Author: Laura Griffiths

The rule aims to protect miners from severe health issues such as silicosis, lung cancer, and chronic bronchitis, which are caused by prolonged exposure to silica dust in mining environments.

Coal mines must be in compliance with the new rule by April 2025, while MNM mines have until April 2026. This staggered timeline provides operators with some time to implement the necessary controls and procedures to meet the new requirements. However, given the complexity of the rule, operators are urged to begin preparations well in advance to avoid penalties and ensure the safety of their workforce.

The Significance of the New Silica Dust Rule

The new rule, outlined under 30 CFR Part 60, mandates that mining operations limit workers’ exposure to RCS to no more than 50 micrograms per cubic meter of air, calculated as an 8-hour time-weighted average. This represents a significant reduction from previous limits and reflects the growing understanding of the dangers associated with silica dust inhalation.

Respirable crystalline silica, often found in dust created during mining activities like drilling and blasting, is particularly hazardous due to its ability to penetrate deep into the lungs. Long-term exposure can result in irreversible diseases, many of which can be fatal. This rule is designed to prevent these diseases by drastically lowering allowable exposure levels.

What Mine Operators Need to Know

Under the new rule, mine operators must adopt engineering controls to limit dust exposure, including ventilation systems, water sprays, and enclosed cabs with air filtration systems. MSHA makes it clear that relying solely on administrative controls, such as rotating workers to limit their exposure, is not acceptable. Instead, operators must focus on preventing the dust from becoming airborne in the first place.

Additionally, regular dust sampling and monitoring will be required to ensure that exposure levels remain below the permissible threshold. If monitoring shows that levels exceed the limit, operators must take immediate corrective action. While respirators may be used in specific, limited cases (such as during maintenance), they cannot serve as a permanent solution. Mine operators are required to implement more robust and permanent controls to bring dust levels into compliance.

Medical Surveillance Requirements

A key component of the new silica dust rule is the medical surveillance program. This program will now extend to miners in the MNM sector, in addition to coal miners who are already covered by similar protections. Under this program, mine operators must offer periodic health examinations to miners, including chest X-rays and lung function tests, at no cost to the workers. These exams are crucial for detecting early signs of silica-related diseases.

For newly hired miners, these examinations will be mandatory, while experienced miners will have the option to participate voluntarily. However, MSHA encourages all miners to take part in the program to monitor their health and catch any issues before they become severe. Operators are responsible for ensuring these exams are conducted and for maintaining records of the results.

Carroll Technologies: A Partner in Compliance

As the mining industry adapts to these stringent new requirements, Carroll Technologies offers a range of solutions to help operators remain compliant with MSHA’s silica dust rule. Carroll provides advanced equipment, such as the Zefon Escort ELF Dust Pump, which is designed for accurate air sampling in mine environments. The Escort ELF Dust Pump features a laminar flow sensor for precise flow control, ensuring reliable sampling even under challenging conditions. The pump also includes features like a flow/fault indicator and a low-battery alert to make dust sampling as seamless as possible.

Carroll Technologies also supplies coal dust sampling cassettes, tubing assemblies, and calibration devices such as the DigiCal Primary Flow Calibrator, which ensures that personal and environmental air pumps are accurately calibrated. These tools are vital for keeping your operation in line with the latest MSHA requirements. With Carroll’s help, operators can implement proper dust control measures and maintain compliance through continuous monitoring.

Key Products:

Zefon Escort ELF Dust Pump: A robust air sampling pump with laminar flow control, designed for use in mining environments. It features automatic adjustments for battery voltage, temperature, altitude, and sample load. The pump is IP65-rated, providing protection against particulates and moisture. It includes alerts for low battery and blocked inlets.

Coal Dust Sampling Cassettes: Pre-weighed cassettes used in coal mine dust sampling, equipped with a 5-micron PVC filter and stainless-steel supports. They come with a mine data card and mailing carton for submission to MSHA for analysis.

DigiCal Primary Flow Calibrator: A calibration device for air sampling pumps like the Zefon Escort ELF. It offers precise airflow verification using a microprocessor and quartz timer for accurate flow measurement. The calibrator is compact, works at any altitude, and provides instant digital readings.

Sampling Line Assembly: A flexible 36-inch tubing used for connecting Zefon air sampling pumps. It is made of clear vinyl (PVC) and includes a clip for attachment.

Cyclone Calibration Jar: A container used for calibrating personal sampling pumps with Zefon or SKC cyclones. It comes with fittings and tubing for easy setup.

Escort ELF Maintenance Kit: A repair kit for the Zefon Escort ELF Dust Pump, containing filters, O-rings, screws, belt clips, and other essential maintenance parts.

ST1000-8 Low-Speed Anemometer from Superior Technologies: An advanced tool designed for accurately measuring airflow in mining and industrial environments. This intrinsically safe device provides precise measurements of air velocity in low-speed applications, ranging from 40 to 5000 feet per minute (FPM), making it essential for monitoring mine ventilation systems.

Josh Johnson, Sales Manager for Carroll Technologies Group, was recently featured on the October Sky Minute podcast, where he shared his expertise on mining safety equipment and how it has evolved over the years. The podcast, part of the popular “Movies by Minutes” genre, dissects the 1999 film October Sky one minute at a time, offering in-depth analysis of each scene. Directed by Joe Johnston, October Sky is based on the true story of Homer Hickam, a boy from a coal-mining town in West Virginia who dreams of becoming a rocket scientist. The film beautifully compares the challenges of coal mining with the boundless aspirations of youth, while also highlighting the often dangerous conditions faced by miners.

Josh’s appearance on the show offered a unique perspective by connecting the film’s portrayal of mining with modern-day realities. During the episode, Josh reflected on the dangers that miners still face and how advancements in safety equipment have helped reduce those risks. He mentioned that while certain tools, like the hard hat, have remained essential throughout the years, technology has vastly improved the gear miners use today. Cap lamps, for example, have transitioned from the heavy, corded models seen in the film to modern, rechargeable LED lamps with integrated tracking systems that can help ensure miners are accounted for while working deep underground.

Hal Bryan and Jim O’Kane, the hosts of the October Sky Minute podcast showed particular interest in the improvements to underground communication systems, such as the leaky feeder system, which allows for continuous communication between miners and surface teams. Josh explained that this system not only facilitates voice communication but also supports telemetry, enabling control rooms to monitor machinery and miners’ locations in real-time, thereby enhancing safety and efficiency.

October Sky is known for its vivid portrayal of coal mining in the 1950s, and Josh’s insights helped bridge the gap between the film’s depiction of the industry and the modern advancements that have reshaped it. One of the most significant upgrades discussed was the evolution of self-rescue devices. While miners in the past relied on basic equipment to survive emergencies, today’s miners are equipped with devices that provide breathable oxygen and additional rescue equipment stored in strategic locations throughout the mine. These devices, Josh emphasized, can be lifesaving in the event of an accident.

As a representative of Carroll Technologies Group, which has been serving the mining industry for over 40 years, Josh’s participation in the podcast highlights the company’s commitment to advancing safety measures in the industry. Carroll Technologies provides a range of mining safety and communication products, from modernized hard hats and cap lights to state-of-the-art rescue equipment and communication systems.

The October Sky Minute podcast not only celebrates a beloved film but also opens up important conversations about the mining industry, the dangers it poses, and the technologies that help keep workers safe. Josh’s appearance on the podcast was a testament to the vital role that safety equipment plays in the lives of miners today, just as it did decades ago when the movie was set. His discussion underscored the importance of continuous improvement in mining technology, an effort that Carroll Technologies Group is proud to support.