Critical Safety Risk Analysis and Prioritization in Underground Mines Using FMEA: A Case Study of Chahargunbad Copper Mine

This study aimed to identify and prioritize critical safety risks in the Chahargunbad underground copper mine using Failure Mode and Effects Analysis (FMEA). The main objective was to develop an evidence-based analytical framework to support managerial decision-making within the Health, Safety, and Environment (HSE) management system, with a particular focus on controlling high-priority hazards in underground mining operations. The research was applied in nature and adopted a descriptive–analytical design. Major mining activities, including drilling, blasting, loading, hauling, supervision, and equipment maintenance, were systematically evaluated. Hazard identification was performed through field inspections, analysis of safety records and documentation, and expert interviews. In total, 58 safety hazards were identified and assessed using the FMEA approach. The results indicated that three hazards were categorized as high-risk and eight hazards as medium-risk. The most critical risks were associated with roof and wall falls, machinery-related collisions, and blasting operations. The findings suggest that concentrating safety resources on critical risks and implementing targeted corrective actions can substantially reduce risk priority levels and enhance overall mine safety performance. Overall, the study demonstrates that FMEA is an effective, reliable, and practically applicable tool for the systematic identification and prioritization of safety hazards in underground mining environments.