Mitchell Plant

UNDER THE SILOS IS A TIGHT SPACE. WAS USING A WALK BEHIND SKID STEER. MOBILITY WAS LIMITED, OPERATOR WAS GOING IN REVERSE WITH A LIMITED FIELD OF VIEW

Elevator was in the process of being test ran after previous repairs, during test run, elevator and one miner was stopped at the top landing unable to exit or move. Repairman was onsite and able to open the elevator and move to ground level. Miner was in the elevator for 33 minutes.

An employee was a passenger inside of a fellow employee's personal vehicle that was involved in an incident on the quarry road headed to return to work from their break. Employee initially declined medical treatment but, on the 12th, requested to been seen by medical professionals. Employee was diagnosed with a mild concussion and was given restrictions.

Employee had a Standard Threshold Shift of greater than 25 db HL on their audiogram from 3-10-2025. Right ear results were 26.6.

Employee had a Standard Threshold Shift of greater than 25 db HL on their audiogram from 3-10-2025. Right ear results were 36.3 and the left ear results 31.3.

Employee was to remove the rotary feeder. The rotary feeder is at ground level, so the employees were working from a seated or kneeling position. The crew used prybars to break the seal of the feeder. One side of the feeder came loose allowing the feeder to swing to the opposite side. As the last side broke free, the feeder fell (18"") to the ground, landing on the employee's knee.

Employee was using the Fraco Elevator to travel the Preheat Tower when the elevator stopped between floors. Employee was stuck on the elevator due to a bad motor and was able to exit the elevator at 2:27 pm.

Employee was cleaning the ground floor of the shipping silos with a vacuum truck. As the employee was sucking up material, they felt discomfort in the groin. Employee was seen by the clinic and placed on restrictions.

Two employees got stuck inside the old shipping silo elevator for 40 minutes. Car was just below the 4th floor landing, so employees were able to climb out the top.

EE was replacing the windshield wiper motor on a F-250 truck. After installing, EE plugged the motor in. The wiper was not in the ""Parked"" position and cycled, pinching their left thumb in the wiper linkage. EE was wearing cut-resistant gloves, but it was a pinching situation resulting in a laceration requiring stitches to close. EE returned to work with no restrictions.

3-man crew was troubleshooting the CKD system for the Kiln. Inspection door was removed from the horizontal rotary feeder to investigate the flow of material. Employee got their hand caught in the rotating equipment. Employee was taken to the local ER and received multiple stitches to the right middle finger.

Employee was walking to the changehouse for a break when the employee stepped on rock rolling their ankle causing pain and discomfort. Employee was seen by the clinic and was placed on restrictions.

As the EE was getting set up to try to tighten a leaking hydraulic fitting and the fitting suddenly came apart. EE's lower left leg (shin) was struck by a piece of pipe that came off the system when the fitting came apart. The strike caused a laceration, impact bone fracture, and a hairline fracture to the EE's left shin.

Employee was using a handheld die grinder cleaning the weld out of a bracket. As the employee was grinding the weld, the grinder kicked back causing the grinder to strike their face. The die grinder caused a laceration to the left cheek of the employee. The employee was wearing a face shield, but it wasn't locked into place allowing the grinder to contact their face.

Employee was adding salt to the sand spreader on the F250, as the employee finished loading the salt, the employee used a nearby post to help lower themself to the ground. As the employee did, they caught their arm on a sharp piece of metal that was attached to the post. Employee received a laceration that required stitches and restrictions.

Employee was attempting to dislodge a stuck jackhammer from material. As the employee attempted to free the jackhammer it broke free causing the employees hand to make contact with the structure. This Caused a fracture to the left pinky finger.

Employee was cutting grating. The grinder kicked back, cutting through EE's gloves and made a small laceration of EE's left thumb. Required four stitches to close the wound and was able to return without limitations.

