DGMS Circulars: Dumpers, Haul Roads, LMVs, HEMM and Opencast Transport

DGMS Circulars: Dumpers, Haul Roads, LMVs, HEMM and Opencast Transport 
Accident Background and Core Findings

• Increased accidents involving dumpers/transport machinery in recent years attributed to poor maintenance and lack of inspections, especially braking and steering.
• Case examples: engine stalling on 1:10 ramp leading to rollback and fatality; dumper-to-dumper collision on haul road with fatal outcomes.
• Root causes commonly include weak/untested braking or steering systems and non-compliance with testing/record-keeping requirements.

• At the start of every shift, operator/competent person (appointed in writing) must test: brakes, steering, horn, other warning devices.
• Defects must be reported, rectified before operation; vehicle must not be used until safe.
• Maintain a bound paged book of tests; entries signed by tester and countersigned by engineer and manager.
• Surprise inspections by engineer/senior officers to ensure brake systems remain in working order.

• Standards referenced: ISO 3450, SAE J1152 (1980) for service and parking brake efficiency (stopping distance tests, gradient hold for 10 minutes).
• Full standard tests are elaborate and not feasible each shift; hence simplified shift tests are prescribed.

• General pre-steps for all tests: fasten seat belt; move to dry, level surface; clear area; start engine; build air pressure to cut-off.
• Service brake test:
  • Apply service brake only; 1st gear forward; raise engine to ~1,400RPM for a few seconds.
  • Desired result: machine should not move.
• Retard brake test:
  • Apply retard brake only; 1st gear forward; raise engine to ~1,300RPM for a few seconds.
  • Desired result: machine should not move.
• Parking (dump) brake test:
  • Apply parking brake only; 1st gear forward; raise engine to ~1,200RPM for a few seconds.
  • Desired result: machine should not move.
  • Interpretation: considered capable of holding a loaded dumper on 15% gradient.
• Steering test:
  • Neutral gear; remove brakes; turn wheels to extreme; remove hands; raise to ~1,000RPM; repeat opposite side.
  • Desired result: no self-movement of steering/tyres; any movement requires immediate checks/repairs before service.

• At least once every two weeks:
  • Service brake test on specified gradient/speed with full load — must stop within OEM-specified distance.
  • Parking brake must hold fully loaded vehicle on maximum permitted roadway gradient for ≥10 minutes.
  • Record results in bound paged book; signed by tester; countersigned by engineer and manager.
• Surprise inspections by engineer/superior at ≤15-day intervals to verify adherence to examination schedules.

• Any machinery/vehicle with defects or unsafe condition: tag “OUT OF SERVICE DO NOT USE”; prohibit use until corrected.
• Repairs to be done at safe locations; shut down equipment with positive means to prevent movement during repairs/manual lubrication.
• Disconnect power for electric machines under repair.
• Block/crib suspended components before working underneath/between.

• Maintain all roads for trucks/dumpers/mobile machinery in good condition.
• Prefer one-way traffic; if not practicable, road width ≥3× width of largest vehicle unless turnouts/waiting points designated.
• Corners/bends must provide ≥30m clear view; if not possible, provide separate up and down roads.
• Gradients:
  • No road steeper than 1:16 without written permission; small ramp stretches may be permitted up to 1:10.
• Edge protection: parapet walls/embankments ≥1m high where road is above surrounding level.
• Signage/delineation: road signs at turnings; parapets/vertical posts with zebra lines at curves, aiding night navigation.

• Bench height ≤ digging height of machine (soft rocks: up to +3m with Regional Inspector’s permission).
• Bench width must be at least:
  • Width of widest machine +2m, or
  • 3× dumper width if dumpers ply, or
  • Equal to bench height, whichever is greater.
  • Reductions require Chief Inspector’s permission with conditions.
• When persons are within 5m of working face: dress sides; ensure adequate precautions.
• Supervision: assistant manager in production shift; foreman during maintenance shift; responsible for regulatory compliance.

