Freeport-McMoRan Morenci Inc.Mining Incidents in 2019

Two maintenance employees and a designated fire watch were tasked with patch welding holes on the Rougher Tail Discharge Box A&B. After realizing the hole was larger than anticipated, they left the area to get a larger patch for the hole. They proceeded to weld a small portion of the hole located on a rubber lined pipe and it caught fire.

An employee was air arcing a two and a half inch crack on the front hoist lug. They began welding and another employee noticed smoke, and they evacuated the shovel. Employees were not injured and no damage was found to the shovel.

A broom handle was sticking up out of trash truck causing trash to fall on truck over hang. Exhaust sparked trash to catch fire on the canopy. No damage to truck.

A bearing seized and overheated causing flames to develop. The fire was extinguished 32 min. after company notification.

While working on the front end of a haul truck, employee was lifting a lock ring and felt a pain in their lower stomach. Employee set the ring down and felt a small bubble on lower stomach.

Employee was descending the lower stairs on the haul truck and fell to the ground landing on their left knee.

Washing a van at the mine wash rack, while spraying the van, employee stepped backwards and tripped over equipment wheel chock.

Employee was climbing back up ladder of water truck when their right foot slipped off step, causing employee to slide down steps, landing on feet, feeling pain in right ankle and then falling backwards. Employee was wearing gloves and had three points of contact. Employee slid down about apx. 6ft.

A ball mill operator was operating the ball cart to recharge mills with media when it traveled off the end of a portion of track where the bridge was missing. The employee fell approximately 12' down into the abandoned a-side classifier.

Employee was pulling shovel cable with a hot stick on the 15 shovel when the hook portion of the hot stick suddenly separated off the hot stick. The employee fell backwards, landing on back, elbow and head.

Employee was operating a bobcat walk-behind skid steer cleaning up material at the P5 mid drive. The employee turned sideways in the skid steer to observe their surroundings while backing up, when their foot got pinned between the equipment and an I- beam on the structure breaking their ankle.

Employee was leaving the 5150 area traveling down hill empty in 5th gear and hit a pothole causing pain in their back.

Employee was walking into the changing room when they missed a step up and tripped. This caused the employee to hit their head on the wall and floor.

After being fueled at the 5100 fuel dock the employee mounted the 621 Haul Truck, the latch on EE's hydraulic stairs did not latch. The employee used EE's right foot to lift up and engage the stairway latch, as they did this they heard a loud pop from their right ankle.

Employee states that they slipped and fell on some ice near the 5280 fuel dock. This incident was reported on 1/22/2019. Employee had no restrictions. HR informed on 3/20/2019 that employee went out for surgery.

Two employees did not follow the identified safety controls on two forms they filled out (Fatal Risk Assessment form & Job Hazard Analysis form). One employee placed self in pinch point between swing radius of backhoe bucket and a steel power pole. Operator of backhoe did not stop operating backhoe when operator observed the other employee within the swing radius of the backhoe.

Driver states EE was assisting Transloader with opening door to rail car that was hard to open. Driver was using pry bar to apply pressure to door when door opened, gave way which caused EE's ankle to buckle and twist in downward motion.

Haul truck 585 was loaded at 43 shovel and proceeded to the Lone Star dump. When the operator attempted to dump the load, the bed raised up only about a foot. While looking back at direction of the bed, employee states they put dump lever in down position, and the bed dropped, slamming onto pads in resting position.

Two employees were each struck in the lower leg by a falling piece of metal during the dismantlement of a haul truck bed. The employees entered the fall zone during processing of material.

Two employees were each struck in the lower leg by a falling piece of metal during the dismantlement of a haul truck bed. The employees entered the fall zone during processing of material.

An apprentice was pushing a hydraulic cart and felt a strain in their lower abdomen.

Employee was attempting to remove a plug from a 3"" water pipe elbow when they felt the right shoulder pop and had pain. Employee tried to turn a water valve and the shoulder continued to hurt.

Employees were moving a work platform when the unit deflected from the original path catching the employee's right hand between the work platform frame and the crusher bowl.