At 6:50 am on February 20, 2023, the Burner Helper noticed a small flame from the Drive Pier of Kiln 3. The fire was small, so the burner helper was able to control it through a small porthole and get it extinguished in approximately ten minutes.

Miner was working on cleaning out a plugged air slide on the silo. After they finished cleaning the section of air slide, miner was attempting to put the port back on with a hammer. As they swung, they lost footing and struck a finger causing a break.

The employee pinched their hand while installing a 10"" pipe.

Employee got stuck inside the shipping silo elevator for 40 minutes. Electrical group was able to reset the elevator to get it back in service. Governor switch had tripped causing the elevator to stop between floors.

Employee was attempting to disconnect an air line from a vibrator on Raw Mill 2 and felt discomfort in their lower back.

While installing metal grating, EE smashed the tip of the finger.

Leveling (pushing/pulling) cement for a mud slab pour with a come along rake in a shallow excavation. While moving backward and pulling rake full of cement, arm came into contact with excavation wall. Sudden stop of arm against wall caused a shoulder separation.

Employee was working on the Kiln Cooler and felt debris enter their eye. Employee continued working not giving any additional thought about the debris. Employee went home at the end of their shift. Employee woke up with discomfort in EE's eye and reported it to their supervisor the day after the incident.

The employee stepped on a raised pallet while it was suspended on the forklift. As the forks began to scope in with the load, the load shifted and as a result of the movement. The employee fell off the load fracturing the left wrist and straining the right knee.

K2 Coal Mill fans stopped operating around 10:30 am. Once fans were fixed the operators tried to start the coal mill. When they bumped the motor, the system over pressurized and opened the rupture disk which opens at 1.5 psi. No injuries or damage occurred.

The injured employee tripped over a cord to a pump that was run through a doorway. When EE tripped, EE fell and hit head on a handrail causing a laceration to the right eyebrow.

While moving a suitcase welding machine, EE felt a sharp pain in EE's lower back.

EE pinched EE's left middle finger while working inside of an aerial lift.

Employee was moving a welding machine by the trailer hitch and pinched right pinky finger between the tongue and a wall.

At 10:30 am, employee taking those measurements the elevator down stopped, leaving EE stuck in elevator between the 1st & 2nd floor. The local Fire Department was able to assist getting our employee out at 11:10 am. The employee was inside the elevator for a total of 40 minutes.

Miner had a reportable hearing loss of 47 after age correction factor in the 4k range in the left ear as well as a loss of 67 after age correction factor in the right ear in the 4k range.

Miner had reportable hearing loss of 42 after the age correction factor in the 4k range in the left ear.

Employee was descending a gravel ramp and slipped losing EE's balance and fell straining EE's lower back. Both sides.

The EE stepped backwards and tripped over one of the 6x6's that a co-worker had just cut. The EE rolled EE's ankle and fell over one of the 6x6's causing a fracture injury to EE's left lower leg. The injury occurred in laydown yard C.

An employee was cleaning out the coal mill rotary feeder for #3 kiln. The employee was closing the door, holding it closed with EE's left hand and using EE's right hand to tighten the nut down to hold the door in place with a wrench. As the employee was tightening the bolt, EE felt discomfort in EE's shoulder.

The employee was attempting to rig up the crane to the K1 tensioner to release tension off the chain that the crew was making repairs on. As the employee went to hook the crane hook to the rigging, the tensioner shifted, pinning the employee's leg against the structure. Laceration to the right leg.

Employee was sweeping material near the sample motor. As the employee stepped forward, the back of their head made contact with the sample port causing discomfort to the neck. Employee was wearing a hard hat and was able to continue their regular shift.

Employee was repairing the grates in the Kiln 3 Cooler. As the employee was in the under grate section, clinker material fell down/breaking (hot center) into the cooler onto our employee causing a burn to the back of the neck.

Right Lower Back Strain while swinging a sledge hammer.

