Front-End Loader

victim entered a hopper without power locked and tagged out and without fall protection

On September 18, 2013, Lonnie Ferrell, Front- end Loader Operator, age 56, was killed when he was engulfed by material in a pug mill hopper (hopper). Ferrell used a front-end loader to place material into the hopper. He then entered the top of the hopper to remove a lump of stone that would not feed onto the belt conveyor below. The unconsolidated material that Ferrell was standing on collapsed, engulfing him. The hopper was operating at the time of the accident. The accident occurred due to management’s failure to establish policies and procedures for safely clearing a hopper. The hopper’s discharge operating controls were not deenergized and locked out before Ferrell worked on or near equipment and he did not wear a safety harness and lanyard, which was securely anchored and tended by another person, prior to entering the hopper. The hopper did not have a heavy screen (grizzly) installed to control the size of material and prevent clogging. Additionally, the hopper was not equipped with any mechanical devices or other effective means of handling material so persons can work where they are not exposed to entrapment by sliding material. Ferrell was not task trained to recognize all potential hazardous conditions and to understand safe job procedures to eliminate all of the hazards before he began work on the hopper.

1. Management failed to establish policies and procedures for safely clearing a pug mill hopper. The hopper’s discharge operating controls were not deenergized and locked out before Ferrell worked on or near equipment and he did not wear a safety harness and lanyard, which was securely anchored and tended by another person, prior to entering the hopper.

   Corrective action: Management installed a grating designed to cover the top of the chute. It has been welded to the top of the hopper to prevent persons from accessing the hopper. This grating also prevents lumps from clogging the discharge chute.

2. Management failed to ensure that Ferrell was task trained to recognize all potential hazardous conditions and to understand safe job procedures to eliminate all of the hazards before he began work on the hopper.

   Corrective action: Management established written policies and safe work procedures to ensure that miners are task trained when working near bins, hoppers, silos, tanks and surge piles. All miners received training regarding working near bins, hoppers, silos, tanks and surge piles. The task training included revised lockout procedures, lockout responsibility, and procedures to restore equipment and/or circuits to service. Requirements for wearing a safety belt or harness equipped with a lifeline when entering such facilities were also discussed.

Findings from MSHA's final investigation report, which supersedes the preliminary narrative above.

Activity at time of incident

Enter/Work In Bins, Silos

Subunit / location

STRIP, QUARY, OPEN PIT

Accident type

Caught in, under or between collapsing material or buildings

Source of injury

BROKEN ROCK,COAL,ORE,WSTE

Nature of injury

SUFFOC,SMOK INHILAT,DROWN

Body part affected

BODY SYSTEMS

Total mining experience

16 years

Experience at this mine

14 years

Experience in this job

14 years

Degree of injury

FATALITY