Operator of the 563HT states they were jostled when a large boulder was placed in the haul truck on the first dipper. Employee was injured on 8/24/2019 and did not report injury until 8/30/2019.

On 7/19/19 an employee was getting tools from their truck when they stepped on uneven ground causing knee pain. The employee heard it pop, but thought it would be okay and continued working the day. on 7/20/19 the employee returned to work and reported the event to the supervisor due to the pain increase.

Employee climbed on the bumper on the back of the LV564 pick up to get out the tie down chains to secure the counter weights for the crane. While EE had reached forward felt right knee pop. Taken to the Clinic strain to right knee with return to work with restrictions 7-19-19.

Employee was walking up the stairs to board a haul truck when their toe of one boot got caught causing them to land on their hip.

Employee was installing a snubber arm and pins when they lost their grip and tried to catch the pin. The employee heard left elbow pop.

Employee dismounted the forklift EE was operating and twisted EE's left knee. Employee did not report incident until 07/17/2019.

A tailings operator who had been gone from their job for an extended period of time suffered blisters to the bottom of both feet. The employee states they occurred the first night back but didn't report the issue until the end of the third shift. Employee states the blisters were caused by the constant walking done during their job.

Employee was descending stairs when they missed bottom step causing them to fall and fracture right foot.

Employee was driving a water truck and hit a pothole. Employee stated the drivers seat bottomed out causing lower back pain that radiated to the chest.

Employee states that on 5/6/19 they were moving heavy metal and pulled a muscle in their left leg and groin. Employee continued to work the next scheduled shifts and did not report the injury. The employee was out on leave until October when they stated the injury was work related.

Employee was hammering a 4"" yellow mine coupling on a pipe with a 4 pound hammer and felt pain in their right wrist.

Employee had just finished fusing a 2"" ball valve on the end of a 2"" line. As employee was walking to the next fuse EE tripped on a metal guide wire sticking out of the ground. Employee stated EE felt a pop as EE fell to the ground.

Employee was attempting to open the drop latch on the doors to the screen. Rocks had wedged in behind the doors putting the latch in a bind. Employee felt pain in their shoulder when trying to lift the latch.

The Employee had loaded off at the 17 shovel and felt fine. The employee hit a pothole between the 17 and 41 shovel as the employee was heading toward the 910 dump. The employee felt back pain as a result and was transported to the clinic.

Employee had set their 17 pound back pack down to get safety supplies, after they got their safety supplies that they needed the employee lifted their back pack and felt a sharp pain in their upper abdomen.

Employee was cutting a large box to throw away. EE was holding the box with foot and using right hand with the box cutter. The box cutter slipped and ee cut left hand on the index finger.

The Employee came in and notified us on 3-6-19 that Employee's back was sore from work the previous day from working with liners. Employee was taken to the Clinic, had no restrictions with a follow up for 3-11. Today Employee was put on restrictions for a lumbar strain.

While loading at the shovel a rock rolled out of the bank hitting the front right tire of the haul truck. The employee notified the shovel operator and walked out on the deck to find a large rock against the truck. While moving out of the shovel pit the operator notified the supervisor that pain was felt.

Line electricians were working out of a bucket truck basket when one of them attempted to move a jib. The employee felt a pop immediately followed by a lot of pain in shoulder.

Employee slipped and fell back down when walking down the stairway of the HT592. The employee's back was hurt as a result.

Operator of HT531 was having difficulty with the bed lever and had to press it with force causing their back to hurt.

A haul truck operator trainee was driving on the dispatch haul road near the 801 Water stand and stated they hit a pothole causing back pain.

Employee was attempting to remove a pre-strip using a tool designed for this and felt a pop in their right shoulder.

As an employee was walking down the stairs on the haul truck to clean the headlights, they stepped in a mud puddle and slipped and fell. The employee slid past the stairs landing between the top and bottom set of stairs and kept sliding down the stairs all the way to the ground.

Employee was walking through Morenci concentrator and ducked down for a low clearance area. The employee stood up before they cleared the low clearance area and struck their head right below their hard hat.