Kiln 2 went down due to an electric motor failure which stopped the kiln from turning. Crew was unable to get the diesel auxiliary drive motor clutch assembly to engage with the gear reducer. Kiln was stopped for 1.5 hours for repairs. We suspect, but cannot confirm, that the oil from the Girth Gear ran onto the Kiln Shell causing a fire to start.

Employee was working on separator and employee hit their elbow off the blow down table. Employee was seen on March 10, 2021 at the clinic and again on April 7, 2021 for a contusion to the left elbow.

Bolt was stuck in the shell of mill, trying to remove stuck bolt holding a pin to remove while other EE was hitting with a hammer. Hammer missed the pin and hit EE on their right hand injuring EE's right ring finger, both EE were wearing proper PPE.

#1 kiln was running in a normal state when the Process Supervisor noticed that the coal mill CO at the mill inlet was reading approximately 100 ppm CO The operator cut the coal feed to the coal mill. As soon as the Kiln Operator stopped the feed of coal to the coal mill EE received an alarm that the coal mill rupture vent was open.

An employee was operating the Vermeer Walk-Behind cleaning up around the #1 Cooler Vent Fan. As the employee was backing up in the tight working space, the employees arm struck an I-Beam. This caused their right arm to go forward and bend EE's right wrist back into EE's arm causing a pinch point between the I beam and the piece of equipment. Fractured right wrist.

At 11:00 am an operator was loading rocks into the haul truck. As the loader was lifting to dump into the truck the loader shifted causing a large rock to come back into the cab breaking through the front windshield. The rock and windshield landed on the employee's knee and hand. Employee has a fractured finger and needed stitches to close a laceration to the left ring finger.

Employee was working in the backend building on the Z drag for Kiln 1 when a big gust of wind came through and blew dust debris in employee's left eye.

Employee was getting onto Finish mill 4 w/ladder. Employee raised ladder it came in contact with a man basket causing dust get in EE's left eye. Employee was wearing standard issued safety glasses. Eyes were flushed on site, taken to clinic for medical evaluation, and given prescription eye drops. MEDICAL TREATMENT ONLY

Employee was pulling on cross-tie trying to square cribbing up under Finish mill. In doing so employee felt right arm pop or strain. Employees were putting cribbing under mill prepping for changing the slide shoes out once the mill was raised.

Employee was removing DA cartridges and in doing so EE scraped EE's left finger. Finger became infected the next day.

While using a mixing drill to mix mortar for brick installation, employee's glove was tangled in the shaft of the paddle bit causing a cut on pinky finger that was treated with stitches.

Employee was working in the clinker cooler when clinker dust went into EE's eye. Employee requested to go to the eye doctor right away.

Employees removing old vacuum truck hose from S end of the clinker tunnel. An employee was at Ground Level while the injured employee was down in the Tunnel. As the hose was pulled, a kinked section flew up and struck employee in the mouth.

Employee was using a prybar to lift the tail pulley on finish mill 4 when the prybar slipped and dropped roughly 6 inches causing employee to injure lower right part of back.

An unplanned ignition of coal dust occurred in the #2 kiln coal mill system fan as a result of an inboard bearing failure. The bearing failure created the ignition source. The rupture vent opened as it should and there were no personnel injuries or equipment damages.

While changing gudgeon bolts on the South Dribble Screw to # 2 Cooler attempted to stand from crouched position. This resulted in twisting of the employees right knee, and feeling a ""pop"" with pain.

The employee states was lifting a 45lb. bottle of water and felt pain in the groin. The employee was later evaluated and determined to require hernia surgery.

The employee was threading a bolt through a coupling when employee's right hand slipped off ratchet. Momentum caused right forearm to come into contact with the north coupling cutting right forearm just past glove.

The employee was removing a starter bucket from MCC 3 for the #3 Kiln Heat Exchanger screw. When they began to remove the bucket a flash occurred causing 2nd degree burns to their left and right hands.

