Mining Incidents

Blue Rapids Mine and MillMetal/Nonmetal

Controlled by Koch Industries Inc
Blue Rapids, KS, Marshall County, KS · Active
MSHA Mine ID: 1400309
Fatalities
0
Total incidents
27
Years on record
2000–2025
Latest incident
Mar 2025
No fatalities recorded at this mine.

Reportable incidents

27 on file

2025 · 1 incident

Fall to the walkway or working surface

The equipment operators were helping with the continuous miner move in the last open cross-cut. The water and power cables that trail the miner were part of the move. The injured employee tripped and struck EE's rt. knee on the uneven ground. Soreness and swelling developed but EE managed to complete EE's shift. An exam occurred. No treatment or RX were required. 7 days off work.

2024 · 2 incidents

(Not Elsewhere Classified)

A recent audiologist report on 12/26/24 revealed a STS in a employees left ear. The sound level of the Rock handling is at dBA 78.4 or below. Potential recordable hearing shift; evaluation ongoing.

Over-exertion (Not Elsewhere Classified)

Employee was shoveling material when they stepped on a loose rock. Employee went to doctor and received prescription medication. Employee returned to work with no restrictions.

2022 · 1 incident

Accident type, without injuries

Smoke was observed exiting the mine prior to the start of the shift. No miners were underground. The light smoke indicated that it might be coming from the battery charging station. This was accurate. One battery was smoldering. Power was de-energized and the smoke stopped. Under MSHA direction a rescue team eliminated the hazard with baking soda.

2021 · 1 incident

Struck by... (Not Elsewhere Classified)

The EE was using a skid steer to carry materials through a curtain. The curtain was raised manually. As EE passed through the machine nicked the bottom of the curtain causing it to drop. The weighted PVC bar on the bottom of the curtain struck EE's safety glasses on the left side. The frame of the glasses caused a small laceration to EE's left eye lid. Five sutures were required.

2020 · 1 incident

Accident type, without injuries

A roof fall occurred on 10/22/2020 during the night time & no miners were in the mine at that time. This occurred at Panel #3 W at cross cut 38 F3 & 38 G3 in an area that had been mined. The area has been barricaded & a formal geotechnical engineering study of this area is bein conducted. It appears the fall occurred below the anchor zone of the 42"" fgr bolts.

2018 · 1 incident

Accident type, without injuries

We had a roof fall in the Blue Rapids mine that was discovered this morning, 2/7/2018, during routine inspections. The exact time of fall is unknown but the area was observed yesterday afternoon too and the fall had not occurred then. No injuries occurred.

2017 · 1 incident

Accident type, without injuries

A roof fall occurred in the underground mine at location of 33 and 2v, the fall blocks passage thru this area. Operators were approximately 1300ft away from the area of the fall when it occurred. No miners were injured.

2016 · 2 incidents

Over-exertion (Not Elsewhere Classified)

Employee notified supervisor that while stepping away from the continuous miner, stepped into a hole about 1-2 inches deep and jarred back resulting in restrictions of no bending or lifting.

Struck against stationary object

During routine scoop operations the right front corner of the bucket caught the rib, suddenly stopping the scoop. Causing the operator to strike EE's head on the door resulting in a laceration of the scalp. After seeing EE's own blood EE felt woozy, laid down and fainted for 30 seconds. Operator returned to work with no medical treatment. no damage to the equipment or the mine.

2015 · 3 incidents

Caught in, under or between (Not Elsewhere Classified)

During the task of bolting, the operator had to hold the head of the bolt to stabilize it while the bolt driver was being positioned. When the driver head contacted the bolt and was pushed into position the employee's left index finger became caught between the bolt head and the plate resulting in a laceration to the inside of the left index finger.

Fall to the walkway or working surface

Employee fell to same level ground when he came in contact with elevated extension cord.

Fall to the walkway or working surface

Employee fell to the same level ground when trailing cable from continuous miner came in contact with his feet/legs.

2014 · 1 incident

Over-exertion (Not Elsewhere Classified)

Employee reported that previously unreported shoulder discomfort that she was having for the past 8 months was work related. There was no event that EE could think of that resulted in the discomfort. Initial evaluation by the doctor on 7/14/14 confirmed work relatedneess dependant on MRI scheduled 7/24/14.

