, shown in Figure 3. Coal mining is the most hazardous, at about seven 

times the national rate. The primary causes of the fatalities in underground mines are 

falls of ground, powered haulage, explosions machinery and electrical, accounting for 

about 90% of all fatalities. In surface mines the primary causes of fatalities are: 

Powered haulage, machinery, slip or fall of person and electrical; accounting for about 

80% of all fatalities. 

Non-fatal injury rates for 2004 (Figure 4), show that coal mining had the highest rate 

within the mining industry, at 5.3 injuries per 100 full time workers compared to 4.5 for 

the national industrial average. The leading causes of injuries in underground mines are: 

Handling materials, slips and falls of person, falls of ground, powered haulage and 

machinery. In surface mines 90% of the injuries are accounted for by: Handling 

materials, slip of fall of person, hand tools, machinery and powered haulage. 

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Figure 3. Fatal injury rate per 100,000 

workers. 

Figure 4. Nonfatal injury rate per 100 full 

time employees. 

While annual fatality and injury rates provide insight into the causes and trends in mine 

safety, low probability but high impact events need to be considered over longer periods 

of time. Figure 5 shows the trend in coal mine disasters between 1900 and 2006.

Page 4 

Figure 5. Coal mining disaster incidents and fatalities, 1900- May 2006. 

 In the 

U.S. mine disasters are defined as events resulting in five or more fatalities. Inspection 

of the disaster statistics for coal mines revealed that eight out of the 10 disasters since 

1981 were related to explosions. 
In 2006 a series of unfortunate accidents in coal mines has resulted in an above average 

rate of fatalities. The United States senate proposed a bill called the “Mine 

Improvement and New Emergency Response” (MINER) Act which became law in 

June, 2006. This bill addresses several aspects of mine safety, disaster response and 

enforcement. NIOSH was mandated in this bill to: 

- Establish a permanent Office of Mine Safety and Health to enhance the 

development of new mine safety technology 

- Establish a competitive grant program to encourage the development of mine 

safety equipment 

- Chair an interagency working group to share technology applicable to mine safety 

and accident/incident management 

- Expedite approval of new mine safety technology through review and testing 

contracts with third party laboratories. 

- Conduct research, including field tests in the NIOSH underground mine, on the 

use of refuge chambers in underground coal mines. 

- Establish a Technical Study Panel to provide independent scientific and 

engineering review and comment with respect to the utilization of belt air and the 

possible use and integration of fire retardant belt components in underground coal 

mining. 

The safety statistics demonstrate that coal mining, and particularly underground coal 

mining poses the greatest challenge in terms of worker safety. The research program at 

the NIOSH Pittsburgh Research Laboratory has been geared to address coal mining 

related issues, being located within the eastern U.S. coal fields and having a historical 

tie to coal research since its inception. The location of the facility near operating coal 

mines has allowed cooperation with industry and labor organizations, and provided 

ready access to experimental sites in coal mines. 

3.1 Research Strategy at NIOSH 

The ultimate goal of NIOSH mining research has been to improve health and safety 

through the elimination of harmful exposures and hazards. A structured approach has 

been followed to develop a research program that addresses the important health and 

safety issues, provides practical outputs that can be implemented in the workplace while 

maintaining the highest quality of scientific research. 

3.1.1 Development of Research Goals 

The scope of the research is determined through an interactive process in which 

surveillance statistics, stakeholder input and loss control principles are combined to 

develop Strategic Goals. Each of these components is discussed below: 

•	 Surveillance Data: Surveillance data is obtained primarily from the MSHA and 

Bureau of Labor Statistics databases, and then analyzed to establish research 

priorities or assess the effectiveness of past research. The surveillance data are 

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highlighted within the three categories of fatalities, injuries, and illnesses. The 

data are analyzed across many categories including the type of commodity, 

geographic location, and in-mine parameters, among others. 

•	 Stakeholder Input: Another major factor in setting research priorities is the input 

we receive from stakeholder groups, which have great knowledge and concern 

about the health and safety of miners. Some of the major customers/stakeholders 

who provide input are the following: Labor: United Mineworkers of America, 

United Steelworkers of America, and International Union of Operating Engineers; 

Industry: Bituminous Coal Operators Association, National Mining Association, 

National Stone, Sand, and Gravel Association, and Industrial Minerals 

Association of North America. In addition, several state organizations, 

universities, manufacturers, and government agencies participate in research 

partnerships and provide important input to the list of priorities. NIOSH also 

maintains a standing advisory committee: the Mine Safety and Health Research 

Advisory Committee. 

