Mining Incidents

Mine #5: 499 MSHA citations Coal

Controlled by Ferroglobe PLC
Barbourville, Knox County, KY  ·  Abandoned and Sealed
MSHA Mine ID: 1518426

Mine #5 has $97K in proposed MSHA penalties and $698 outstanding across 14 contested dockets, plus health sampling and the full incident record.

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Fatalities
0
Total incidents
9
Years on record
2007–2024
Latest incident
Jan 2024
Compliance record
MSHA citations since 2002
499
citations
115
significant & substantial
$97,315
proposed penalties
$92,615
paid to date
95% of proposed penalties paid to date, a $4,700 gap.
Source: MSHA violations data, updated weekly.
Inspection activity
MSHA inspections since 2002
118
inspections on record
8,545
inspection hours
5.8
citations per 100 inspection hours
This rate is recorded citations divided by MSHA inspection hours, per 100 hours. It reflects inspection effort, not mine size or production.
499 citations across 8,545 inspection hours.
Source: MSHA inspections data, updated weekly.

Mine #5 has $97K in proposed MSHA penalties and $698 outstanding across 14 contested dockets.

Penalty disposition
Differences between proposed and paid penalties reflect both settlements and conference reductions and amounts still owed. Outstanding is the balance currently owed.
$97K
proposed penalties
$93K
current assessed
$93K
paid to date
$698
outstanding
490 assessments are final orders; 14 contested dockets.
Of $20K in penalties contested before the Commission, $16K was upheld in final decisions.
As of the most recent assessment on 2024-07-30.
Source: MSHA assessed-violations and conference/litigation data, updated weekly.
Violation severity profile
Shares are computed over citations that carry the MSHA gravity and negligence coding; a small share of records are uncoded.
23.5%
significant & substantial
2.0%
high negligence or reckless
23.7%
reasonably likely or greater
6.7%
permanently disabling or fatal if injury occurs
Negligence coding: 0.4% none, 3.5% low, 94.1% moderate, 2.0% high, 0.0% reckless.
Source: MSHA violations gravity and negligence coding, updated weekly.
When citations were contested
Contesting a citation before the Federal Mine Safety and Health Review Commission is a lawful right. These figures state the public outcomes of that process, from MSHA's Contested Violations file.
48 citations taken to the federal commission · 10% of citations on record
  • Settled 44 · 92%
  • Stood as issued 4 · 8%
81%
S&S designation survived the contest
Counts a Significant & Substantial citation as surviving when a settlement or judge's decision kept the designation, or the contest was dismissed or defaulted so the citation stands as issued. Vacated and withdrawn citations, and settlements that removed the designation, count against.
of 27 decided S&S contests · industry: 79%
20%
Penalty reduction in decided contests
$20K proposed, $16K after decisions · industry: 39%
Source: MSHA Contested Violations file (public record), updated weekly. A dismissed or defaulted contest leaves the citation standing as issued; a vacated or withdrawn citation is removed from the violation record. Latest contest filed 2024-06-30.
Contested penalties
A reduction or dismissal at the Commission is a lawful outcome of contesting a proposed penalty. Figures are the proposed amount and the amount upheld in the docket's decision.
Largest penalties this mine contested before the Federal Mine Safety and Health Review Commission, with the outcome on record.
Docket Decision Judge Year Proposed / upheld
KENT 2024-0087 Default 2024 $3K → $3K
KENT 2018-0325 Settlement Bulluck 2018 $3K → $2K
KENT 2020-0081 Settlement Bulluck 2020 $2K → $586
KENT 2024-0136 Settlement Paez 2025 $2K → $2K
KENT 2023-0035 Default 2023 $2K → $2K
KENT 2023-0043 Default 2023 $2K → $2K
Source: FMSHRC civil penalty dockets and decisions (public record), updated weekly.

MSHA sampling at Mine #5 shows 99% of 2,204 respirable coal dust samples met the 1.5 mg/m3 standard.

Health sampling
A sample is a point in time compliance measurement, not an individual exposure history. These figures describe MSHA sampling records and do not establish causation or personal dose.