• Provide and maintain a separate roadway for LMVs that does not cross dumper haul roads, to the extent practicable.
• If crossings are unavoidable:
  • Vet by Internal Safety Organization (ISO); obtain Regional Inspector’s written approval.
  • Prefer level ground at crossing segment.
  • Ensure visibility of at least 3× braking distance of largest dumper.
  • Haul road HEMM has right of way over LMVs.
  • Manned crossings in all shifts; proper barricading and audio-visual warning systems on both LMV approaches (as approved/vetted by ISO).
  • Speed barriers within ≤30m of crossing on LMV carriageway (ISO vetted).
  • ISO to periodically review and add conditions as workings advance.
• This requirement supersedes earlier DGMS Tech Circular No.6 of 2008.

• Objective: reduce accidents from brake failures, reversing incidents, and unauthorized riders.
• Roads:
  • Maintenance in good condition.
  • One-way arrangement where practicable; otherwise width ≥3× largest vehicle or designate turnouts/waiting points.
  • Visibility ≥30m at corners; otherwise separate up/down roads.
  • Gradients ordinarily ≤1:16; small ramps up to 1:10 may be permitted.
  • Parapet/embankment ≥1m where elevated; signs at turning points; zebra-marked posts/parapets at curves for night guidance.
• Maintenance:
  • Weekly thorough examination by engineer/competent person; defects remedied before use.
  • Record inspections in bound paged book with dated signatures.
  • Prompt attention to driver-reported defects.
  • Regular servicing/overhauling per OEM; maintain written records.
  • Lockout for repairs; prevent operation during testing/trial unless necessary; block/crib suspended parts.
• Daily examinations:
  • Shift-start inspection by appointed competent person, verifying brakes and warning devices; for after-daylight work, verify lights.
  • Record each inspection; do not release vehicle unless mechanically sound.
• Operations:
  • No riding on running boards; avoid carrying loaders/labourers. If unavoidable, provide a separate rear compartment for seating.
  • Avoid reversing loaded vehicles on gradients; use sufficient stop-blocks at every tipping point, every time.
  • Adopt/display standard traffic rules prominently in workings and roads.
  • Park only at proper parking places.
  • No work on chassis with body raised unless securely blocked; do not rely on hoist alone.
  • Restrict access: no unauthorized persons in dumping yards/turning points.
• Driver duties:
  • Pre-shift roadworthiness check: tyres, air pressure, brakes, horn, lights; report and rectify defects before operation.
  • Defensive driving; avoid distractions; overtake only when clearly safe and after audible signal.
  • Reduce speed and check both directions before crossing roads/railways; sound at blind corners.
  • Reverse only with clear rear visibility or authorized spotter; sound before reversing.
  • Ensure clearance through tunnels/archways/structures.
  • Do not operate in fog/mist without manager-specified precautions.
  • Prevent overloading; no material projecting beyond sides; flagging (red flag by day) and lighting (red light after daylight) for front/rear projections.

• No unauthorized riders on shovels/draglines; no riding in shovel buckets.
• Maintain minimum 3m clearance from exposed high-voltage lines unless de-energized; post notice at operator’s station.
• Lay electrical cables to avoid danger from falling rocks/mobile equipment.
• Shovel bucket to be pulled out of bank once full; when not operating, keep out of bank.
• On soft/unstable ground, support shovels/draglines with heavy planks/poles to distribute load and prevent overturning.
• Park shovels/draglines on stable ground when not in use.
• Space multiple stripping machines to avoid risks from flying/falling objects between machines.
• Loading practice: do not swing buckets over passing haulage units; swing over truck/dumper body, not cab, unless cab is adequately protected.

• Use suitable protective cages when inflating tyres.
• Never inflate by sitting in front/on top of tyres.
• When loading/unloading on gradients: secure vehicle with parking brake and additional stopper blocks under tyres.

