Employee was welding a piece of small metal plate to cover a hole in some ductwork. After tack welding the plate the employee raised welding hood up to adjust the welding rod. Employee then heard a noise and looked up and the metal plate broke off and fell striking the employee in left incisor tooth causing a chip.
MULCOA PLANT NO 2Metal/Nonmetal
- Fatalities
- 0
- Total incidents
- 59
- Years on record
- 2000–2024
- Latest incident
- Aug 2024
Reportable incidents
59 on file2024 · 1 incident
2023 · 1 incident
A maintenance supervisor was walking up the Kiln 4 upper product belt carrying a piece of chute to be installed and EE's right forearm contacted a piece of expanded metal which was in close proximity to the catwalk. This contact caused a laceration which required seven staples to close.
2019 · 1 incident
Employee was walking down a set of stairs carrying a box in one hand and a cup of coffee in the other. EE misjudged the last step causing ee to fall forward onto hands and knees. The fall caused a contusion to right knee.
2018 · 2 incidents
Two maintenance employees were engaged in horseplay involving a pocket knife. The injured employee attempted to grab the hand of the other employee but instead grabbed the blade of the knife causing a laceration the palm of EE's right hand.
Employee was assisting with the installation of a tail roller which required lifting and maneuvering the part in a tight small area. At the end of the shift the employee was experiencing some minor discomfort in lower back. As the evening progressed the pain increased. Employee was taken to the doctor and diagnosed with a minor lower back strain.
2017 · 1 incident
A maintenance technician was operating a Kubota utility vehicle on a wet slippery unpaved surface and then transition onto a paved roadway, lost control of the vehicle and then fell out striking the back of the head on the concrete. The employee sustained a 2 inch laceration to the back of the head.
2016 · 2 incidents
Employee was inspecting a v-belt and inadvertently got left little finger caught between the v-belt and pulley.
Employee assisting two other maintenance personnel install 14 V belts on Pug Mill Extruder drive. Employee maneuvered the belt into position while other personnel rotated the top sheave (pulley). Contract employee allowed hand to get caught in the bottom sheave during rotation. Caused a laceration to little finger. Employee taken to local physician and received 6 stitches.
2015 · 1 incident
Employee was cleaning out a coal chute when his right forearm contacted a small metal burr on the side of a railcar causing a laceration to his forearm.
2014 · 3 incidents
Worker was using a JLG450A Man lift while welding on a hopper. He failed to realize that the boom was in a reverse direction. He moved the lift in the wrong direction and was pinned. He had fractured ribs and vertebra.
Drop hopper fell off track, EE attempted to help operator get hopper back on track, he slipped on clay on the ground and fell backwards and as he caught himself with right hand, breaking middle finger.
While assisting in lifting a guard, employee felt pain in right calf muscle
2013 · 2 incidents
Employee was lifting and installing a bearing and later felt pain in his lower back.
Employee was changing out a Sweco screen when the ring finger on his left hand contacted the edge of the screen cutting through his cut resistant glove causing a laceration just above the knuckle.
2012 · 2 incidents
Employee was mixing mortar when whipper drill bit broke throwing him off balance into a nearby vertical I beam. When he collided with the I beam his middle finger got pinched between the handle of the whipper drill and the corner of the beam causing the injury.
Employee was repairing a tire for a skid steer loader using a pry bar when he felt a slight pain in his stomach. The employee did not report the injury until two days after it occurred and did not feel he needed medical attention. Two weeks after the injury he went to the doctor and was told he had an abdominal strain.
2010 · 1 incident
Employee opened a door to an electrical control room to access the control panel for a bucket elevator. After entering the room the employee rested his right hand on the door frame and the door closed on his right middle finger cutting the tip of the finger.
2009 · 3 incidents
Employee was using a metal rod to loosen material in a hopper when his right index finger struck the edge of an i-beam support causing a laceration on his knuckle.
Employee was tightening structure bolts with another employee using torque wrench. Injured employee was using a backup wrench. The employee using the torque wrench asked IE if he was ready & he said yes. The torque wrench began to tighten and the back up wrench mashed his thumb against steel.
Employee was at home when he felt something in his right eye, employee had been using a hand held grinder earlier that day at work and thinks a small piece of metal shaving got into his right eye at that time but did not notice until after he got home from work.
2008 · 4 incidents
Employee was walking between the Plant Two office and the Plant Three Mill building when he tripped over a culvert for a storm water drain and fell. The employee sustained a fracture to the right hip.
Employee was operating a small skid steer loader. While backing the unit, his elbow struck a support brace, jamming his right wrist into the steering handle. The injury caused some swelling of the right wrist.