Employee was riding in the man van when they hit a pothole, and they felt pain in their neck and shoulder.

The operator of the 629 haul truck was traveling empty down the HHH going to the 15 shovel, when according to the employee they hit a pothole causing back and neck pain.

The operator of the 545 haul truck was traveling from the ""no name ramp (Lonestar dump) in third gear"", when they hit a pothole causing back pain, a cracked back window, and a drivers side mirror.

Operator of HT521 was traveling down the Triple H when they hit a pothole and felt pain in their back.

While working at the acid gate, security got an emergency call, so employee attempted to push the perimeter gate closed. The gate was difficult, and they felt a sharp pain in their lower back.

At approx. 1700, operator began dislodging material from chute behind the 28 ball mill. Employee was utilizing a large piece of wood (2X4) to ""tap"" the top of the chute. Employee was using their right hand to perform a ""tapping"" motion, while supporting the wood with EE's left hand. The employee felt pain in their left ring finger during the work.

The operator of HT525 hit a series of potholes and ruts and began to feel numbness and pain in their lower back.

Employee was changing out the castle seal on the 19B Drill using the sand lot to lift the seal and smashed their fingers in between the housing of the seal and a hose.

Employee was at the 25 ball mill installing a pinion cap when they twisted while bending over and strained lower back.

Employee was walking down stairs to roll up a hose and missed the last step causing them to roll their left ankle.

Employee was operating the 573 HT traveling to the 16 shovel when they hit a pothole and felt a sharp pain in their back and both legs.

Employee was walking on the rougher deck floor. Employee was wearing appropriate fall protection and tied off correctly. Employee moved quickly causing the yoyo to lock. This caused the employee to fall backwards onto level below. Which was about 2ft landing on bottom causing pain in lower back.

A mechanic was lifting a dozer cutting edge by hand to position it for rigging when it slipped from a height of approximately 2"" and fell on the employee's index finger causing an open fracture to the right index finger.

While stripping the leach pipes on the 6320 King stock pile, the employee was stepping over a 4"" pipe to get to the 2"" pipe in order to strip the wobblers. The employee's left foot slipped on a unstable rock causing the left ankle to twist inward.

Employee was getting off the F122939 Rental Water Truck at the 801 water stand to turn on the water valve to fill the water truck. As they stepped off the last rung of the boarding ladder they felt a dull ache/discomfort in their left ankle.

The operator of the 505 HT was loading on the left side of the 46 shovel when the second dipper opened prematurely and a large boulder hit the dovetail causing the haul truck to be jostled. The operator struck their head on the window post of the driver side door. Case#1877901

The operator of 519 was loading at shovel 15 and experienced a rough load event. The operator felt some discomfort in their back and the driver side window was cracked in the process.

Employee picked up a 10"" 90 degree bent pipe weighing approximately 80 lbs from the floor onto a work table when they felt a pain in their chest.

Haul truck trainee and mentor were being loaded at the 40 shovel when on the second dipper, a rock rolled and made contact with the side of the bed. The operator stated they felt back pain after they left the shovel.

Employee was pulling drip line when UTV pulled up and turned off. Employee grabbed lines and cut them, causing them to snap back while employee was still holding them. Employee then felt pain in lower left arm

Employee found blisters on the heels of both feet and tried to treat them. The blisters were not healing so the employee reported it to their supervisor and was taken to the clinic.

While replacing the floor after a main frame replacement employees were lifting the grating to place them back, the grating (2 feet wide 4 feet long approximately) did not sit right and flipped through the opening coming back and hitting the employee's right knee.

Employee stated they were driving down the 801 early in their shift and believes they hit a pothole or a hard knob and the seat bottomed out. Seat was checked and in good working order.

Employee was attempting to pick up a 50lb bag of floor dry and felt pain in their left wrist and shoulder.

Employee picked up two cases of bottled water and felt a sharp pain in lower back.

Employee stated they were backing into the 46 shovel to be loaded when the dipper tripped and dropped the dipper load onto the dovetail of the haul truck causing the bed to raise and slam back down.