•	 Loss Control Considerations: Low probability high impact events are identified 

as part of a loss control approach to mine safety. Statistics on mine disasters show 

that mine explosions, mine fires, mine collapses, and mine inundations are events 

that have a low frequency of occurrence, but can have a high impact. While these 

events have become much less deadly over time, they still do occur, albeit 

sporadically as shown in Figure 5. An increasing risk of disaster from explosions, 

fires, and inundations is expected, largely due to the worsening conditions as 

mines progress into gassier deposits, go deeper, and work under generally more 

adverse geologic conditions. The greatest risks were identified in underground 

coal mining, although metal/nonmetal mining entails significant risks as well. In 

addition to preventing these disasters, a concurrent priority is to develop safer and 

more effective response methods and technologies. 

After consideration of the above components the mining health and safety research 

program was formulated through seven Strategic Goals as listed below: 

1. Reduction of Respiratory Diseases: Reduce respiratory diseases in miners by 

reducing health hazards in the workplace associated with coal worker 

pneumoconiosis, silicosis, and diesel emissions 

2. Reduce noise-induced hearing loss (NIHL) in the mining industry: 

Although NIHL is the most common occupational disease in the U.S.; the 

problem is especially acute among workers in the mining industry. 

3. Reduce repetitive/cumulative musculoskeletal injuries in mine workers: 

Musculoskeletal injuries, primarily to the low back, neck, knees, shoulders, and 

arms, are a continuing concern within the mining industry. 

4. Prevention of Traumatic Injuries: The primary focus of the research is to 

prevent traumatic injuries related to electricity, machinery, powered haulage, 

and slips and falls in mining. 

5.	 Disaster Prevention : Reduce the risk of mine disasters (fires, explosions, and 

inundations); and minimize the risk to, and enhance the effectiveness of, 

emergency responders. 

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6. Reduce ground failure fatalities and injuries: Mining has the highest fatal 

injury rate of any U.S. industry, at more than five times the national average, 

and ground failures have historically accounted for up to 50% of the fatalities in 

underground mines. 

7. Surveillance and training: Determine the impact of changing mining 

conditions, new and emerging technologies, training, and the changing patterns 

of work on worker health and safety. 

3.1.2 Development of the Research Program 

The research program is driven by the Strategic Goals. Each goal is assessed and the 

technology barriers and knowledge gaps are identified that prevent the achievement of 

the goal. Intermediate Goals are developed which have the objective of addressing the 

technology barriers and knowledge gaps. Research projects are then developed to 

address specific Intermediate Goals. 

Performance measures have been established which help to focus the research on a 

critical path, and also provide a method to assess progress. For example, the 

performance measure to reduce rock fall injuries by 50% in five years causes research 

managers and their staff to concentrate their efforts on projects that have the greatest 

likelihood to achieve the target. 

The research program is subject to various levels of external review to ensure its 

relevance and quality. Each project proposal is submitted for external review to ensure 

relevance, technical quality and the achievability of the outcomes within the budgetary 

and personnel constraints. All publications and other outputs are subject to an external 

peer review process, including all conference presentations. The entire research 

program is reviewed from time to time by the National Academies of Science, a process 

that is currently underway. 

Research products can only have an impact if they are implemented in the workplace. 

NIOSH has implemented a Research to Practice (r2p) initiative to increase workplace 

use of effective NIOSH and NIOSH-funded research findings. NIOSH is continuing to 

focus research on ways to develop effective products, translate research findings into 

practice, target dissemination efforts, and evaluate and demonstrate the effectiveness of 

these efforts in improving worker health and safety. 

The NIOSH research program has evolved over the years and is flexible to address new 

challenges as they arise, such as the recent spate of accidents in coal mines, which 

resulted in focused research into refuge chambers and belt air. The program strives to 

address important safety and health problems and provide outputs that will be accepted 

by the mining industry and implemented in the workplace. 

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4.1	 NIOSH Research Achievements in Coal Mine Health and Safety Since 

1995 

The contribution of NIOSH to the safety and health in the U.S. coal mining industry are 

best illustrated through the research achievements since 1995. Successful research 

outputs are products or methods that have 1) been implemented and accepted in the 

mining industry, and 2) have had an impact on the safety of mine workers. The NIOSH 

research achievements are grouped below in terms of the Strategic Research Goals. 