EE was lifting a machine part using a mobile crane.EE placed left hand on the cable of crane to move the part away from I-beam,the glove he was wearing got caught in head pulley, pinching his finger between the pulley and the cable, causing a laceration and a break at the end joint of his pinky finger on the left hand.
Employee was lifting a 50 lb bag of material when he felt a pain in his right shoulder. Possible muscle strain in the right upper arm and shoulder.
2007 · 3 incidents
Employee tripped and fell over a pallet. While falling the employee extended his left arm out and fell on his his left hand and elbow. The fall caused a bruise along the medial side of his left elbow. Prognosis is good. The employee was returned to work without any restrictions.
Employee was assisting another employee in lifting a motorized trolley into place onto a monorail I-beam when he felt a pain in his left shoulder.
2006 · 7 incidents
Employee was climbing an elevator ladder and felt a strain in his neck and shoulder.
Miner states that he was placing a guard over the drive belt that had fallen off. His glove came in contact with the belt and the pulley, pulling his thumb into the belt.
Maintenance Tech was hammering a plate that was just welded. When he struck the plate, a piece of slag flew into his eye.
Employee was working on a piece of equipment in Plant 3 Kiln MCC. When he was tightening the motor leads he felt a sharp pain in the left side of his back. EE was taken to the local physician and was ordered physical therapy for strained back muscle.
Employee removed a bag from the bagging machine spout and strained his back when he turned to place the bag on a pallet.
Employee was cleaning stuck feed from the Plant 2-3 roller mill chute with a crowbar. Employee hit the side of the chute causing him to hit his hand with the crowbar.
The employee received a sprain to his left knee. A supersack of product was being moved off of a scale with a forklift when the material in the supersack shifted and pinned the employee's left leg between the full supersack and the scale. The employee was attempting to put another supersack on the machine loading spout as the forklift was moving the full sack off the scale.
2005 · 5 incidents
Walking and stepped up when knee pain began. During his Christmas vacation, EE sought medical treatment with his private physician. Notified us of this action on 12/30/05.--220060680011--orthoscopic surgery on 3/8/06 to access damage to ligaments and cartilage.
When picking up a boxed printer, EE felt a strain in her lower back. Reported injury, but did not seek medical attention until 10/03/05. Physician gave her samples of a prescription anti-inflamatory medication.
While replacing a fan motor, EE had to move the unit. When doing so, his left index finger was caught between the fan blade and fan housing resulting in a laceration
Employee directed a truck in the work area to move forward. When he turned to walk away he slipped on some material on the ground and fell, hurting his left knee and right wrist.
04/28 employee working on land leveler and got dirt in his ear. Ear washed out returned to work. On 04/29 ear still hurts, taken to doctor, small piece of dirt washed out of ear. 05/03 return to doctor, ear was infected so employee given medicine for infection. Resulting infection caused accident classification to be changed from first aid to medical.
2004 · 7 incidents
Employee was cleaning out tractor bucket with a shovel. When the employee swung the shovel at the build up with a left motion the employee lost his balance. Falling backwards his left hip and left buttocks landed on another removed chunk of clay causing the employee to have a severe buring sensation in that area.
Employee was picking up a pallet when he felt a pain in the right lower elbow to the forearem.
Advanced lung disease
Claim arose out of pre-surgery physical for back surgery.
Employee working as a kiln operator in the kiln control room complained of chest pains to his assistant. The local emergency medical services were contacted and put in route to the plant. The employee had a heart attack before the emergency medical services arrived and received CPR from other employees until the EMS unit arrived. The employee died as a result of the heart attack.
An experience contractor employee failed to recognize the fact that a belt, made of combustible rubber material, within an elevator housing would catch on fire while they were using a cutting torch to cut through said elevator housing. Burnt belt within elevator.
Miner raised shop overhead door 6"" with a fork truck to remove & repair a track roller. He didn't put a safety block under the door. To replace the roller, he sat on the floor & to reach the bottom corner of the door, he allowed his foot to go under the door. He bumped the door to push it into alignment causing it to fall on his right leg above the ankle. Cracked lower leg bones.
2003 · 4 incidents
THE EE WAS USING A PNEUMATIC JACKHAMMER TO BREAK UP PRODUCT STRUCK IN A HOPPER. THE EE HAD POOR BODY POSITION WHILE PERFORMING THE TASK RESULTING IN STRAIN TO THE LOWER BACK MUSCLES. THE EE CO MPLETED HIS SHIFT & RETURNED TO WORK THE FOLLOW-ING DAY & COMPLAINED OF PAIN. HE WAS AT THIS TIME TAKEN TO THE CO. DR. WHO PLACED HIM ON LIGHT DUTY.