The operator of the 527HT had placed their lock on the possession of operation swing gate, when they turned and slipped off the step above. The employee got their left foot caught between the bottom four steps and twisted their left knee.

Employee was walking down stairs, tripped, and hit their knee. Employee experienced sharp pains in their hip after the fall.

Employee was transferring a 55 gallon drum that contained oil from a wood pallet to another wood pallet that was positioned next to each other using the roll method. The 55 gallon drum over rolled off the wood pallet and landed on top of the employee's right foot on the bridge behind the steel toe of the boot.

Employee was operating the 621 Haul truck following EE's assignment to the 15 shovel. The employee was coming around a left hand turn and hit a hard knob causing the left front tire to bounce. When the incident occurred the employee felt immediate pain to their lower back and neck.

Employee was doing prep work for an upcoming concave job. A forklift placed the concave on the prep rack, the employee then attempted to move it into place when their right middle finger was pinned in between the concave and the frame causing a laceration.

Employee was performing a shell liner job. The individual was preparing a cart with bolts and liners when a bolt fell off and struck the employee's finger.

Crew was tripping pipe at the drill site and were asked to vacate the site due to concurrent customer operations. During prep to leave the site, employee was pushing on pry bar with EE's left leg facing forward. As EE pushed on the drill pipe, EE felt a pop in EE's left knee and fell to the ground due to a complete tear to medial, patella, and lateral aspects of knee.

The haul truck trainee went to enter the cab on the passenger side of the haul truck when their kneecap shifted to the left and popped back into place on its own.

The crew working at the 14/15 Chute at Metcalf Crush Convey loading metal liners into a truck. The affected Employee picked up a liner that had a bur on the bottom side hidden from Employee's sight, as Employee reached out to pick it up the burr cut the left palm of Employee's hand through the glove. Employee received 4 stitches.

The Operator of the 640 Haul Truck was loading on the right side of the 16 shovel when on the third dipper a boulder struck the top left bed rail causing the 640 Haul truck to shake. The motion of the truck shaking caused the Haul Truck Employees head to whip back and forth.

The Employee was trying to remove a guide roller by hitting it with a 4 lb. sledge hammer to loosen the guide roller. EE swung the hammer with both hands on the handle striking finger between the hammer handle and the structure. Fracturing the tip of right index finger.

The operator of the 548 Haul Truck was going to receive their first dipper of muck at the 45 Shovel when the dipper door opened prematurely which caused the bed to rise. The employee was jostled due to the impact of the incident.

While two employees were repositioning a classifier drive shaft after it was placed on a repair stand, the drive shaft slipped off one of the stand saddles and one of the employees right middle finger was caught between the shaft bearing guide and a stand saddle causing a fracture to the last bone in that finger.

Employee was stacking drained hoses in a pickup when they felt pain in their back.

Employee went to check work and ducked down underneath hoses and felt pain in their lower back. Employee was not lifting or pulling anything at the time.

Employee states they rolled ankle after they stepped out of cab on 41 shovel in vicinity of PLC room at top of access ladder.

An employee felt pain in their right shoulder after lifting a wheelbarrow of material.

While loading at the shovel the bucket hit the truck and caused the operator to bounce in the seat, the operator felt pain in the lower back. There was a second operator in the buddy seat that operator was not injured.

Employee was raking under a conveyor belt and felt pain in their lower back but refused treatment at the time. Employee later reported back injury on 02/04/2019.

EW employee was removing a cathode within the bandsaw machine. As employee ran their hand along the edge of the cathode it sliced their finger through the glove they were wearing.

Employee was walking down the stairs at the original re-grind. As the employee reached the bottom of the stairs they walked through a puddle of water and twisted their ankle on even ground.

540 HT was loading at the 12 shovel. As the operator was backing the haul truck bed scrapped against the dipper of the shovel. After the truck was loaded the operator drove to the 4560 tie down where they reported that their neck was hurting from the impact.