Respirable coal dust
Respirable coal dust and silica figures cover coal facilities. Dust compliance is measured against the current 1.5 mg/m3 standard; samples predating the 2014 standard are included, so compliance rates are a coarse historical signal.

Last sampled: 2024-10-07
99%
within 1.5 mg/m3
2,204
samples
2.95
dust max (mg/m3)
12
over MSHA ECV
The excessive concentration value (ECV) is MSHA's own per-sample enforcement threshold, which builds in measurement uncertainty; a sample over its ECV can trigger a citation. The count covers only samples MSHA assigned an ECV.
332 samples taken by MSHA inspectors, 1,872 by the operator.
Most-sampled occupations
  • CONTINUOUS MINER OPERATOR642
  • MOBILE BRIDGE OPERATOR529
  • ROOF BOLTER (TWIN HEAD) (RETURN SIDE)366

Silica (quartz)

Last sampled: 2024-04-16
6.3
silica avg (%)
132
samples
13.5
silica max (%)
Most-sampled occupations
  • CONTINUOUS MINER OPERATOR38
  • MOBILE BRIDGE OPERATOR31
  • ROOF BOLTER (TWIN HEAD) (RETURN SIDE)26

Noise
The share counts noise samples whose measured dose exceeded the 90 dBA permissible exposure limit. It describes the sampled workplace, not what reached the miner's ear: hearing conservation programs and the hearing protection worn during the shift are recorded separately and are not reflected here.

Last sampled: 2024-10-07
5%
over PEL
203
samples
Most-sampled occupations
  • CONTINUOUS MINER OPERATOR43
  • SCOOP CAR OPERATOR28
  • MOBILE BRIDGE OPERATOR25
Source: MSHA respirable dust, quartz, and noise sampling records, updated weekly.
Health sampling trend
A sample is a point in time compliance measurement, not an individual exposure history. These figures describe MSHA sampling records and do not establish causation or personal dose.
Respirable coal dust by year
Respirable coal dust and silica figures cover coal facilities. Dust compliance is measured against the current 1.5 mg/m3 standard; samples predating the 2014 standard are included, so compliance rates are a coarse historical signal.
Year within 1.5 mg/m3 samples
2024 100% 115
2023 100% 221
2022 99% 302
2021 100% 482
2020 99% 536
2019 98% 273
2018 99% 211
2017 100% 14
2015 100% 33
2014 100% 9
2007 100% 8
Silica (quartz) by year
Year silica avg (%) samples
2024 4.9 8
2023 7.5 8
2022 6.9 22
2021 5.3 27
2020 7.1 24
2019 6.1 19
2018 6.3 18
2017 8.9 2
2015 4.6 3
2007 4.6 1
Noise by year
Year over PEL samples
2024 14% 14
2023 0% 23
2022 3% 34
2021 7% 42
2020 6% 34
2019 0% 20
2018 0% 24
2017 0% 5
2015 0% 2
2014 40% 5
Source: MSHA respirable dust, quartz, and noise sampling records, updated weekly.

Mine #5 recorded 3.30 reportable injury cases per 100 full-time workers in 2023.