At approximately 8:40am a contractor employee was using the passenger elevator in the cement silos. The elevator experienced a problem that shut the elevator down while the elevator car was positioned near the 4th floor. The employee was inside the elevator car for approximately 38 minutes.

The employee was lowering a raw mill feed chute into position when the chute shifted and the employees left hand was pinched between the chute and elevator.

The employee was swinging a sledge hammer to drive in a wedge on a Symons crusher. The employee partially struck the pin and the sledge hammer continued around. Both hands were on the handle of the sledge hammer. EE right hand middle finger struck an adjacent support causing a laceration requiring sutures.

At approximately 11:45am two Millwrights were using the Blending Bins passenger elevator when it stopped moving. The Lehigh electrical dept. was called to the Blending Bins to troubleshoot the problem. The electrician reset an interlock switch in the drive room to restore operation of the elevator. The two millwrights were in the elevator approximately 45 minutes.

The #1 kiln coal mill shutdown by interlock when the gas conditioning tower lost water flow. The coal mill went down loaded. While attempting to empty the coal mill by jogging the main mill motor the cyclone rupture vent opened. There were no injuries or equipment damages.

The employee was using a ratchet to remove a bolt while trying to uncouple a motor. The ratchet being used was a 1/4"" drive with a 3/8"" allen socket inserted. While using left arm/hand to loosen the bolt the ratchet slipped. When the wrench slipped the employee felt pain in left shoulder/neck area. The employee reported continued pain later and was sent for evaluation.

The employee was attempting to install a shackle onto the crane cable for the west overhead crane when ee felt pain in left forearm. The employee was seen by a local physician who placed the employee on work restrictions.

The employee received dust in eye while trying to clean an air slide and removing a chunk of material from the #1 FM vibrating conveyor. The employee was seen by a local eye doctor who removed the piece of debris from eye.

The employee was attempting to clean an airslide in the Mill Dept. when they began feeling nauseous. The employee felt that they had gotten too hot during the 45 minutes that they worked on the airslide. The employee was treated at a local hospital for a heat illness and was placed on a work restriction for two days.

The employee was in the electrical shop when EE was picking up tool bag out of the bed of a Kawasaki Mule. While picking up the bag the employee felt pain in left elbow. The employee was seen at a local clinic where EE was given an injection and prescribed physical therapy.

The employee was helping to install a new disconnect switch on the stand-by compressor in the blending bins. While the employee was lifting the disconnect to insert wires felt pain in left shoulder. The employee was eventually prescribed physical therapy.

The employee was actuating a lever for the FK pump feed chute gate. While pulling the lever downward the back of hand contacted a piece of angle iron causing a laceration to the backside of the right hand. The laceration required stitches.

While removing a tarp off a man lift, there was a wedge that was wrapped up in the tarp that fell and struck the employee in the face causing a laceration to the upper lip and loss of the right K9 tooth

Employee was stepping off a ladder when ee felt pain in lower back.

Employee claims that as EE was grinding on top of kiln shell, EE slipped on some product and twisted left knee.

Team member pulling 7/8 inch steel cable and strained right arm and shoulder. Team member was placed on restrictive work functions by medical personnel.

The employee was opening the door #3 on the electrostatic precipitator when ee felt a pain in right arm bicep area.

On 10 December 2015 at/about 11:30 PM, a rupture disk on No. 3 Coal Mill opened releasing pressure build up to system.

Team member preparing to repair a leak in cement chute when clinker dust was knocked free from duct work and fell in left eye of team member.

On 06 November 2015 at/about 9:20 AM Coal Conveying Blower locked up burning belts off, blower motor remained running. This resulted in pressure build up that caused pressure relief devices (Rupture Disks) to blow off releasing built up pressure. No injuries were incurred when incident occurred or during repair activities.