Driver of the 525HT backed into the right side of the shovel to get loaded. The shovel operator honked for the driver to stop. The haul truck operator felt what they believe to be the dipper door drop open and hit the haul truck bed followed by the material being dropped into the bed. This caused a rough load to the driver of the haul truck.

Samplers were up on phase 14 drill patterns taking samples of drill cuttings when a handheld drill hit rock chips causing the drill to torque and sprain the employee's lower arm.

Operator of the 632 HT just finished dumping at the Lone Star dump. As the 632 HT was traveling to next assignment the truck hit a pot hole and caused the bed to raise and slam back down jarring the cab. Operator then drove to a nearby tie down and reported injury to lower back and damage to the suspension.

Employee was helping another employee lift a fan to the back of the pickup truck and their finger got caught in the fan cutting it.

A drill mechanic was cutting a zip tie on hydraulic hoses and accidentally cut their hand with a box cutter razor.

Two employees were checking welds on a lip shroud. Both employees were leaning on the dipper lip, with their heads turned downward to inspect the welds, when the crane began to lift upwards. They both then stood back from the lip when the clevis broke from the tension, shooting parts upwards between them. The supervisor was struck in the left arm by part of the clevis.

While attempting to adjust the drivers seat, haul truck operator smashed left middle finger under the seat causing a fracture to the middle finger.

Employee was eating lunch, tried to cut a saladito, and cut their left index finger.

EE slipped on a ladder and cut hand on the danfoss valve trying to gain balance. EE was not wearing gloves. The ladder was not dirty but the work area had some water in it with the recent storms and the employees boots slipped on the rung.

A heavy duty truck shop mechanic was replacing a transmission on a haul truck oil cooler standing on a step ladder. While reaching overhead and looking up to tighten bolts, a clump of dirt mixed with grease came loose and landed on forehead, and some material landed in their left eye.

The employee was cutting a 1/4 inch thick, 20 inch wide piece of belt with a OLFA razor knife. The knife slipped and cut the employee's right lower leg.

Employee was exiting a haul truck when they struck their knee on an open door and received stitches.

A diagnostic mechanic was working on removing the railing for the wash chain assembly when the chisel broke free and struck the employee in the face causing a laceration between the upper lip and nose.

Employee tried to get blank between saddles with a long hook. The hook slipped off the eye when the employee was pulling it which resulted in the employees right finger hitting a rail and cutting it.

As employee was walking to badge in, they fell to the ground, scraped their right, left arms, and received a small cut on the left knee.

As employee was installing drip line, EE's hand got in between the drip line and cutters which caused a laceration to EE's left palm

Employee parked water truck and was descending the stairs when they missed the last step of the ladder and fell backwards onto the ground hitting their head. The employee received 3 staples to the head.

An employee was grinding a weld on the Rev Deck of the 16 Shovel when debris flew under their hood and safety glasses. The employee had metal embedded in the cornea of their eye.

Employee was on ground helping move cable with bull rope and noticed a rock in the roadway. Employee picked up rock and threw it to the side to get out of the road way and the momentum of throwing the rock caused the employee to fall forward catching themselves with their hands. When employee stood up they noticed a laceration to the left hand where the thumb attaches to the palm.

While filling the oil in the front left hub during a main PM the employee stated the hose came out when their co-worker squeezed the trigger for the 60w oil. The oil then sprayed the employee in the face which resulted in oil getting into their left eye.

Employee was driving a LV in the tailings area and hit a pot hole causing them pain to the right side of the neck.

Employee was checking the derailer and shook it causing the sign to come loose and make contact with their ear.

A FMI Diagnostic mechanic was adjusting the packing on the 4412 pump, when a 15/16 open end wrench made contact with the locking ring. The wrench flew and hit the employee in the face.

Employee was doing cell maintenance when ladder shifted causing the employee to strike their shin on the ladder.

Employee was operating a rubber tire dozer when they hit a pothole causing back pain.

Employee was removing air lines from the starter of the HT517 when EE slipped off of the second rung of the ladder falling to the ground. EE hit elbow cutting it.