4.1.1 Preventing Respiratory Diseases 

NIOSH research into respiratory diseases in miners addresses health hazards in the 

workplace associated with coal worker pneumoconiosis (CWP), silicosis, and diesel 

emissions. The last 35 years have seen major gains in the national effort to reduce 

CWP. The percentage of dust samples exceeding the 2 mg/m3 federal regulatory limit 

for continuous miner workers has dropped from 49% to 9%. For longwall workers, the 

percentage has dropped from 44% to 12%. Likewise, the prevalence of CWP category 

1/0+ or higher has dropped from 28% to 8%. 

Our research has resulted in dozens of new and practical ways to control dust that are 

now used in the coal mining industry throughout the United States. For example: 

•	 Research for longwalls has identified optimum spray types and locations in 

cutting drums, developed directional spray systems for the longwall shearer, 

identified optimum operating pressures for different water spray types, 

demonstrated methods to control dust from crusher/stageloader units, and 

improved operating practices such as worker positioning and cutting practices. 

•	 Continuous miner research showed that blocking sprays, if properly used, can 

reduce dust levels at the operator locations. Blocking sprays create a water 

barrier near the cutting face, which prevents dust from rolling back to the 

operator locations at the back of the machine and allows the dust to be captured 

by the scrubber inlets. A major continuous miner manufacturer now offers 

blocking sprays on its machines, and new continuous mining machines are 

underground with these sprays installed. 

•	 NIOSH researchers also found that thinner filters were being used in floodedbed scrubbers on continuous miners. Research showed that these thinner filters 

allowed 30% more dust back into the mine air. NIOSH recommended the use of 

thicker filters in a NIOSH Hazard ID flyer. MSHA requested 1,000 copies of 

this Hazard ID to distribute to mine inspectors as part of its initiative to lower 

silica dust exposure. 

•	 A parallel research effort devoted to improved dust sampling has been ongoing 

for the past 10 years. These samplers use a size-selective cyclone to collect the 

respirable fraction of dust on a filter. The mass of dust, pump flow rate, and 

sampling time are used to calculate an average dust concentration for the shift. 

This concentration is not determined until the filter has been weighed at 

MSHA’s Pittsburgh lab several days after the sample is collected. This sampling 

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process has not changed in the past 36 years. In 1999, NIOSH began developing 

a mass-based, continuous dust monitor that could be worn as a personal dust 

sampler. This personal dust monitor (PDM), built into the miner’s cap lamp 

system, provides a running average of dust exposure at any point in the shift, 

projects an end-of-shift concentration, and provides an actual end-of-shift 

concentration without any delay. This information will allow mine operators and 

workers to monitor the dust exposure during the shift. The PDM is now 

commercially available. 

4.1.2 Preventing Noise Induced Hearing Loss 

Noise-induced hearing loss (NIHL) is the most common job-related illness in the 

United States today. It is especially common among miners. A NIOSH analysis of more 

than 60,000 audiograms showed that by age 51 about 90% of the coal miners and 49% 

of metal/nonmetal miners had a hearing impairment. By contrast, only 10% of the nonoccupational noise-exposed population had a hearing impairment by age 51. A 2005 

analysis of changes in noise exposure showed that the renewed emphasis on hearing 

loss prevention has already had a substantial impact. There has been a 40% reduction in 

the average coal miner’s noise dose from 1997 to 2003. The rate of decline in exposures 

increased around 2000 when a new federal noise regulation took effect. Around the 

same time, the NIOSH Hearing Loss Prevention Branch became fully staffed. The 

NIOSH role in increasing awareness of NIHL and provision of testing facilities has 

contributed to the improvement of this illness. 

4.1.3 Preventing Musculoskeletal Disorders 

Mining is one of the most physically demanding occupations. It is also one of the most 

dangerous in terms of exposure to ergonomic hazards. Musculoskeletal disorders 

(MSDs) resulting from repetitive manual work have long been identified as a significant 

and costly problem for the mining industry. Strain and sprain injuries account for 24.0% 

and 25.2%, respectively, of all reported injuries for underground coal mining. They 

account for 19.4% and 20.4%, respectively, of all injuries for underground 

metal/nonmetal mining. In 2003, MSHA reported that 44% of all illnesses were joint, 

tendon, or muscle inflammation. Using a new process integration and interventions 

development approach in mining, NIOSH contributed to a 34% overall reduction in lost 

workdays due to repetitive-type injuries during 1998-2004. This approach focuses on 

incorporating the ergonomics process in existing safety and health programs of the 

mining companies and empowering the workers to proactively develop injury 

prevention solutions to their tasks. 

