Rear-end collision involving two haul trucks on a haul road.
Freeport-McMoRan Morenci Inc.: 16 recorded fatalities operator
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Email me when a new MSHA incident is filed at any Freeport-McMoRan Morenci Inc. mine.
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This rate is recorded citations divided by MSHA inspection hours, per 100 hours. It reflects inspection effort, not mine size or production.ⓘ
Differences between proposed and paid penalties reflect both settlements and conference reductions and amounts still owed. Outstanding is the balance currently owed.ⓘ
Shares are computed over citations that carry the MSHA gravity and negligence coding; a small share of records are uncoded.ⓘ
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.| Year | total case rate | days-away | fatal |
|---|---|---|---|
| 2026 | 3.25 | 1.12 | 0.049 |
| 2025 | 2.31 | 0.78 | 0.000 |
| 2024 | 3.33 | 0.96 | 0.000 |
| 2023 | 3.98 | 1.01 | 0.000 |
| 2022 | 3.98 | 1.07 | 0.000 |
| 2021 | 3.35 | 1.11 | 0.000 |
| 2020 | 2.91 | 0.63 | 0.000 |
| 2019 | 3.07 | 0.81 | 0.000 |
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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.Metal and nonmetal contaminants (personal samples)
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Many samples are screening measurements of substances with no applicable exposure limit; they are counted as samples but excluded from every over-limit figure. Over-limit shares use only limit-tested samples.
Last sampled: 2026-07-27
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Many samples are screening measurements of substances with no applicable exposure limit; they are counted as samples but excluded from every over-limit figure. Over-limit shares use only limit-tested samples.- Quartz, respirable, >1% Qtz16462 over
- Respirable dust, <.1mg46
- Arsenic fumes32
- Beryllium fumes32
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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.- Settled 621 · 74%
- Stood as issued 212 · 25%
- Vacated or withdrawn 8 · 1%
- Still open 2 · 0%
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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.ⓘ
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.| Docket | Decision | Judge | Year | Proposed / upheld |
|---|---|---|---|---|
| WEST 2019-0281 | Settlement | Miller | 2019 | $120K → $78K |
| WEST 2025-0356 | Settlement | Simonton | 2026 | $104K → $20K |
| WEST 2014-120M | Settlement | Moran | 2015 | $102K → $65K |
| WEST 2009-155M | Settlement | Melick | 2010 | $95K → $66K |
| WEST 2018-0076 | Settlement | Miller | 2018 | $91K → $63K |
| WEST 2016-0113 | Default | Lesnick | 2016 | $90K → $90K |
Top causes
- POWERED HAULAGE 7 fatalities · 477 non-fatal
- OTHER 3 fatalities · 151 non-fatal
- SLIP OR FALL OF PERSON 2 fatalities · 864 non-fatal
- ELECTRICAL 2 fatalities · 19 non-fatal
- HANDLING OF MATERIALS 1 fatality · 1564 non-fatal
- MACHINERY 1 fatality · 526 non-fatal
Incident timeline
Mines on record
Fatalities under this operator
16 recordedOur mixer driver was hauling for Freeport McMoRan at their Morenci mine location, the load was rejected and sent back, driver followed the escort down a hill with a full load, lost brakes and turned the mixer on its driver's side.
Weld crew initiated an argon purge on a 30" pipe that had been fit up afternoon prior. When argon purge was established, two welders began to make their root pass welds. Upon inspection "sugaring" was observed. a welder entered the open end of the 30" pipe for unknown reasons where they were found by a coworker to be unresponsive. No witnesses observed them enter the pipe.
The victim had been instructing persons making a belt splice. He fell through a 4 foot by 6 foot opening 28 feet to the floor below.
EMPLOYEE ALLEGEDLY SUSTAINED A SPONTANEOUS FRACTURE OF THE LEFT ANKLE WALKING ON A CONVERYOR BELT WALKWAY.
