An employee was operating a drill press in the maintenance shop when metal shavings became lodged in the equipment. The employee stopped the drill press and attempt to manually remove the obstruction, and a sharp metal shaving penetrated the glove and caused a laceration to the employee's left index finger. The employee received stitches for their injury.
Freeport-McMoRan Morenci Inc.Metal/Nonmetal
- Fatalities
- 0
- Total incidents
- 200
- Years on record
- 2024–2026
- Latest incident
- Apr 2026
Reportable incidents
200 on file2026 · 40 incidents
Employee was rolling up mantos on a leach stockpile, when their right forearm became irritated by the raffinate solution. The employee wash off arm with 4 bottles of water and reported incident to supervisor. The employee was taken to clinic to be evaluated.
At the end of their shift an employee began descending the front boarding ladder. As employee was reaching the bottom step to get on the platform, they lost footing/overstepped the top rung for the breakaway ladder. This caused the employee to fall approximately 4.5 ft and land on their left elbow.
The employee was walking from the lower lunchroom. Upon reaching the top of the stairway, the employee missed a step, resulting in a twisting injury to the right knee and reported hearing a popping sound.
Employee was using an 8-foot steel bar at the P 9/10 chute to remove a slab (rock) at the bottom of the chute. As the employee was attempting to hit the slab, their left hand hit the bottom of the chute door and smashed their left pinky finger.
Morenci Mill Maintenance employee was in the belt shop attempting to cut some skirting for a belt job. As they began to cut using the Olfa knife, the knife slipped cutting into the A6 rated glove and HexArmor sleeve into the employees left thumb, side cutting the skin next to the nail.
Operator was attempting to fill in a hole from where the shovel came out of. While pushing material, the operator claims that they came to a sudden stop causing them to be jarred forward. Operator went restricted duty on 3/11/2026.
Operator was mounting a Haul Truck and raising the boarding ladder. The operator's hand was on the boarding ladder switch when the handrail to the ladder pinched their finger between the switch and the handrail.
Employee was walking down the stairs attempting to remove something from EE's bag and missed the last step, causing EE to fall and injure EE's right elbow and left knee
Mill Crusher Ops employee was making their rounds this morning checking all the unit screens at the Secondary Crusher, employee went to close the ""doghouse"" door and smashed their middle finger.
Haul Truck 629 was loaded at a shovel and traveling uphill to a dump when smoke and flames were observed in the engine bay. The haul truck came to a stop the operator descended the haul truck.
The haul truck operator had completed dumping and was traveling back down the haul road. While driving, the operator struck a pothole at approximately 13 miles per hour. As a result of the impact, the operator reported experiencing lower back pain. Operator went restricted duty on 3/9/2026.
A Haul Truck was being loaded by a Shovel. During the third dipper, a boulder was at the top of the dipper leaning on the teeth. When the bottom of the dipper opened, the boulder did not fall through with the rest of the load. Instead, it rolled over the teeth, hit the driver side of the haul trucks canopy and fell to the ground. Operator went restricted duty on 3/12/2026.
An operator was using a rock hook to unplug a chute. They were pulling up on a stuck rock when it broke loose which caused the tool to come up and make contact with the employee's central incisor #8 (front upper) tooth.
A Morcon ops employee was washing off material behind the ball mills area when they took a break. Upon returning from the break they went to bend over to pick up the water hose to continue spraying down area when they felt a pain in their back.
The Shovel Operator walked the shovel back down off of the 3'-4' hard knob and the shovel jolted. This resulted in the operator experiencing neck pain.
Mill Diagnostic Mechanic missed a step on the floor grating. They stumbled and attempted to regain balance but fell forward, landing on right knee.
While employee was cleaning up debris in a 90 degree pipe. A rock dislodged and stuck employee on right hand.
The employee had noticed red on the under part of their eyes 2/18/2026 at the end of their shift and over the next couple of days a rash appeared and on 3/4/2026 the employee reported the injury when coming back to work due to the condition not improving.