• Transport explosives only in original packing; limit quantity to one round; deliver to site ≤90 minutes before charging commencement.
• Vehicle requirements:
  • Use only types approved in writing for explosives transport; Jeeps/Land Rovers may transport detonators under specified conditions (box-in-box with approved metal case bolted/fixed; max 200 detonators; no riding on rear).
  • Placard “Explosives” on both sides and ends (white letters ≥15cm on red background).
  • Provide ≥2 extinguishers (petroleum and electrical types) positioned for convenient use.
  • No overloading; cases not higher than body sides; do not transport explosives and detonators together.
  • Only driver and helper(≥18 years) may ride; never leave loaded vehicle unattended.
  • Stop engine/set brakes before unloading/standing; max speed 25km/h; no garage/repair shop/congested parking; refuel only in emergencies with engine off and precautions; no trailers.
• 24-hour inspection by competent person for extinguishers, wiring, cleanliness, leaks, lights, brakes, steering; sign/date report.
• Personal supervision by foreman in charge of blasting operations.
• Blaster to search all involved personnel for smoking/ignition sources before transport/use.
• Firing precautions:
  • Fire shots in daylight or adequate artificial light; charge holes fired on same day; schedule between shifts/rest intervals/end of work where practicable.
  • During electric storms: do not handle explosives/detonators; suspend charging; coil and recess firing wires; keep away from rails to avoid lightning-induced premature explosions.

• Mines must have a clear safety management plan for fire hazards, developed via risk assessment; led by ISO, in consultation with Regional Inspector.
• Plans include assessment of quality/quantity and placement of fire-fighting equipment for oil, electrical, and flammable material fires.
• Periodically review/update plans with changes in mechanization and technology.
• Provide and maintain automatic fire protection systems for large surface HEMM (coal/mine haulers, ash haulers, dozers, loaders, draglines, BWE, blast-hole drills, hydraulic/electric shovels):
  • Suppression agent containers (often dry chemical), fixed plumbing, targeted nozzles.
  • Optical/thermal/other suitable detection sensors.
  • Manual override and alarms.
  • Follow manufacturer’s testing schedules.

• Ensure specified safety features are provided in trucks/tippers; include in NITs for new procurement.
• Retrofit safety features to existing trucks within a specified timeframe, not later than 1 year from circular issue date.
• Include same safety feature requirements in contractor agreements; ensure compliance before operation in mines.
• Owners/Agents/Managers must ensure full compliance to minimize and eliminate transport-related accidents.

• Vet and approve LMV–dumper crossings, speed barriers, barricading, and warning systems.
• Review crossing arrangements and road safety controls periodically as workings advance.
• Lead risk assessments for fire safety plans and transport layouts; coordinate with Regional Inspector for approvals/permissions.
• Recommend additional conditions as needed based on local conditions.

• Mechanics/fitters/engineers:
  • Shift-start personal inspection/testing of every machine/vehicle (brakes, warning devices, lights if after daylight).
  • Maintain bound paged inspection records with dated signatures; release only if mechanically sound.
• Machine operators:
  • Do not operate when persons are endangered by proximity; prohibit unauthorized riders.
  • Follow loading swing protocols and cab protection requirements.
• Truck/dumper drivers:
  • Conduct pre-shift checks; drive defensively; adhere to signaling and reversing protocols with spotter or clear view.
  • Prevent overloading and manage protruding loads with proper flags/lights.
  • Obey traffic rules and speed limitations; ensure clearances and adhere to fog/mist precautions.

• Maintain bound paged books for:
  • Shift tests (brakes, steering, lights/horns).
  • Weekly thorough vehicle/machine examinations.
  • Fortnightly brake performance tests.
  • 24-hour explosive vehicle checks.
  • Surprise inspection records (≤15-day intervals).
• Ensure signatures by responsible persons and countersignatures by engineer/manager where required.
• Enforce tag-out and return-to-service only after verified rectification.

• Reclaiming mineral from dump workings carries risk of collapse of loose debris.
• Treat as analogous to working in loose overburden benches; apply Reg.98 CMR 1957/Reg.106 MMR 1961 precautions.
• Example incident: large fines slide (~120m³) burying a worker; emphasizes need for strict precautions.
• Management must implement opencast loose soil safeguards to protect workers in ore dumps