Intelligent safety systems: AI paving the way for zero-harm mining – International Mining

Mining has long been recognised as one of the world’s most dangerous industries. Workers entering the vicinity are exposed to risky environments, from unstable rock formations that can collapse without warning, invisible toxic gases in the confined tunnels, massive machinery operating in their proximity and remote site locations where emergency response may take some time to arrive.

Against this backdrop, “zero-harm mining” has often seemed more like an idealistic slogan than an achievable target, Gary Ng, CEO and co-Founder of viAct, says.

Yet the mining sector is now in the hands of a profound transformation. Artificial intelligence (AI) is changing the situation by bringing intelligent safety systems to daily operations, doing more than observing and reacting ─ with the algorithms able to anticipate, predict and prevent.

By reimagining the safety fundamentals of operations through automation and intelligence, AI-based safety systems in mining are enabling a future where accidents can be drastically reduced, risks continuously monitored and safety elevated to a substantially stable level.

The persistent hazards of mining

Over the years, safety statistics have revealed the scale of the challenge. The International Labour Organization mentions that although the sector is responsible for the employment of only 1% of the global workforce, it accounts for roughly 8% of workplace fatalities worldwide.

As per the Mine Safety and Health Administration (MSHA), between January 3, 2025, and March 5, 2025, 10 fatalities occurred in the US mining sector. This is more than three times higher than the same period in 2024. The most common cause of fatality highlighted is that of powered haulage, followed by machinery faults and falls on site.

South Africa, a major mining region, saw a total of 74 fatalities in 2021 and 49 in 2022, according to data from the Minerals Council of South Africa.

The observations reported over the years make it evident that while safety practices have evolved for the better, the extent of human monitoring has its own limits. In the case of silica dust exposure, for example, the traditional method includes periodic sampling across sites using handheld monitors. The levels might spike in between such checks, leading to hours of exposure.

Further, supervisors or safety teams can be under the influence of workplace fatigue, stress and other unpredictable conditions that can impact on safety oversight. For years, the mining industry has relied on human monitoring as its frontline defence, but now AI offers the chance to extend that oversight into a 24/7 guardian.

Mining safety enters the age of intelligence

What distinguishes digital safety systems from traditional approaches followed for monitoring is their capacity to analyse vast streams of data in real time and to transform that data into actionable insight. CCTV on mining sites embedded with computer vision can immediately identify whether workers are wearing the correct personal protective equipment before they even step into a shaft, for instance.

The contrast becomes particularly striking in underground mining environments. AI-based modules now run continuously to assess seismic activity, rock stress levels and ventilation data, identifying subtle warning signs of instability that would be missed during periodic inspections.

When a hazard such as a gas leak does occur, the system doesn’t just sound a generic alarm; it delivers context-rich insights – pinpointing the source, highlighting nearby personnel and recommending immediate mitigation steps, enabling EHS teams to respond with speed.

Beyond physical hazards, AI is also being applied to monitor behavioural risks that indirectly affect safety solutions.

For example, at the site of a major mining operator in Ghana, an AI-powered safety monitoring system was introduced to address increasing disputes among its workers, especially during the night shifts and meal breaks. Within the first three months of deployment, a 62% reduction in aggressive incidents, physical altercations and other workplace conflicts were observed. This resulted in a reduction in operational disruptions and increased productivity. While deemed to be non-traditional hazards, reducing tension and fatigue-related conflicts directly lowers the risk of accidents, improves site discipline and contributes to a safer overall working environment.

Global mining leaders turning to AI

This revolution brought about by AI in mining safety is not just theoretical – it is already underway. Mining giants across the globe are investing heavily in AI to safeguard workers and optimise operations.

For example, a leading iron ore mine site in Western Australia deployed autonomous haulage systems using sensors and machine learning to, among other things, help boost its accident prevention processes.

Similarly, at a mine site in Chile, the real-time monitoring provided by AI helped the operation save more than 3 gigalitres of water along with 118 gigawatt hours of energy since 2022. It also used sensor technology on operator hard hats to measure extreme levels of fatigue that could result in accidents.

These initiatives show that AI is not an experiment at the margins of mining operations; it is becoming embedded in the very safety culture of these operations. Each deployment hereby creates a feedback loop of improved compliance for EHS leaders to work on.

Safety, efficiency and sustainability intertwined

One of the most compelling aspects of AI-enhanced safety systems is their ability to extend far beyond accident prevention. When safety is at an advanced state, efficiency and sustainability follow. Predictive maintenance ensures equipment remains operational at the right times, reducing costly downtime and avoiding sudden failures that compromise both safety and productivity.

AI-driven optimisation of energy use in ventilation systems, for example, reduces emissions while maintaining a safe underground atmosphere.

For safety managers, the AI-driven insights are quite clear. They no longer hold the raw data but instead use data-backed risk heat maps, safety trends and predictive warnings. For the frontline workers, knowing that hazards are being continuously monitored by the AI cameras around instils confidence, which is itself a vital component of safety culture.

“What AI adds to mining is visibility,” Ng says. “Risks that once went unnoticed are now flagged in real time, giving both managers and workers the confidence to act before incidents escalate. This is how the industry can move closer to making zero-harm mining not just an ambition, but a measurable reality.”

Reimagining the safety fundamentals with AI

One misconception commonly seen in discussions around the use of AI in workplace safety is that it seeks to replace existing safety frameworks. The reality is, in fact, the opposite. Safety automation systems are not substitute for established protocols such as inspections, training and signage; they are amplifiers.

They free compliance officers from repetitive tasks, allowing them to focus on higher-level strategic improvements; they give supervisors visibility into risks in real time as they unfold, instead of waiting for after-action reports; and they provide workers with real-time feedback, improving on-the-spot behaviour and reinforcing training.

This represents a shift where safety ceases to be about simply checking the compliance box and becomes continuous, intelligence-driven protection. For the first time, the vision of zero-harm mining is not only aspirational; it is operationally feasible.

The road ahead for mining

The path forward for mining safety is clear. AI-powered intelligent safety systems will only grow more sophisticated, more predictive and more embedded into everyday workflows. In the near future, digital twins of mines will allow operators to simulate risk scenarios before they proceed with deployment in actual operations.

IoT wearables powered by AI can be integrated to monitor miner fatigue, detect exposure to toxins and warn workers of their proximity to hazardous machinery. Conversational AI working as co-pilots are becoming a part of every team, enabling EHS members to query live site data using natural language commands on their mobile devices.

For mining companies, the choice is not about whether they should embrace AI, but how quickly they can integrate it across sites and operations. Those who act decisively are not only protecting their workers but positioning themselves as leaders in an industry where safety, sustainability and competitiveness increasingly intersect.

A safer future within reach

It is quite evident that mining can never be categorised as a risk-free industry. But the advent of advanced safety technologies marks a turning point in how those risks are managed. It takes the leap from being answers to incident responses to creating a data-driven prevention plan, altering inspections into continuous monitoring, and by empowering operational leaders, safety executives and frontline workers alike.

The mining industry has historically been defined by its ability to overcome the toughest challenges, from digging deeper into the earth, working harder and innovating against the odds. Today, with AI at the heart of safety, it is redefining what it means to protect its people.