Research outcomes have addressed issues such as whole body vibrations and 

developing ergonomic processes through partnerships with mines. Examples are seat 

design for low-seam shuttle cars and collaborative research with coal mining companies 

to reduce overload conditions affecting the neck, back, forearms, arms, shoulders, 

fingers, and hands associated with coal mining operations. 

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4.1.4 Prevention of Traumatic Injuries 

Research into the prevention of traumatic injuries has focused on injuries and fatalities 

related to blasting operations, electrical equipment and machinery accidents. The 

research achievements in each of these fields are listed below: 

Blasting Related Injuries and Accidents: The frequency of blasting-related injuries 

and fatalities at mining operations has dropped significantly over the past 25 years. In 

1978, 140 miners were killed or injured in U.S. blasting accidents. By 1998, this 

number had dropped to 22 and continued to decline to 7 in 2001. Factors contributing to 

increased blasting safety include the development of nonelectric initiation systems; the 

change from the use of cartridged explosives to bulk explosives; increased use of safer, 

non-nitroglycerine explosives; development of safer blasting practices; and an increase 

in the knowledge and professionalism of the average blaster. Industry, labor, and 

government all contributed to the improved safety record. Research products that have 

found acceptance and application at mine operations are: 

•	 Modification of high-detonation pressure explosive boosters and initiation 

systems to reduce the potential for explosives accidents, in response to a request 

by MSHA. 

•	 Safe use of waste oil to make ammonium nitrate fuel oil (ANFO) blasting agent. 

MSHA regulations prohibited this practice because of concerns that 

contaminants in the oil could lead to the production of unusually sensitive, 

insensitive, or thermally unstable ANFO. NIOSH to conduct research to 

evaluate the safety of waste oil-produced ANFO and help MSHA to develop 

safety guidelines for this practice. 

•	 Guidelines for prevention of CO poisoning near blasting sites. Cases of CO 

poisoning have been almost eliminated after a NIOSH investigation and 

recommendations for CO monitoring procedures. 

•	 Mines in the Powder River Basin of Wyoming asked for NIOSH assistance 

when concerns arose about the orange or red product clouds rising from largescale surface blasts. NIOSH conducted in-house research to determine the 

factors that lead to excessive NO2 and recommended practices that might reduce 

NO2 production. 

Electrical Safety Research: The NIOSH program in electrical safety research has 

focused on a variety of topics, including trailing cables, motors, trolley systems, ground 

fault protection, intrinsic safety, explosion-proof enclosures, overhead power lines, and 

lasers. Data from MSHA show that from 1990 to 2004 fatal electrical accidents 

decreased by 50%, lost workday electrical accidents decreased by 75%, and lost 

workdays decreased by 60%. Nevertheless, electrical accidents remained the fourth 

leading cause of on-the-job death in mining. Major research outcomes are: 

•	 Feasibility of high voltage coal mining equipment. The demand for larger, more 

powerful mining equipment stimulated the need for increased voltages for coal 

mine face machinery. Several NIOSH studies showed that higher voltages were 

feasible. The resultant research reports provided technical information to MSHA 

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that was used to help formulate new regulations. These regulations went into 

effect on May 10, 2002, and allowed the use of high-voltage longwall machines 

in coal mines. The reports also contributed to the formulation of proposed new 

regulations for high-voltage continuous miners. These are now in the formal 

rulemaking process. 

•	 Contact with overhead power lines. MSHA data show that nearly one-fifth of 

mine electrical deaths occur when workers contact overhead power lines. 

Research to protect workers from overhead power line electrocution led to one 

patent and stimulated two U.S. manufacturers to introduce stand-alone power 

line contact alarms. 

•	 Laser technology has become common in several fields, e.g., surveying and 

level detection. The use of lasers in potentially hazardous underground 

atmospheres was recognized as a new area of concern. Research was done to 

measure the risk of igniting flammable atmospheres by radiation from optical 

equipment. American National Standards Institute and International 

Electrotechnical Commission standards are now in process, based in part on 

NIOSH laser ignition research. These standards will result in safety guidelines 

for the safe use of lasers in gassy and dusty atmospheres. 