A Mechanic was removing the propel shaft on a Shovel using a steel cable and a Dozer. While positioning the cable on the dozer's ripper, a mechanic placed a hand near the line. When the dozer moved forward, the cable shifted and caught their left hand between the cable and the ripper.
Employee suffered seizure causing EE to fall from standing to the ground. Fracture to the skull was sustained in the fall.
An employee was traveling in a van when the driver encountered a pothole on the haul road, resulting in a sudden jolt to the passengers.
An employee was traveling in a van when the driver encountered a pothole on the haul road, resulting in a sudden jolt to the passengers.
An employee was traveling in a van when the driver encountered a pothole on the haul road, resulting in a sudden jolt to the passengers.
Offloading Ammonia Nitrate Solution, the hose was clogged. Employee closed the line to check the hose but there was still pressure in the line. When they unhooked the line the pressure sprayed solution hitting them in the face and entering eyes. They washed their eyes out well onsite but went to an eye doctor to be checked out and they prescribed antibiotic ointment
Employee was unloading a hose crimping machine and hit EE's left index finger on something and created a laceration.
Two employees had checked a belt and were walking on the lower level of the screen plant when a rock from the next level up fell over toe board striking one of the employees on top/right side of their head.
The backup monitor fell from the mount and struck the haul truck operator on the left side of the head.
Employee was picking up parts for their task and one of the required parts the employee needed was a cylinder for the dust curtain on the drill. While lifting the cylinder, the employee stood upright and experienced a sharp pain on the left side of the body.
During a maintenance activity, a maintenance employee was replacing some dust collector ducting in the tunnel when they pinch their right index finger.
Employee sustained a laceration to right hand ring finger when it was cut by a burr on the inside of the drill pipe and received 5 sutures. Employee identified one of the burrs, but not the second. EE had Impact Cut 5 gloves on at the time of occurrence.
While walking through the mud, the employee's feet became stuck. During an attempt to free themselves, they felt a pop in their left knee.
Water hose nozzle struck employee in chin, chipping 2 teeth, cracking 1 tooth and causing a laceration which required 3 stitches.
The operator exited the cab and unintentionally inhaled turbo fumes when exiting haul truck.
Employee was cleaning the Dc box for the ball mill when they felt something fall between their glasses. Employee felt like something got in their eye and started to flush them out.
Employee was stepping out of van when they stepped onto uneven terrain and twisted their right ankle.
Tailings operator was walking up to west centerline when they stepped in mud and rolled left ankle.
A haul truck operator was traveling on a haul road when the equipment struck a pothole.
An employee reported pain in knee after bending down to collect samples in tailings.
A Crush and Convey employee rolled their right ankle while stepping off the crusher ring during maintenance.
2025 · 130 incidents
Operator of a haul truck fell while cleaning windows on the truck deck, striking their right wrist against the windshield. Received work restrictions on 12/29/2025.
Employee was lifting 50-pound bucket, when they felt a pull in their abdomen. There was no pain, so employee continued working. Employee noticed a bump after they went home. Employee reported it the following morning start of shift. incident occurred at the Lone Star array site.
Mechanic sustained a hand laceration while replacing air filters on haul truck within the bay.
While grinding the employee felt a foreign object enter their right eye. A small metal fragment was removed on-site, and the eye was flushed. The employee was transported to the local occupational clinic, where no remaining foreign body was found, but an injury to the cornea consistent with the flushed object was observed.
Employee was cutting drip, when EE placed the cutters in EE's pants pocket without engaging the safety latch. Open cutters caused a laceration on EE's left thigh. The employee also was given sheath for cutters and was not using it at the time.