Injury rate, 2023
This rate is reportable injury cases per 100 full-time-equivalent workers per year, computed as 200,000 times cases divided by MSHA operator-reported employee-hours. Cases are injuries MSHA graded degree 01 through 07; accident-only events that hurt no one are excluded, and so are contractor injuries, whose hours do not attach to a single mine. Rates begin in 2000, when quarterly employment reporting starts, and are withheld below 20,000 hours in a year.
3.30
total case rate
0.00
days-away rate
0.000
fatality rate
About average. The US coal mining average was 3.17 and the all-US-mining average was 2.10 cases per 100 workers.
In Kentucky, coal mining averaged 4.32 cases per 100 workers that year.
Under 100,000 employee-hours were reported that year, so a single case moves the rate by two or more. Read the figure as approximate.
Year total case rate days-away fatal
2023 * 3.30 0.00 0.000
2022 * 3.13 0.00 0.000
2021 * 3.07 3.07 0.000
2020 * 3.60 3.60 0.000
2019 * 0.00 0.00 0.000
2018 * 7.14 3.57 0.000
2015 * 9.06 0.00 0.000
* Fewer than 100,000 employee-hours that year; the rate is less stable.
Source: injury cases from MSHA accident and injury records; employee-hours from MSHA quarterly employment reports. Rate is cases per 100 full-time-equivalent workers, operator employees only.
Ownership history
  1. Goodin Creek Contracting Inc 2001 to 2002
  2. PC Contracting Inc 2002 to 2003
  3. Blue Gem Mining Company, Inc. 2003 to 2006
  4. Goodin Creek Mining Company Inc 2006 to 2007
  5. Alden Resources LLC 2007 to 2014
  6. Knox Operating LLC. 2014 to 2015
  7. Ferroglobe USA Mining, LLC 2016 to present
Source: MSHA controller and operator history, updated weekly.
Workforce and production
Coal production is reported quarterly and lags the current period; the most recent quarters may be incomplete.
Year Employees Coal produced (tons)
2024 15 10,971
2023 19 27,146
2022 22 49,716
2021 23 71,174
2020 26 43,759
2019 21 78,370
2018 22 58,966
2017 12 4,575
2015 12 27,308
2014 3 170
2008 0
2007 9 2,315
2006 3 281
2003 1 391
2002 5 1,488
Source: MSHA quarterly employment and production, updated weekly.

Mine #5 sits in Knox County, Kentucky, where the Census mining category is 2.8% of county employment.

Local economic context
County figures come from the US Census Bureau's American Community Survey, 5-year pooled estimates, so the 2023 vintage covers 2019 through 2023. The Census category is 'mining, quarrying, and oil and gas extraction', which is broader than MSHA jurisdiction and includes oil and gas workers no mine employs. These figures describe the surrounding county, not this mine, and are not a factor in any specific incident.
Knox County, Kentucky · Population 30,034
2.8%
Mining share of county employment
$33,153
Median household income
Source: US Census Bureau, American Community Survey 2023 5-year estimates.
Quarterly safety rates
Citations per million reported employee-hours. Rates begin in 2000, when MSHA's quarterly employment data starts; earlier incidents are counted but cannot be rate-adjusted. Quarters under 100,000 reported hours are greyed: too few hours for a stable rate.
Citations per million employee-hours, as reported to MSHA
Quarter Hours worked Citations S&S Per 1M hrs
2024 Q3 9,962 22 3 2208.4
2024 Q2 12,933 24 4 1855.7
2024 Q1 15,033 25 1 1663.0
2023 Q4 14,036 19 7 1353.7
2023 Q3 16,367 10 3 611.0
2023 Q2 15,781 8 2 506.9
2023 Q1 14,348 17 4 1184.8
2022 Q4 5,100 19 11 3725.5
Show 37 earlier quarters
Quarter Hours worked Citations S&S Per 1M hrs
2022 Q3 17,982 14 2 778.6
2022 Q2 21,876 16 0 731.4
2022 Q1 18,981 14 6 737.6
2021 Q4 18,856 4 0 212.1
2021 Q3 14,754 8 2 542.2
2021 Q2 17,401 17 1 977.0
2021 Q1 14,048 12 4 854.2
2020 Q4 14,850 28 14 1885.5
2020 Q3 13,825 9 1 651.0
2020 Q2 14,419 25 6 1733.8
2020 Q1 12,449 18 3 1445.9
2019 Q4 12,041 17 3 1411.8
2019 Q3 13,046 16 3 1226.4
2019 Q2 12,570 15 4 1193.3
2019 Q1 11,463 12 3 1046.8
2018 Q4 12,203 9 3 737.5
2018 Q3 15,604 10 3 640.9
2018 Q2 15,241 32 7 2099.6
2018 Q1 12,998 5 2 384.7
2017 Q4 8,057 13 0 1613.5
2017 Q3 1,000 0 0 0.0
2015 Q4 1,424 0 0 0.0
2015 Q3 4,750 3 1 631.6
2015 Q2 9,719 9 2 926.0
2015 Q1 6,184 5 0 808.5
2014 Q4 555 4 0 7207.2
2014 Q3 259 4 1 15444.0
2008 Q1 0 1 0
2007 Q4 2,633 0 0 0.0
2007 Q3 6,189 14 2 2262.1
2007 Q2 960 0 0 0.0
2007 Q1 1,166 0 0 0.0
2006 Q4 1,608 0 0 0.0
2006 Q3 0 2 0
2003 Q2 0 0 0
2003 Q1 119 1 0 8403.4
2002 Q4 1,205 6 3 4979.3
No fatalities recorded at this mine.

