Report – Coal – Structural collapse or failure – September 2024 to March 2026

This report provides the findings of an assessment program at surface & underground coal mines focussing on the mechanical engineering control plan

Sector	Coal – surface and underground
Principal control plan	Mechanical engineering control plan
Material unwanted event	Structural collapse or failure
Topic	Uncontrolled structural collapse or failure

Operation type assessed

Operation type	Number of mines assessed
Surface	27
Underground	17
Total	44

Criteria assessed

Critical control	Criteria
Fit for purpose structural design	Do workers understand how structures are maintained as per design? Can workers identify and report potential structural concerns
Fit for purpose mine design (management of subsidence)	How does the mine ensure they are executing to design and minimising the potential impact on structures? Can workers identify and report subsidence or potential subsidence impacting structures on site?
Reduction of mine activities or removal of personnel	Do workers understand operational restrictions in place due to structural integrity concerns? Are workers aware of any access restrictions implemented due to structural integrity?
Separation / segregation	Can workers describe the controls in place to prevent vehicles and equipment from striking structures? Are the controls in place to separate / segregate vehicles and equipment from structures maintained and fit for purpose?

Findings with issues identified – surface and underground mines

Critical control	Criteria	Findings of concern	Findings of contravention	Total findings with issues
Fit for purpose structural design	Do workers understand how structures are maintained as per design?	1	0	1
	Can workers identify and report potential structural concerns?	2	0	2
Fit for purpose mine design (management of subsidence)	How does the mine ensure they are executing to design and minimising the potential impact on structures?	0	0	0
	Can workers identify and report subsidence or potential subsidence impacting structures on site?	0	0	0
Reduction of mine activities or removal of personnel	Do workers understand operational restrictions in place due to structural integrity concerns?	2	0	0
	Are workers aware of any access restrictions implemented due to structural integrity?	2	0	0
Separation / segregation	Can workers describe the controls in place to prevent vehicles and equipment from striking structures?	1	0	1
	Are the controls in place to separate / segregate vehicles and equipment from structures maintained and fit for purpose?	2	1	3
Total program findings with issues		10	1	11
Other topic findings – not related to MECP-structural collapse		19	9	28

Compliance notice type issued during the program

Notice type	Notice	Percentage of all notices issued
WHS(MPS)A s23 notice of concerns	25	68%
WHSA s191 improvement notice	12	32%
WHSA s195 prohibition notice	0	0%
Total	37	100%

A total of 37 compliance notices were issued to 26 coal mines

Note: This data represents all notices issued during the program and may include notices other than MECP-structural collapse or failure topics.

Recommendations

Operators of surface and underground coal mines should review their site principal mechanical engineering control plan and the critical controls assessed for the topic of uncontrolled structural collapse or failure.

Critical control	Criteria	Recommendations to industry
Fit for purpose structural design	Do workers understand how structures are maintained as per design?	Ensure safety critical structural design load rating information is available for relevant workers in MECP procedures Ensure the mine undertakes annual structural integrity inspections by qualified assessors Ensure identified structural defects are managed by the site defect management reporting system linked to the MECP Ensure relevant workers are notified of structural defect repairs and change management for structural modifications
	Can workers identify and report potential structural concerns	Ensure workers are instructed to report damaged or corroded structures through the site defect management reporting system
Fit for purpose mine design (management of subsidence)	How does the mine ensure they are executing to design and minimising the potential impact on structures?	Ensure life cycle management for structures on site is documented in the site MECP Ensure structural engineering design, installation and repairs are assessed by a suitably qualified person
	Can workers identify and report subsidence or potential subsidence impacting structures on site?	Ensure all workers are instructed in the site defect management reporting systems for reporting observations of structural defects
Reduction of mine activities or removal of personnel	Do workers understand operational restrictions in place due to structural integrity concerns?	Ensure all workers are instructed in the use of site demarcation and isolation procedures for defective structures Ensure solid barriers are used where practicable for restricting access to defective structures
	Are workers aware of any access restrictions implemented due to structural integrity?	Ensure all workers are notified and kept up to date at tool box talks or other communication methods on access due to structural integrity issues
Separation / segregation	Can workers describe the controls in place to prevent vehicles and equipment from striking structures?	Ensure all workers are instructed in protective device controls on structures from vehicle collision with the structure (applicable to site ROVOA and MECP) Ensure regular audit and inspection of structural protection devices Ensure competent persons inspect and report on structural protection devices
	Are the controls in place to separate / segregate vehicles and equipment from structures maintained and fit for purpose?	Ensure hard barrier controls are in place to protect structures from operating vehicles and equipment Ensure height warning signage and fixed height barriers are in place to notify vehicle/machine operators near to elevated fixed structures