Accidents in the Production, Transport, and Handling of Explosives: TOL Method Hazard Analysis with a Mining Case Study

Explosives (EXP) are an essential component of technological processes across numerous civil industry sectors, particularly in surface mining. Despite their technological benefits, their use is associated with a high risk of serious accidents. This study aimed to present available data sources on explosive-related incidents and to highlight the limitations in their accessibility, quality, and comparability. The analysis included the SAFEX, eMARS, and PAR databases, as well as national reports from the Polish State Mining Authority, focusing on discrepancies in the classification and description of events. The review was complemented by an analysis of an accident in a Polish open-pit mine, in which an excavator operator was injured due to the uncontrolled detonation of an unexploded charge. The TOL method was employed to analyze the root causes, allowing for the identification of technical, organizational, and human contributing factors, with specific adaptations for the explosives domain such as safety barrier verification, post-blast supervision, and quality control of detonators. The results indicate that most incidents arise from the interaction of multiple causes rather than a single error. The study underscores the need for more effective verification procedures, improved oversight of post-blast operations, and enhanced protective equipment. The article highlights the importance of a systems-based approach to safety management, encompassing both consistent incident data analysis and practical preventive actions throughout the entire life cycle of explosives.