While walking to the HT629 at Shannon Q-Point, the dayshift operator tripped on a rock and fell forward. At the time of incident, the operator was wearing their backpack, carrying a water bottle and an additional bag full of cleaning supplies. The operator stated they normally use a flashlight while walking but were not at the time of this incident
Employee smashed finger - became reportable 11/25/2025
Employee injured finger when shroud material fell onto it
CC Employee was welding a wear liner block to the crusher saddle liner, in the process of building material with weld, molten Material size of a dime dropped and landed on top of pants where the top of where boot opening is. The molten material burned through pant leg and entered the boot landing on the top of the left foot. Causing a burn.
Employee fell dismounting power step on haul truck - became reportable 11/12/2025
Concussion from rolling water truck - became reportable 11/10/2025
Employee was hit in head with shovel - became reportable 11/12/20205
Employee felt pain in back after hitting a hard knob
Employee fell backwards and hit head on rock
Employee tripped on det cord injuring wrist and shoulder - became reportable 10/31/2025
Employee driving haul truck hit another haul truck
While disembarking a man van, a dayshift haul truck operator stepped into a low, rocky spot and rolled their ankle. The operator stated they felt immediate pain and sat down and asked for help.
Contract employee was wearing rubber boots to work in a wet/muddy area for clean-up. They had some of the wet material go over the top of boots causing it to irritate the middle of the calves on both legs where the boots touched the skin. This rubbed the skin causing a burn in a circumference pattern around both legs.
A mechanic was working on a mast raise cylinder. Attempting to loosen a flange bolt with a wrench and it would not loosen. The mechanic then grabbed a 2lb hammer and struck the wrench several times. On the last strike they missed the wrench and struck their left hand in between the finger and the thumb
Employee was hit by 25lb bucket - became reportable 10/20/2025
Employee was rough loaded in haul truck - became reportable 10/16/2025
Employee cut finger with knife - (website was down to report)
Employee injured knee going up stairs
Employee was finishing work on a platform that had about a 6 in step down to grading. Employee stepped backwards with left foot then with the right foot EE did not step completely off of platform causing EE to fall twisting EE's ankle.
Employee hit soft spot in road and felt back spasm - became reportable 9/26/2025
Employee tripped over piping on ground - became reportable 9/25/2025
While lifting an oil pan onto a 793 haul truck engine, employee felt a pop in EE's groin area. The employee reported the incident later in the shift. EE was treated as a first aid from 9-25-25 to 10-16-25 when EE was given restrictions.
Employee was walking down stacker and missed a step - became reportable 9/24/2025
Employee had neck pain after hitting hard knob in haul truck
Employee slipped in mud and fell injuring back
Employee had back pain after hitting pothole in haul truck - became reportable 9/15/2025
Employee injured back after seat bottomed out on haul truck
Employee was inspecting and flushing on a stockpile when EE's left foot sank into wet material, lost balance and fell striking EE's left knee on a rock.
Employee tripped and injured knee -- became reportable 9/11/2025
Employee picked up cribbing and felt pop in back
Employee struck hard knob in rubber tire injuring back
Employee felt pop in shoulder lifting 50 lb bag of clay
Employee overexerted themselves trying to get out of mud
A retired employee claims hearing loss due to occupational exposures over 30 year career. Employee says this was identified in a 2024 occupational exam.
Employee smashed hand with drive line guard - Restrictions received same day of injury prior to next night shift.
Employee smashed hand between two air boats.
Employee was pulling power cable with hot stick and fell on back - became reportable 8/9/2025
At approximately 7:05 AM, a crew was transferring buckets of concrete cure and seal to a new pallet due to damage on the original. One bucket had leaked and adhered to its cardboard base. After failed removal attempts, a utility knife was used to cut around it. During the cut, the blade slipped and struck a worker's leg above the knee.
New employee on EE's 3/4 day acclimation period, Employee started having cramps in leg and side.
Employee fell onto idlers injuring leg - became reportable on 8/11/2025
Driver was walking back to the cab of EE's semi-tractor on flat, even ground after lowering landing gear on semi-trailer when EE's knee gave to the left side. EE suffered a left knee strain, possible patellar subluxation. The driver aggravated a pre-existing condition.
