Investigations launched after fire at Broken Hill underground mine

An investigation into the causes of an underground mine fire at Broken Hill has been launched by the NSW Resources Regulator, with the causal investigation examining safety and management failures that may have contributed to the incident. This incident took place on 12 January 2025.

The Regulator has stated that the investigation will examine whether a polyurethane ground stabiliser experienced self-heating after its application by workers engaged in ground support and remedial activities in a remote underground location. Ground support management practices are central to preventing this type of underground fire from occurring again.

According to the Regulator, workers operating underground detected the presence of fumes and vapors during the application of the product, prompting an immediate response from onsite safety and health personnel. Exposure to hazardous fumes underground poses serious health risks, making early detection critical to worker safety.

“The workers successfully retreated to fresh air where they remained until it was assessed as safe to leave the mine,” the regulator said.

“All workers were safely removed from the mine and there were no injuries reported by the mine operator regarding this incident.”

Why Ground Stabiliser Management Matters for Mine Safety

Polyurethane ground stabilisers are widely used across underground mining operations for reinforcing rock surfaces and supporting excavated areas. Proper management of these hazardous materials, including storage, application, and monitoring for self-heating reactions, forms a critical part of any mine's broader safety management framework.

Effective management of chemical stabilisation products requires:

• Strict adherence to manufacturer application guidelines and temperature monitoring
• Ventilation management to disperse fumes and vapors quickly
• Clear evacuation procedures for workers if hazardous conditions are detected
• Regular health and safety audits of ground support activities

Broken Hill's Perilya mining emergency rescue team plays a key role in responding to underground incidents, supporting safe evacuation and helping mine operators manage emergency situations until conditions are confirmed safe.

Regulatory Oversight and Next Steps

The NSW Resources Regulator's investigation will assess whether existing safety management systems adequately addressed the risks associated with hazardous ground stabilisation chemicals. Findings from the investigation may prompt updated guidance for mine operators regarding self-heating hazards linked to polyurethane products.

This incident follows a pattern of regulatory scrutiny into underground mine safety across NSW. For related coverage, see our reports on investigations launched following an incident at another NSW mine and investigations launched after an NSW mine worker suffered a serious leg injury during a lifting operation.

Workplace fires remain a significant risk across heavy industry, not just underground mining. Our coverage of investigations launched after a Melbourne factory fire killed a worker highlights how critical robust fire safety management remains across all industrial settings.

Strengthening Fire and Emergency Preparedness

Mine operators and safety professionals across construction, manufacturing, and resources sectors can strengthen their emergency preparedness with SafetyDocs' range of fire safety resources, including our Fire Services Safety Packages and Fire Services SWMS templates, both designed to support compliant safety management practices onsite.

Additional resources such as our Fire Fighting Equipment Procedure and Fire Extinguisher Use Instructions provide practical guidance for workers responding to fire hazards, while our Fire and Emergency Evacuation Policy outlines broader evacuation management obligations for employers.

Read more here.