2012 · 1 incident

Struck against a moving object

A scoop that was cleaning the slope after a beltline was removed lost traction on the slope and slid approx 10' to the apex at the bottom and came to a sudden stop. This caused the operator inside to hit his head on the window frame in the cab resulting in 6 sutures.

2011 · 1 incident

(Not Elsewhere Classified)

Annual audiogram testing indicated the employee suffered hearing loss in the past year that may be related to work noise

2009 · 3 incidents

Caught in, under or between a moving and a stationary object

Mechanic was backing up a scooter and trailer when he ran over something that made his foot come off the side of the scooter. His foot then became pinned against a piece of equipment causing a puncture wound to the upper left ankle.

Struck by falling object

The roofman had finished drilling a hole to install a hanger and was attempting to install resin and the bolt when an approximately 75-100lb rock sprawled away form the rib and struck the roofman in the right shoulder.

Struck by flying object

Mechanic was replacing a broken block pin in a cutter block using a punch and 3 lb. hammer. Upon striking the punch with the hammer, a piece of pin that was being driven out broke away. This ""zinger"" struck the mechanic in the tooth and upper lip. A small corner was broken off the tooth.

2007 · 2 incidents

Struck against a moving object

While moving cutter from rib to rib the cutter blade is left ""sumped in"" and the body of the cutter is lifted off the ground and shifted to the other side. 3/4 of the way through the shift, the motor housing/outer cone attachment suffered a catastrophic failure dropping the machine approx. 8"" to the ground causing the operator to bump his head.

Fall to the walkway or working surface

Miner stepped off the man trip at the top of the mine slope, onto a mud clod, causing him to slip/lose his balance and drop to a ""3 point stance"". On 2-21-07, the miner reported soreness in his left wrist. X-rays were negative on 3-7-07. The doctor did not prescribe or restrict. On 5-1-07 a wrist brace and prescription anti-inflammatory were prescribed.

2006 · 1 incident

Caught in, under or between running or meshing objects

Two mine mechanics were attempting to replace 6 worn belts for our primary crusher. These belts drive the flywheel that power the jaw of our crusher. While attempting to place the 4th belt on, the injured miner had his hand caught between pulley and belt. He fractured his left middle finger. It was locked out.

2005 · 2 incidents

Over-exertion (Not Elsewhere Classified)

Prying on a rim when the whole rim let loose. Pushed off on the largest piece falling at me with my roof bar. Twisted to the left, fell over a piece of fly rock behind me. Twisted my back. The roof bar was wrenched from my right hand, caught my thumb and twisted my wrist.

Over-exertion (Not Elsewhere Classified)

Employee noticed pain in his right hand from running the controls on our undercutters. He requested to see a doctor and was given a brace. We changed the controls to make them more ergonomic friendly. One week later he states he is fine. He asked to see a doctor on 2/7/06, went 2/14/06.

2003 · 2 incidents

Fall to the walkway or working surface

MINER WAS PREPARING TO SERVICE HIS UNDERCUTTER. HE REMOVED HIMSELF FROM HIS CAB AND WALKED ABOUT 5 STEPS BEHIND HIS CUTTER. HE STEPPED ON A ROCK, THIS CAUSED HIM TO LOSE HIS BALANCE. HE TRIED TO CATCH HIMSELF WITH HIS LEFT ARM. THE WEIGHT OF HIS BODY CAUSED A STRAIN ON HIS LEFT SHOULDER.

Over-exertion (Not Elsewhere Classified)

INJURED WAS OPERATING BOBCAT AND WHEN HE DISMOUNTED FROM THE MACHINE HE STEPPED ON A ROCK, TWISTING HIS RIGHT ANKLE.

2000 · 1 incident

Caught in, under or between a moving and a stationary object

INJURED WAS INTERUPTED BY ANOTHER PERSON, HE STEPPED FORWARD TO ASK WHAT DID HE SAY WHEN THE TAIL JACK WAS COMING DOWN HE AHD PUT HIS RIGHT FOOT UNDER THE JACK AT THAT POINT, THE STEEL TOED SH OES SAVEDHIS TOES FROM BEING CRUSHED, INJURED HAD SMALL FRACTURE TIP OF BIG TOE AND STITCHES.