Product Overview

Summary: This Surface Mining Operations Safety Safe Operating Procedure provides a clear, step-by-step framework for planning, conducting and supervising open-cut mining activities in a safe, compliant and efficient manner. It helps Australian mining operators control critical risks associated with heavy mobile plant, blasting, pit design, and changing ground conditions, while demonstrating due diligence under WHS law.

Surface mining presents a unique combination of high-energy equipment, variable ground conditions, and constantly changing work areas. Without a robust, documented procedure, even experienced crews can be exposed to unacceptable risks such as vehicle interactions, wall failures, misfires and uncontrolled dust. This Surface Mining Operations Safety Safe Operating Procedure sets out a practical, site-ready framework for controlling these hazards across the full mining cycle – from planning and pre-start inspections through to loading, hauling, dumping, stockpiling and rehabilitation activities.

Developed with Australian WHS obligations and mining industry expectations in mind, this SOP helps operations move beyond informal “tribal knowledge” to a consistent, auditable way of working. It clarifies roles and responsibilities, embeds critical controls for high-risk tasks, and integrates key elements such as traffic management, fatigue management, communication protocols, and emergency response. By implementing this procedure, mine operators can improve workforce competency, reduce incident rates, and provide clear evidence of systematic risk management to regulators, clients and corporate stakeholders.

Key Benefits

• Ensure a consistent, defensible approach to managing critical risks in surface mining operations across all shifts and crews.
• Reduce the likelihood of serious incidents involving heavy mobile plant, vehicle interactions, ground instability and blasting activities.
• Demonstrate compliance with Australian WHS legislation and mining-specific regulatory requirements through a documented, auditable procedure.
• Strengthen supervisor capability with clear guidance on pre-start checks, task allocation, communication, and monitoring of safe work practices.
• Improve contractor management by setting clear safety expectations and standardised operating rules for all parties on site.

Who is this for?

• Mine Managers
• Open Cut Examiners (OCEs)
• Surface Mining Supervisors
• WHS Managers and Advisors
• Mining Engineers
• Drill and Blast Coordinators
• Heavy Mobile Plant Operators
• Contractor Managers
• Safety and Training Coordinators
• Maintenance Supervisors (Mining Fleet)

Hazards Addressed

• Vehicle and mobile plant collisions (haul trucks, loaders, dozers, graders, light vehicles)
• Interaction between heavy equipment and pedestrians in active mining areas
• Ground instability, wall failures, and pit slope collapse
• Uncontrolled movement of vehicles on grades, including roll-aways and loss of braking
• Drill and blast hazards, including misfires, flyrock, fumes and premature detonation
• Exposure to respirable dust, including silica, and diesel particulate matter
• Noise exposure from large mining equipment and fixed plant
• Fatigue-related incidents due to shift work and extended roster patterns
• Limited visibility and environmental conditions (fog, dust, rain, night operations)
• Contact with overhead and underground services (powerlines, pipelines, utilities)
• Manual handling injuries during maintenance, ground support and housekeeping tasks
• Slips, trips and falls on uneven, wet or unstable ground around pits and stockpiles
• Fire and explosion risks associated with fuel farms, refuelling and mobile plant
• Working near highwalls, voids, water bodies and open edges

Included Sections

• 1.0 Purpose, Scope and Applicability
• 2.0 Definitions and Key Terms (including critical controls and high-risk activities)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Planning and Risk Assessment for Surface Mining Operations
• 5.0 Site Access, Induction and Contractor Management
• 6.0 Traffic Management and Mobile Plant Interaction Controls
• 7.0 Pit Design, Bench Management and Ground Stability Controls
• 8.0 Pre-Start Inspections and Equipment Safety Checks
• 9.0 Safe Operation of Haul Trucks, Loaders, Dozers and Ancillary Equipment
• 10.0 Drill and Blast Safety Requirements (including exclusion zones and misfire management)
• 11.0 Loading, Hauling, Dumping and Stockpile Management Procedures
• 12.0 Dust, Noise and Vibration Control Measures
• 13.0 Fatigue Management and Fitness for Work Requirements
• 14.0 Communication Protocols, Two-Way Radios and Positive Communication Rules
• 15.0 Adverse Weather, Night Operations and Reduced Visibility Controls
• 16.0 Isolation, Lockout/Tagout and Maintenance Activities in Operational Areas
• 17.0 Emergency Preparedness and Response for Surface Mining Incidents
• 18.0 Incident Reporting, Investigation and Corrective Actions
• 19.0 Training, Competency Assessment and Refresher Requirements
• 20.0 Document Control, Review and Continuous Improvement

Legislation & References

• Model Work Health and Safety Act 2011 (Cth) and Regulations
• Work Health and Safety (Mines and Petroleum Sites) legislation applicable in the relevant state or territory (e.g. NSW WHS (Mines and Petroleum Sites) Regulation 2014, QLD Mining and Quarrying Safety and Health Regulation 2017)
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Confined Spaces (where applicable to surface mining infrastructure)
• AS/NZS ISO 45001:2018 Occupational health and safety management systems
• AS 2187.2: Explosives – Storage and use – Use of explosives (for drill and blast activities)
• AS 4024 series: Safety of machinery (relevant parts for fixed and mobile plant)
• AS/NZS 3012: Electrical installations – Construction and demolition sites (for temporary electrical installations on mine sites)
• Relevant state and territory mining safety and health guidelines and recognised standards (e.g. QLD Recognised Standards for Traffic Management and Mobile Equipment)