Employee was attempting to remove plug on left front spindle to take an oil sample when the ratchet with an 1 1/2 socket slipped off the plug pinching the employees left little finger between the shaft of the ratchet and the rim. Employee was wearing gloves.

Employees were task with cutting and moving grating, while employee went to move a piece of grating that was sitting on top of another piece. Employees left index finger was pinched between the two pieces of grating causing injury to nail on finger. After additional information was provided injury classified as Medical Treatment.

Employee was working inside the flotation cells changing out the baffles. They were using a chain fall to take them out. The employee reached underneath the baffle to readjust not aware there was a sharp edge lacerating 4 fingers on the right hand.

EE was tasked with getting a 3 inch by 12 foot mild steel pipe for a project. The EE pulled the pipe out of the rack and attempted to place one end on a stand, missing the stand the pipe fell striking the EE on the foot just behind the steel toe of the EE's boot.

While using and angle grinder to bevel casing the employee had the grinder kick back and lacerated left ring finger.

Employee was replacing cutting edges, and when they stood up their hand slid down the edge guard onto a bolt causing a laceration.

While employee was cutting blanks, employee jammed left ring finger on roller ball of the cutting machine. Incident didn't become reportable until physical therapy was prescribed in February.

Employee was operating loaded haul truck on the Pondarosa ramp en route to the Lone Star 5220 H dump when the fire suppression system chirped. Employee noted smoke and flames coming from exhaust pipes. Employee discharged fire suppression and while exiting the unit they inhaled smoke and fire suppression agent.

Employee was lifting a dumbbell over their head exercising when they passed out and the dumbbell struck them in the head causing a laceration.

An employee was changing the filter housing on the #4 short head. As the employee was attempting to remove the lid from the housing, it slipped from their hand and fell onto the employees foot behind the steel toe portion of their boot.

Operator of the 556HT began to feel dizzy and nauseous after being exposed to exhaust fumes.

Approximately 3 weeks ago an employee was working in various areas when they noticed a rash on their right inner elbow. The employee didn't report it then because they didn't notice it until after work. The next two weeks that employee was moved to the MetCalf Mill. Today the employee was working in C&C and the same symptoms came up again on the same elbow (right inner side).

The employee found a rash on both lower legs after taking the required rubber boots off at the end of shift.

Employee stated they were working on cleaning a discharge box for the section 1 ball mills when they became hot and dizzy.

Employee was working at the P11 upper sump when they started feeling dizzy and light headed.

Operator of the 28RTD was driving down dispatch to crusher 3 and hit a pothole. They tried to brace themselves, and their hand slipped from the steering wheel causing the employee to sprain right pinky finger.

Employee started feeling dizzy and ill after smelling some fumes that were coming from the tile glue chemical that was used for the re-roofing activities on the building. The fumes were traveling through the air-handlers on the roof into the hallways of the building.

Employee was walking up the creek, inspecting the gabions, when their left foot got caught on a rock, and they fell injuring their left knee.

EE was preparing fuel tank bracket to install a fuel tank on a 793 haul truck. The bracket fell to the ground and rolled striking EEs right foot behind the safety toe. EE was treated at urgent care and was released to full duty with no restrictions.

On 5-18-2019 the EE was using a bar to remove copper from a starter late at the stripping machine. EE reportedly felt pain in the left shoulder and wrist at the end of shift, the EE stated the supervisor had already left, EE went home and returned to work this morning complaining of the same symptoms with a higher level of pain.

Mine maintenance employees were welding blocks in a shovel dipper inside #1 bay at the fab shop. At the end of the shift one of the two employees noticed their eyes felt heavy and believed they were just tired from the shift. Employee went home and went to bed and woke up experiencing a burning sensation in both eyes.

Employees were participating in a polar plunge event at the recreation center. While standing near the pool one of the employees attempted to push another employee in the pool. As the employees struggled they both fell backwards onto the deck. The employee who was pushed caught an ankle underneath the other employee's leg causing injury to left ankle

EE was cleaning deep fryer of fugitive food when their right fourth and fifth fingers made contact with hot grease.