Employee's foot fell into sump dump causing discomfort in leg - became reportable 7/24/2025
Employee received bruising on foot from lock ring striking it - became reportable 7/25/2025
The driver grabbed the stinger and as they moved it, right ring finger became pinched between the stinger handle and the guard rail of the gangway basket.
Employee cut hand with razor knife
Employee were working on 901 feeder when separating the unit with a ram the unit roller causing the ram to pop as the employee was walking away something hit EE's PARP as EE turned EE's back causing the PARP to scratch EE's forehead
Employee misplaced hand and smashed finger
Employee twisted knee at sump pump
Operator was running the A-crane at Central Tankhouse. While hooking up the mist ball basket, a small piece of debris fell from the inside of their full-face Respirator into their eye causing irritation. They went to the clinic for treatment where a small scratch was found and prescription eyedrops were administered.
Employee was bolting up a cover for the NGR behind the transformer. It started to slide down. EE tried to stop it and EE's had was struck by the corner on the Handle.
While attempting to place a heavy object in the bed of a truck, the load shifted and pinched employees finger between the bed and the item itself. The injury sustained caused by the weight of the item was a pinch. The pinch caused a laceration requiring four stitches
A haulage operator was performing their walk around of the HT630 in the 15 shovel tiedown area when they stepped on lose material in the parking ditch and slipped. This caused a strain in their lower back.
The employee was assisting co-workers with reeving a lower block. During this task, the employees were removing the slack from the wire rope by hand. The wire rope had a twist in it that came loose and made contact with the employee while removing the slack by hand. The incident resulted in a minor chip to the employee's front tooth.
Employee cut finger with grinder
Production Superintendent was attempting to re-rig an air winder to a forklift to be picked and put into place for a belt change out. The air winder was placed on a wood core for cribbing. The air winder load shifted and contacted the employees left foot causing a fracture.
Employee was operating shovel, swung shovel dipper around and felt back pain -- became reportable 5/31/2025
Employee was cleaning dump in dozer and ran over rock injuring back -- Injury became reportable on 5/31/2025
Employee was coming down steps on haul truck and missed step - Became reportable 5/20/2025
Employee was braiding a piece of rope. They cut the end of the rope and cut their ring finger.
Injured employee was assisting another employee with emptying a core sample from an innertube. The co-worker was handling the innertube and lost grip causing it to fall. The injured employee reacted and tried to catch it and pinched their finger between the innertube and core tray, causing a laceration to their left middle finger requiring 6 stitches.
Employee was being loaded in haul truck when they felt pain in back - did not become reportable until 6/30/25
Employee was shoveling when they felt pain in leg - became reportable on 5/9/2025
Employee was ascending steps and felt a pop in knee - experienced dislocation requiring alignment
Employee injured finger changing tire
Empty pallet on the floor of walkway in between two pallet racks that caused EE to trip and fall to ground breaking EE's wrist in two places. Low visibility in this area of warehouse.
Employee hit pothole in rubber tire injuring shoulder - became reportable 7/9/2025
Employee smashed finger in door
Employee cut finger between door and door jam - did not become reportable until 4/24/2025
Employee stepped into small hole and felt pain - became reportable 4/22/2025
Employee felt pain in back after getting off forklift - determined to be occupational illness
After clocking out from work, EE was walking to EE's car and twisted EE's ankle. EE proceeded home without telling anyone. EE called our local office 1 hr and 5 minutes after EE arrived home to let us know EE twisted EE's ankle in the parking lot. The parking lot is gravel and rocks.
Fire at salvage yard, cardboard bailer/materials area - cause of fire still being investigated
Employee was getting mill liners ready for installation, when it slipped and pinched their finger.