Reportable incidents

9 on file

2024 · 1 incident

January 16, 2024 KY · Coal mine manager, mine foreman, mine owner HANDTOOLS (NONPOWERED)
Ferroglobe USA Mining, LLC · Struck by... (Not Elsewhere Classified)

The mine foreman was assisting in getting the belt drive in the pit unclogged. The belt had somehow become tangled in the drive rollers. They were trying to pull slack in the top belt when the hook failed on the chain hoist (come-a-long). The hoist struck the foreman in the shoulder and the side of the head. EE had a cut that had to have staples and perforated ear drum.

2023 · 1 incident

February 10, 2023 KY · Coal electrician, lineman HANDTOOLS (NONPOWERED)
Ferroglobe USA Mining, LLC · Struck by... (Not Elsewhere Classified)

Employee was using a chain hoist to pull (align) the "low-low" belt structure when the chain hoist broke loose from the anchor point and struck EE in the side of the head.

2022 · 1 incident

May 3, 2022 KY · Coal master mechanic, foreman, supervisor OTHER
Ferroglobe USA Mining, LLC · Bodily reaction, (Not Elsewhere Classified)

Employee was on their knees marking centerline and when they got up to a "duck walking" position, their knee "popped" causing some pain. The knee has bothered them intermittently since, so they went to a specialist and had surgery on 9-26-2022. Employee returned to work the next day and is now on restricted work duty on the surface.

2021 · 1 incident

August 30, 2021 KY · Coal section foreman, bullgang foreman, labor foreman, leadman, shift boss POWERED HAULAGE
Ferroglobe USA Mining, LLC · Struck against stationary object

Employee (foreman) was on a personnel carrier while by self. EE said EE backed up and struck EE's head on a brow causing a sore neck. EE finished the shift and didn't want medical attention. EE didn't go to the doctor until weeks after the accident.

2020 · 1 incident

September 30, 2020 KY · Coal maintenance man, mechanic, repair/serviceman, boilermaker, fueler, tire tech, field service tech HANDLING OF MATERIALS
Ferroglobe USA Mining, LLC · Over-exertion in lifting objects

Employee putting a guard back on the tail piece when EE felt a sharp pain in EE's back.

2018 · 2 incidents

December 4, 2018 KY · Coal belt foreman, maintenance foreman, maintenance supervisor HANDTOOLS (NONPOWERED)
Ferroglobe USA Mining, LLC · Struck by flying object

Employee was tightening the conveyor chain on the MBC, and the grease fitting on the jack blew out, striking EE's left hand.

August 7, 2018 KY · Coal roof bolter, rock bolter, pinner, mobile roof support operator (mrs) HANDLING OF MATERIALS
Ferroglobe USA Mining, LLC · Struck by falling object

Bolt steel got hung in top and EE tried to get it out and slipped and hit EE's chest on the drill pot. The bolt steel fell out striking EE's pinky finger.

2015 · 1 incident

May 14, 2015 KY · Coal continuous miner operator, coal mole operator MACHINERY
Knox Operating LLC. · Struck by powered moving object

Working on foot shaft on Joy 14-9 continuous miner. Had scoop hook to change pulling it and got hit with claw in the back and rib on left side of body.

2007 · 1 incident

July 25, 2007 KY · Coal roof bolter, rock bolter, pinner, mobile roof support operator (mrs) DISORDERS (REPEATED TRAUMA)
Alden Resources LLC · Rubbed or abraded

Right Knee of employee swollen up due to Crawling in low coal.