EE ALLEDGES TO HAVE HIT A BUMP IN THE CLAY SHED AREA WHILE OPERATING A 980 G CAT FRONT-END-LOADER CAUSING AGGRAVATION TO HIS NECK AND LOWER BACKTHIS IS AN AGGRAVATION FROM A PREVIOUS INJURY EE LOST TIME ON JULY 31.
EMPLOYEE WAS ATTEMPTING TO CATCH A BAG THAT FELL OFF THE BAGGING SPOUT WHEN HIS HAND HIT THE SPOUT CAUSING A LACERATION ON THE RIGHT INDEX FINGER. EMPLOYEE RECEIVED 5 STITCHES.
EE WAS HEATING THE OUTSIDE OF A BALL MILL WITH A TORCH. THIS WAS TO LOOSEN THE GLUE ON THE INSIDE SO THE BRICK LINER COULD BE REMOVED. AT 3 A.M.THE NEXT MORNING, EE WENT TO THE MEDICAL CENTER COMPLAINING OF EYE PAIN. THE VAPORS FROM THE GLUE HAD AN ADVERSE AFFECT ON HIS EYES.
2002 · 2 incidents
EE WAS REMOVING BRICK FROM A KILN WHEN A BRICK FELL & STRUCK THE TOP OF HIS RIGHT FOOT (STRUCK FOOT WITH THE POINT OF THE BRICK). HIS FOOT WAS X-RAYED & NOT BROKEN BUT DEVELOPED A HEMATOMA ON THE TOP OF THE FOOT WHICH WAS EVENTUALLY CUT OUT REQUIRING 6 STITCHES. EMPLOYEE WAS WEARING STEEL TOED BOOTS.
EE WAS CLEARING A HOPPER WITH A 2"" BAR WHEN THE BAR SLIPPED AND MASHED HIS LEFT PINKY FINGER BETWEEN THE BAR AND THE HOPPER. RESULTED IN 2 STITCHES.
2001 · 2 incidents
EE WAS CHECKING FUEL PRESSURE ON A FORKLIFT WHEN HIS RIGHT HAND ENTERED THE FAN AREA OF THE MOTOR. THIS CAUSED 3 LACERATIONS TO THE HAND AND FINGER AREA RESULTING IN 12 STITICHES.
EE WAS MODIFYING ROTARY SCREENS ON A SPROUT VAUER WHEN HIS HARD HAT FELL OFF. HE DID NOT PUT IT BACK ON. A FEW MINUTES LATER, THE EE RAISED HIS HEAD AND STRUCK IT ON A IN-FEED CHUTE, CAUSING A LACERATION TO THE TOP OF THE HEAD. THIS RESULTED IN EIGHT STITCHES.
2000 · 5 incidents
EE WAS WALKING OFF A STOCKPILE WHEN HE LOST HIS BALANCE CAUSING HIM TO FALL LANDING ON HIS RT SHOULDER. THIS RESULTED IN 2 STIGHTLY FRACTURED RIBS. *EE WALKED ONTO A STOCKPILE TO RETRIEVE A SI GN. WHEN HE CAME TO THE BOTTOM HE FELL TO THE GROUND.
EMPLOYEE WAS ATTEMPTING TO OPEN AN ACTUATOR VALVE WHEN HSI WRENCH SLIPPED CAUSING HIS RIGHT HAND TO GET PINCHED BETWEEN THE VALVE AND A STANDING PIPE. THIS RESULTING IN 4 STITCHES TO THE PALM ON RIGHT HAND.
EMPLOYEE WAS REPAIRING THE LINER IN A BATCH MILLWHILE SITTING WITH HIS LEFT FOOT UNDER HIS BODY HE ATTEMPTED TO STAND UP VERY QUICKLY WHEN HE FELT A ""POP"" IN HIS LEFT KNEE. AFTER MRI HE WAS FOUND TO HAVE A TEAR IN HIS MEDIAL MENISCUS WHICH REQUIRED SURGERY.
EMPLOYEE WAS LIFTING A 2 HP MOTOR (APPROXIMATELY 40 LBS.) WHEN HE FELT PAIN IN HIS LOWER BACK.
EMPLOYEE WAS ATTEMPTING TO CLIMB ON A DOZER WHEN HIS FOOT SLIPPED, HE FELL AND LANDED ON HIS WRIST AND FOREARM.