Mining Incidents

Freeport-McMoRan Morenci Inc.: 16 recorded fatalities operator

Controlled by Freeport-McMoRan Inc
MSHA operator ID: L12058

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Fatalities
16
Total incidents
4,479
Mines on record
1
Years on record
1983–2026
Compliance record
MSHA citations since 2000
5,016
citations
910
significant & substantial
$5,068,266
proposed penalties
$4,130,739
paid to date
82% of proposed penalties paid to date, a $937,527 gap.
Source: MSHA violations data, updated weekly.
Inspection activity
MSHA inspections since 2000
466
inspections on record
51,312
inspection hours
9.8
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.
5,016 citations across 51,312 inspection hours.
Source: MSHA inspections data, updated weekly.
Penalty disposition
Differences between proposed and paid penalties reflect both settlements and conference reductions and amounts still owed. Outstanding is the balance currently owed.
$5.1M
proposed penalties
$4.3M
current assessed
$4.1M
paid to date
$153K
outstanding
4,792 assessments are final orders; 80 contested dockets.
Of $2.3M in penalties contested before the Commission, $1.4M was upheld in final decisions.
As of the most recent assessment on 2026-04-28.
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.
18.3%
significant & substantial
4.5%
high negligence or reckless
18.4%
reasonably likely or greater
37.9%
permanently disabling or fatal if injury occurs
Negligence coding: 0.0% none, 7.0% low, 88.6% moderate, 4.5% high, 0.0% reckless.
Source: MSHA violations gravity and negligence coding, updated weekly.
Injury rate, 2025
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.
2.31
total case rate
0.78
days-away rate
0.000
fatality rate
Above average. The US metal and nonmetal mining average was 1.65 and the all-US-mining average was 1.97 cases per 100 workers.
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
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.
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.

Metal and nonmetal contaminants (personal samples)
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
26%
of limit-tested samples over the exposure limit
295
samples
238
limit-tested
Most sampled contaminants
  • Quartz, respirable, >1% Qtz16462 over
  • Respirable dust, <.1mg46
  • Arsenic fumes32
  • Beryllium fumes32
Source: MSHA respirable dust, quartz, and noise sampling records, updated weekly. Metal/nonmetal contaminant figures come from MSHA's Personal Health Samples and Area Samples files (public record), 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.
843 citations taken to the federal commission · 17% of citations on record
  • Settled 621 · 74%
  • Stood as issued 212 · 25%
  • Vacated or withdrawn 8 · 1%
  • Still open 2 · 0%
65%
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 409 decided S&S contests · industry: 79%
36%
Penalty reduction in decided contests
$2.2M proposed, $1.4M 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 2026-05-20. Vacated and withdrawn citations are removed from the file this view attributes through, so that outcome is slightly undercounted here.
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 operator contested before the Federal Mine Safety and Health Review Commission, with the outcome on record.
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
Source: FMSHRC civil penalty dockets and decisions (public record), updated weekly.

Top causes

Incident timeline

2026
81 (1f)
2025
131
2024
164
2023
190
2022
181 (1f)
2021
151 (1f)
2020
122
2019
145
2018
106
2017
78
2016
72
2015
91
2014
102
2013
114
2012
57
2011
50
2010
54
2009
45
2008
216 (1f)
2007
199
2006
159
2005
74
2004
59
2003
70
2002
55 (1f)
2001
45
2000
104
1999
101 (1f)
1998
154 (1f)
1997
182
1996
74 (1f)
1995
79 (1f)
1994
80
1993
58
1992
68
1991
102 (3f)
1990
114
1989
94 (1f)
1988
95 (1f)
1987
91 (1f)
1986
58
1985
74
1984
71 (1f)
1983
69

Mines on record

Fatalities under this operator

16 recorded
July 6, 2026 AZ · Metal/Non-Metal haul/off road/coal/ore/pit/quarry/rock/rubber tire truck driver, transportation truck driver Fatality · POWERED HAULAGE
Freeport-McMoRan Morenci Inc. · Struck against a moving object

Rear-end collision involving two haul trucks on a haul road.

January 28, 2022 AZ · Metal/Non-Metal haul/off road/coal/ore/pit/quarry/rock/rubber tire truck driver, transportation truck driver Fatality · POWERED HAULAGE
Freeport-McMoRan Morenci Inc. · Struck against a moving object

Our 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.

September 15, 2021 AZ · Metal/Non-Metal welder (non-shop) Fatality · OTHER
Freeport-McMoRan Morenci Inc. · Unclassified, insufficient data

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.