WHILE OPERATING A CHEVY PICKUP TRUCK, EE, A ROAD MACHINERY CO. EE, MOVED IN FRONT OF A PARKED 320 TON KOMATSU HAUL TRUCK. THE HAUL TRUCK, OPERATED BY A PHELPS DODGE EE PROCEEDED FORWARD, THE P ICKUP TRUCK WAS DESTROYED AND EE WAS FATALLY INJURED. EE WAS TRAINED HOW TO PROPERLY APPROACH A HAUL TRUCK AND WHERE BLIND SPOTS EXISTED IN AN OPERATOR'S FIELD OF VISION.
THE EMPLOYEE WAS GOING TO SHUT OFF A VALVE IN THE 4 WEST TAILINGS DAM. HE WAS FOUND RECLINING BESIDE THE VALVE.
AN AA TRUCK DRIVER POWERED BACKWARDS THROUGH A WELL ESTABLISHED BERM AT AN ANGLE. THE TRUCK OVERTURNED CAUSING FATAL INJURIES TO THE EMPLOYEE.
EE WAS WORKING IN THE SOUTH SIDE SX/EW SUBSTATION TRACING LOW VOLTAGE WIRING WHEN AN ELECTRICAL FLASH OCCURRED FROM ANOTHER AREA.
HE WAS DRIVING THE #28 HYDRAULIC CRANE IN LOW GEAR DOWN A MINE ROAD WITH THE BOOM IN AN ELEVATED POSITION CREATING A HIGHER CENTER OF GRAVITY, WHEN THE CRANE STARTED TO TIP. HE EXITED THE CAB AND THE CRANE LAID OVER ON TOP OF HIM.
A "AA" TRUCK DRIVER, AFTER INITIALLY STRIKING A WELL ESTABLISHED BERM WHILE BACKING, THEN PULLED FORWARD APPROX. 25'. UPON HIS SECOND ATTEMPT IN BACKING, AT A SPEED GREATER THAN NORMAL, HE WEN T THROUGH SAID BERM, DOWN THE DUMP, RESUTLING IN FATAL INJURY.
THE EMPLOYEE WAS FATALLY INJURED WHEN HE CAME IN CONTACT WITH A 4160 V FUSE IN THE #19 SWITCH HOUSE WITHIN THE MORENCI MINE.
UNLOADING PIPE FROM TRUCK. TRYING TO LEVERAGE LENGTH OF PIPE OFF THE TRAILER ONTO THE FORKLIFT. ALMOST HAD PIPE ON FORKLIFT WHEN IT BEGAN TO ROLL BACK TO DECEASED.
EMPLOYEE WAS RETURNING TO WORK STATION JUST AFTER LUNCH CLIMBING STRUCTURAL STEEL TO GET THERE WHEN HIS FEET SLIPPED CAUSING HIM TO LOOSEN HIS GRIP AND FELL
WHILE EMPLOYEE 4AS BACKING INTO A DUMP SITE HIS TRUCK OVERTURNED ON A 50' BENCH WITH HIM INSIDE
EMPLOYEE WAS OPERATING THE 52 LOCOMOTIVE AND HAD LEFT THE 23 SHOVEL LOCATED AT 4600 AMERICAN MOUNTA. THE TRAIN WAS LOADED WITH WASTE AND EVENTUALLY WORKED HIS WAY TO THE 4500 DISPATCH HILL WHI CH IS THE MAIN LINE. WHILE ON THIS TRCK THE CABOOSE DERAILED AND TRAVELED APPROX. 9 CAR LENGTHS. THE EMPLOYEE EITHER ATTEMPTED TO JUMP, OR WAS THROWN OFF THE CABOOSE. THE EMPLOYEE WAS FOUND B
Where Freeport-McMoRan Morenci Inc. stands on silica, penalties, and injury rate
MSHA's standard limits respirable silica to 50 micrograms per cubic metre, but MSHA publishes dust and quartz as separate files and never the silica figure itself. We derive it per sample, score it against the limit, and set the operator's injury rate against a benchmark built from the full MSHA operator record. With the 26-year penalty trail, contest posture, and fatality history. Delivered as a PDF with the underlying data as CSV.
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