Contract employee was handing scaffold parts into the vessel at the CLP. There was some dust that got into EE's eyes from the parts as EE handed it to another employee. EE's left eye became red and irritated
Employee felt pop in back - injury became reportable 4/1/25
Employee rolled ankle on rock - injury became reportable 4/1/25
Employee has used wrists to toggle joystick rather than fingers for the past 8-10 years resulting in pain & discomfort - Became reportable 4/8/2025
Employee injured back trying to get a bar unstuck
Employee was welding a beam to the structure. There was another welder from behind grinding material. Employee noticed sparks coming up from behind. Employee noticed a spark came in under the welding hood and landed under neath their safety glasses. The spark hit the employee in their eye. Employee imediatately flushed their eye and called for saftey.
As the employee was exiting the skid steer, right foot got caught between the wheel, causing them to twist their ankle.
Employee rolled ankle coming down steps
Employee injured foot trying to unhitch light plant
Employee cut hand with pocketknife
Employee injured back prepping floor at shovel
As the crew was tripping 20-foot rods, the driller assistant (DA) requested an adjustment to the jib boom. Driller contacted the head tilt lever instead of the Jib boom causing the rod to move forward unexpectedly and striking the DA between the chin and the lip causing a laceration that required 4 stitches to close.
Van moved before employee sat down and the employee hit their face on the window.
Employee was setting up service cart and took step back into crack causing them to roll ankle. Became reportable on 10/31/2025.
Employee suffered minor burns after coming in contact with diluted lime water
Haul truck operator backed into the dipper of the shovel causing pain in their lower back.
Employee felt continuous pain in wrist
The employee was attempting to remove the retaining pins to an elevated skid steer bucket. The retaining pins were removed causing the bucket to fall on their left foot. The employee was
Employee smashed fingers.
Employee pinched and cut finger.
Employee was pulling hose and foot got stuck in mud causing them to fall forward onto their knee. Incident became reportable on 2/12/25
The employee was working at the CLP Plant jack hammering concrete, when the jack hammer bounced up and landed on the employee's left foot. The jack hammer tip struck the boot between the steel toe and the Metatarsal cover. Causing a fracture to the left big toe.
Employee felt sick after cleaning.
IP's 4 fingers on right hand were crushed between Horse head and block & tackle of service truck mounted crane. IP required surgery on all 4 fingers with a portion of middle 2 fingers requiring amputation
An employee tried to cut a hose with a utility knife and slipped, causing a laceration to the left middle and index finger. Went restricted duty on 1/30/2025
Employee pinched finger moving liner
Employee had completed the transfer of fuel from a light vehicle diesel tank to another and removed the fuel nozzle and placed it on top of the tank to place the fill cap back on. In the process of securing the hose, EE inadvertently stepped on it, causing the fuel nozzle to slide back and strike EE in the mouth; chipping a tooth (left lateral incisor-#10).
Removing wear plate when the plate fell striking the employees finger causing a fracture at the tip of the left middle finger.
Employee smashed finger.
2024 · 30 incidents
Employee slipped and pulled shoulder muscle.
Employee was disassembling scaffolding, felt sting in left eyebrow
Employee smashed finger between hook and handrail
Employee cut finger cutting bolt
Employee lost balance and fell
Employee stepped back, stepping in wick (drill hole), became unbalanced spraining right ankle.
Employee felt debris in eyes when removing cutting edges
Employee smashed finger
Employee was sitting in the driver's seat of the employee's GMC 3500 when the truck was struck by a forklift operated by an FMI employee. The FMI employee was picking up wall liners with a Teloiza extend fork PIT. Minor damage was caused to the GMC Truck.
Employee received irritation on both feet from contact with lime.
Employee popped knee while moving pipe.
Employee injured back after hitting pothole
Employee injured back after hitting rough section of road
Employee stepped off concrete base & popped knee
Employee jarred back while operating shovel
Employee had pinky get snagged in belt.
Employee had an allergic reaction while working at Moly Plant
Employee injured shoulder lifting HDPE pipe
contract employee was moving scaffold parts in Metcalf mill and had dust fall into their left eye.