Machine Safety Research: Despite advances in mechanization, mining remains among 

the most physically demanding and hazardous of all occupations. Traumatic injuries 

resulting from machinery, powered haulage, and falls have long been identified as a 

significant problem for the mining industry. According to MSHA, during 1995–2004 

there was a 42% decrease in days lost due to machinery injuries, a 51% decrease in 

days lost due to powered haulage injuries, and a 34% decrease in days lost due to falls. 

Examples of NIOSH research products that have contributed to these achievements are: 

•	 A close-proximity warning device: The research product (HASARD ­

Hazardous Area Signaling and Ranging Device) has been recently licensed to 

three firms that manufacture the system for their own use and commercial sales. 

•	 Technical guidance in the application of proximity warning systems: MSHA 

and equipment manufacturers make use of NIOSH expertise to aid in decisionmaking on effective proximity warning systems and technologies to prevent 

accidents. 

•	 A set of best practices for system safety: NIOSH collaborative research has 

developed a set of documents relating to the safety life cycle for programmable 

electronic mining systems. The research has been integrated into the national 

and international mining communities. 

•	 A computer program that evaluates mine illumination systems: NIOSHdeveloped software (called the Crewstation Analysis Program) is routinely used 

by MSHA’s Approval and Certification Center in the approval process for mine 

lighting systems. 

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4.1.5 Prevention of Mine Disasters 

Since the mid-1990s, NIOSH research has led to the development of prevention, 

detection, control, and survivability technologies to reduce the probability of and 

fatalities from devastating fires and explosions. Many of these technologies have been 

adopted by the coal-producing and equipment manufacturing industry and are 

recognized in MSHA rulemaking. These technologies have also contributed to fire and 

explosion protection improvements in Australia and the Republic of South Africa. 

The number of fatalities and injuries from mine fires and explosions declined greatly 

from 1970 to 1999. There were several "zero" years during the late 1990s despite a 

700% increase in coal production during the same period. A rise in the number of 

injuries and fatalities since 2000 has prompted further NIOSH research into the causes 

and preventability of these accidents. These events, unlike other types of accidents 

where only a few workers are involved, often extend to every underground worker in 

the mine. 

The significant research achievements in this area are listed below: 

•	 Open industry briefings on mine fire preparedness conducted at NIOSH’s Lake 

Lynn Laboratory, have enhanced the mining industry’s awareness of the dangers 

of underground mine fires. Realistic rescue and response training exercises for 

federal, state, and mine rescue teams at Lake Lynn have improved the 

effectiveness of rescue teams during numerous mine emergencies. 

•	 Development and implementation of a fire prevention checklist for profiling fire 

prevention and response capabilities at a mine site have played a key role in 

preventing and responding to incipient mine fires. NIOSH-developed 

discriminating fire sensors and optimum deployment strategies based on neural 

networks and combustion particle detection have reduced the number of false 

fire alarms when used in mining operations where smoke must be distinguished 

from normal diesel equipment exhaust. 

•	 Implementation of automatic fire suppression systems on conveyor belt drives 

and underground diesel storage areas has successfully controlled the rapid 

spread of belt fires within mine entries. NIOSH research on flammability of 

noise control materials in operator cabs led to MSHA’s acceptance of the 

American Society for Testing and Materials (ASTM) E-162 Radiant Panel Test 

as a major criterion in the selection and use of these materials. 

•	 Fire and explosion safety expertise, test equipment, and test procedures that we 

developed for the mining industry have been transferred to other industries. The 

consensus standard test methods of the ASTM International committee E27 on 

the Hazard Potential of Chemicals apply to numerous other industries besides 

mining. Many of NIOSH’s research findings were incorporated into the 2004 

revised National Fire Protection Association (NFPA) mining fire protection 

standards (NFPA 120 (underground coal) and NFPA 122 (metal and nonmetal)). 

•	 NIOSH research to determine the risk of ignition of flammable atmospheres by 

laser-based optical and telecommunications equipment (fiber-optic networks) 

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led to the development of ANSI standards governing the power thresholds for 

such lasers. 

•	 Postexplosion accident investigation and forensics tools were developed and 

used by MSHA to help understand and identify the root cause of explosions. 

Blast-resistant seals and performance test methods were developed at Lake Lynn 

Lab and implemented in partnership with MSHA. Passive and active explosion 

suppression techniques developed at Lake Lynn are routinely used in 

underground mines throughout the United States and in other countries, such as 

Australia and the Republic of South Africa. 

•	 Real-time, automated gob gas venthole monitoring and wireless data 

transmission permits continuous monitoring of individual gob gas ventholes to 

optimize methane drainage and reduce the potential for explosive methane-air 

mixtures. 

