Business Interruption Drives 80% of Mining Losses as Industry Faces Volatile, Under-Recovered Claims

Operational incidents — not natural catastrophes — account for roughly three-quarters of total mining losses, with recovery ratios averaging just 50%, according to Marsh.
By: | May 21, 2026
Idle mining equipment concept

The mining industry faces a loss landscape dominated by operational failures and compounded by business interruption costs that dwarf physical damage, according to a report from Marsh.

The analysis of significant insured loss events recorded between 2006 and 2025 found that business interruption represents approximately 80% of total gross losses in the sector, with fires, explosions, machinery breakdowns and geotechnical failures accounting for around 70% of total gross claim value, or roughly $10.3 billion out of $15.3 billion in recorded losses, the report said.

The findings underscore the financial vulnerability of mining operations, where a single equipment failure or structural collapse can halt production for months, and where insurance recovery ratios lag behind other industries, according to the report.

Operational Failures Outweigh Natural Catastrophes

Fire and explosion events account for almost one-third of all claims in Marsh’s dataset, with an average claim size of $115 million per event, the report found. Machinery breakdowns — particularly failures of single large mills or crushers — represent the next most frequent and severe operational loss category.

James Fryer, chairman of the Mining Insurance & Risk Association, noted in the report that “many sectors may be characterized by having one or two principal exposure types be it fire, explosion, or machinery breakdown — but mining has them all.” Fryer also observed that the industry trend toward single giant processing units has reduced redundancy, meaning one failed mill can trigger multi-month outages.

Patrick Walker, global head of group risk finance at Rio Tinto, warned that dependence on complex, interconnected equipment “amplifies the impact of single-point failures.”

Geotechnical and structural events, though less frequent, produce the sector’s largest individual losses, according to the report. The 2015 Fundão tailings dam collapse and the 2019 Brumadinho dam disaster in Brazil illustrate the potential scale, with the latter prompting a settlement exceeding $7 billion with Brazilian authorities.

Natural catastrophe events accounted for over a quarter of gross claims, with flooding driving 69% of that category’s losses, the report said. The data also revealed an increasing frequency of natural catastrophe events affecting mining operations, a trend expected to intensify as climate change drives more extreme rainfall and storm activity.

The Recovery Gap

Mining companies recover a notably smaller share of their losses through insurance compared with other industries. Average recovery ratios hover around 50% — typically between 45% and 55% — according to the report. By comparison, sectors such as renewable energy report recovery ratios of approximately 75%.

Several factors contribute to this gap. Mining policies often carry waiting periods lasting several weeks before coverage begins, and sub-limits cap indemnity for specific hazards such as natural catastrophes, tailings events and underground losses, the report said. Calculating business interruption losses is also inherently complex in mining because production may continue at reduced capacity using stockpiles, and commodity price volatility further complicates valuations.

Lars Gono, global head of mining at Swiss Re, highlighted in the report that there has been a “substantial increase in the business interruption component of claims, driven by a range of factors,” including commodity price volatility. When a loss occurs during a period of elevated metal prices, every lost ton of production translates into disproportionately higher revenue loss — even if the physical damage is limited.

Replacement parts for large mills, crushers or conveyors can take months to source, and MIRA’s Fryer recounted cases where the lack of a spare mill motor forced an operation to wait more than a year for a replacement, far exceeding policy sub-limits.

Building Resilience Through Maintenance, Redundancy and Risk Transfer

The report recommends that mining companies implement layered maintenance strategies combining preventative, predictive and proactive approaches, and maintain structured critical spare parts programs to reduce extended downtime. Flood controls, drainage investments and scenario planning for extreme weather were also cited as essential measures.

On the insurance front, the report said enhanced program design — including captive utilization, parametric solutions tied to weather indices, and structured reinsurance — can help close protection gaps where traditional policies fall short.

Obtain the report here. &

The R&I Editorial Team can be reached at [email protected].

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