September 1, 2008 AZ · Metal/Non-Metal warehouseman, bagger, palletizer/stacker, store keeper, packager, fabricator, cleaning plant operator Fatality · SLIP OR FALL OF PERSON
Freeport-McMoRan Morenci Inc. · Fall to lower level, (Not Elsewhere Classified)

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.

December 20, 2002 AZ · Metal/Non-Metal warehouseman, bagger, palletizer/stacker, store keeper, packager, fabricator, cleaning plant operator Fatality · OTHER
Freeport-McMoRan Morenci Inc. · Over-exertion (Not Elsewhere Classified)

EMPLOYEE ALLEGEDLY SUSTAINED A SPONTANEOUS FRACTURE OF THE LEFT ANKLE WALKING ON A CONVERYOR BELT WALKWAY.

February 15, 1999 AZ · Metal/Non-Metal electrician, lineman Fatality · POWERED HAULAGE
Freeport-McMoRan Morenci Inc. · Caught in, under or between (Not Elsewhere Classified)

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.

August 9, 1998 AZ · Metal/Non-Metal maintenance man, mechanic, repair/serviceman, boilermaker, fueler, tire tech, field service tech Fatality · OTHER
Freeport-McMoRan Morenci Inc. · Drowning

THE EMPLOYEE WAS GOING TO SHUT OFF A VALVE IN THE 4 WEST TAILINGS DAM. HE WAS FOUND RECLINING BESIDE THE VALVE.

January 25, 1996 AZ · Metal/Non-Metal haul/off road/coal/ore/pit/quarry/rock/rubber tire truck driver, transportation truck driver Fatality · POWERED HAULAGE
Freeport-McMoRan Morenci Inc. · Caught in, under or between a moving and a stationary object

AN AA TRUCK DRIVER POWERED BACKWARDS THROUGH A WELL ESTABLISHED BERM AT AN ANGLE. THE TRUCK OVERTURNED CAUSING FATAL INJURIES TO THE EMPLOYEE.

October 31, 1995 AZ · Metal/Non-Metal electrician, lineman Fatality · ELECTRICAL
Freeport-McMoRan Morenci Inc. · Flash burns (electric)

EE WAS WORKING IN THE SOUTH SIDE SX/EW SUBSTATION TRACING LOW VOLTAGE WIRING WHEN AN ELECTRICAL FLASH OCCURRED FROM ANOTHER AREA.

October 17, 1991 AZ · Metal/Non-Metal crane operator, mobile equipment operator (meo), dragline operator, dropball operator, rigger Fatality · MACHINERY
Freeport-McMoRan Morenci Inc. · Caught in, under or between a moving and a stationary object

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.

September 13, 1991 AZ · Metal/Non-Metal haul/off road/coal/ore/pit/quarry/rock/rubber tire truck driver, transportation truck driver Fatality · POWERED HAULAGE
Freeport-McMoRan Morenci Inc. · Struck against a moving object

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.

May 22, 1991 AZ · Metal/Non-Metal electrician, lineman Fatality · ELECTRICAL
Freeport-McMoRan Morenci Inc. · Contact with electrical current

THE EMPLOYEE WAS FATALLY INJURED WHEN HE CAME IN CONTACT WITH A 4160 V FUSE IN THE #19 SWITCH HOUSE WITHIN THE MORENCI MINE.

March 1, 1989 AZ · Metal/Non-Metal Fatality · HANDLING OF MATERIALS
Freeport-McMoRan Morenci Inc. · Struck by rolling or sliding object

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.

October 6, 1988 AZ · Metal/Non-Metal laborer, blacksmith, bull gang, parts runner, roustabout, pick-up man, pitman Fatality · SLIP OR FALL OF PERSON
Freeport-McMoRan Morenci Inc. · Fall from scaffolds, walkways, platforms

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

January 16, 1987 AZ · Metal/Non-Metal haul/off road/coal/ore/pit/quarry/rock/rubber tire truck driver, transportation truck driver Fatality · POWERED HAULAGE
Freeport-McMoRan Morenci Inc. · Struck against a moving object

WHILE EMPLOYEE 4AS BACKING INTO A DUMP SITE HIS TRUCK OVERTURNED ON A 50' BENCH WITH HIM INSIDE

December 5, 1984 AZ · Metal/Non-Metal electrician, lineman Fatality · POWERED HAULAGE
Freeport-McMoRan Morenci Inc. · Caught in, under or between a moving and a stationary object

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

For insurers, brokers, and safety consultants

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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