•	 NIOSH testing showed that safety for roof bolter operators could be improved 

by sweeping the area inby the bolter with a methanometer in addition to the 

machine-mounted methane monitor. This requirement was implemented in 

MSHA’s methane testing requirements. 

•	 Based on data obtained by NIOSH, the Pennsylvania Bureau of Deep Mine 

Safety permits the use of powered haulage to evacuate a mine in case of a main 

mine fan outage. Prior to NIOSH’s evaluation of worker safety during egress, 

the use of powered haulage was prohibited during main mine fan stoppages. 

4.1.6 Reduction of Ground Failure Fatalities and Injuries 

 

Ground falls in U.S. underground mines (coal and nonmetal) caused more than 50,000 

deaths or about half of all mining fatalities during the 20th century. Over the past 10 

years, there have been significant improvements in ground control safety. The roof fall 

fatality rate in U.S. underground mines has averaged 0.001 per 200,000 hrs worked in 

recent years, down 69% from its average during 1980-1995. In addition, the rock fall 

injury rate has fallen in each of the last 4 years to a level about 25% below its former 

plateau. Important NIOSH research products in ground control that have been 

successfully transferred to and implemented by the mining community during the past 

decade include: 

•	 Software for coal mine design that addresses nearly every aspect from coal pillar 

design, roof support and retreat mining to longwall panel layout. 

•	 The Support Technology Optimization Program (STOP) and Analysis of 

Longwall Pillar Stability (ALPS) programs, which together have contributed to 

a virtual elimination of tailgate blockages. 

•	 Guidelines for coal pillar recovery and widespread use of mobile roof supports. 

These have helped make pillar recovery much safer. 

•	 Guidelines for designing deep-cover mines to prevent coal bumps (violent 

failures of highly stressed coal). These guidelines have contributed to 7 

consecutive years with no fatalities due to coal bumps. 

•	 New standing roof supports. These have helped reduce the number of roof falls 

and the number of injuries to miners while installing roof support. 

Page 13 
•	 A research and educational campaign aimed at increasing awareness about rock 

fall injuries and the use of surface controls in coal mines. This has helped reduce 

rock fall injury rates. 

•	 Mine design technologies such as the Coal Mine Roof Rating (CMRR) and 

Analysis of Horizontal Stress in Mines (AHSM), and guidelines for preventing 

massive pillar collapses. These have helped provide more stable mining 

environments. 

An essential part of the success of the NIOSH ground control program has been an 

effective technology transfer effort, which includes: 

•	 Hands-on ground control software computer training workshops held in six U.S. 

coalfield locations. These were attended by nearly 300 mine planners. 

•	 Open industry briefings on coal mine roof support. These were held in eight 

U.S. coalfield locations and reached 750 mining industry personnel. 

•	 Ground control short courses conducted for Massey Energy and Peabody 

Energy. 

•	 Ground control training provided in eight sessions for all 400 coal mine 

inspectors from MSHA at the agency’s request. 

•	 An annual response to an average of 200 technical requests and 40 visits at coal 

and nonmetal mine sites. 

5.1 CONCLUSION

The remarkable improvements in mine worker safety and health have been made 

possible through the concerted efforts of the mining industry, manufacturers, labor 

organizations, government agencies and research organizations. NIOSH has contributed 

to the improvements since 1995 through a research program that is directed to 

addressing important issues and providing practical outcomes. The NIOSH research 

achievements in coal mine safety have been described, showing impacts in traumatic 

injury prevention, mine disaster prevention and ground fall reduction. These 

achievements contributed to the significant improvement in mine worker safety and 

health over the past decade. 

REFERENCES 

BUREAU OF LABOR STATISTICS, Website http://data.bls.gov/GQT/servlet/Request 

Data, retrieved May 2006a. 

BUREAU OF LABOR STATISTICS, Website http://www.bls.gov/iif/oshwc/osh/ 

os/ostb1479.pdf, retrieved May 2006b. 

DEPARTMENT OF ENERGY, Website: http://www.eia.doe.gov/fuelcoal.html, 

retrieved May 2006. 

Page 14 
KOHLER, J.L. Mining safety and health research initiatives in the United States, 31st 

International Conference of Safety in Mines Research Institutes, Brisbane, Queensland, 

Australia: Safety in Mines Testing and Research Station (Simtars), 2005. pp 10-16. 

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