Team member sustained fractured right foot and diagnosed as fractured on 10/26/15 by medical personnel. *This was determined to be a contusion by the Podiatrist.

Team member opening boxes and lacerated right thumb requiring sutures.

Chunks at grate truck bulk loading area.

Team member strained ligaments to left elbow.

Team member strained back

Employee was stepping down from #2 rock feeder, stepped on uneven surface and fell to the ground, striking his left knee.

while using a pipe wrench to loosen a pipe, pain felt in left palm of hand at middle finger joint

The employee was sweeping material near the kiln firing hood when a foreign object entered his left eye. The employee was seen by the local eye doctor where the foreign object was removed.

The employee was using a punch bar to poke material that had stopped flowing in a the #2 shale bin that feeds the shale feeder table. As the employee tried to dislodge the material with the bar he slipped fell forward striking his right knee against the steel plate surround the bin. The employee was seen by a physician and placed on restricted duty.

Employee was bricking in a kiln. While driving in shims to tighten the brick up he struck his hand itching it between the shim and the head of the hammer causing a 1"" cut in his hand. Supervisor transported him to the ER where he received 3 stitches in his hand.

Employee was climbing up 2-rung ladder to cross over #2 reclaim screw at backend of kiln #3. Employee stated he slipped or lost grip of ladder and fell and hit left side of body on top cross-over ladder.

Employee bent down on right knee, picked up a 4 conductor #6 cable to check that it was the correct wire spool. As employee raised back up to standing position, employee felt a pinch in lower back and by 12:30pm employee could hardly stand up straight.

Employee was cleaning the 990H on overtime, employee stated that he was climbing down off of the loader when he slipped and fell to the ground (roughly 5'). No witnesses. Supervisor arrived shortly after the fall and noticed the employee laying on the ground. Supervisor asked if he was ok and the employee stated that he couldn't get up and his neck was hurting. 911 was notified.

At approximately 9:10pm the feeder helper ee was traveling in the passenger elevator at the cement silos. The elevator car stopped and the employee was inside the car for more than 30 minutes without the elevator working.

At approximately 2:08pm the kiln operator received an alarm that the East and West explosion vents had opened on the #2 kiln coal mill system. After inerting the system and required safety checks were completed an internal inspection was conducted. Some accumulations of coal was found around the inside of the explosion vent framework.

Employee finished flashing the refractory in the #2 Kiln and was cleaning up the area. Employee stepped up onto the #2 kiln sill to help clean when some uncured refractory fell and landed on him causing the employee to fall backwards (roughly 2'7"") onto the ground on left hip. Employee after taken to the ER the employee has a fractured bone in the hip.

Explosion Vents were modified to fit new style of clips. Manufacturer of old clips went out of business, causing us to fabricate/modify the bracket so the new clips could be used. When new bracket was installed it left a small lip/pocket for coal fines to collect causing it to smolder and build up and then fall down into cyclone causing ignition. (3rd Time) Has not since.

Explosion Vents were modified to fit new style of 1 PSI rated clips. Manufacturer of old clips went out of business, causing us to fabricate/modify the bracket so the new clips could be used. When new bracket was installed it left a small lip/pocket for coal fines to collect causing it to smolder and build up and then fall down into cyclone causing ignition. (2nd Time)

Explosion Vents were modified to fit new style of 1 PSI rated clips. Manufacturer of old clips went out of business, causing us to fabricate/modify the bracket so the new clips could be used. When new bracket was installed it left a small lip/pocket for coal fines to collect causing it to smolder and build up and then fall down into cyclone causing ignition.

Employee walked out of the mechanics shop on the east side and slipped on some ice. Employee fell down and hit head on ice causing a cut on the back of the employees head. Cut required 3 staples to close.

Employee was up on #2 ball mill removing man head. Employee was using 20lb sledge to hit a wrench that was on a nut on the man head. While swinging sledge employee missed the wrench causing him to twist un-normally and tense up causing a muscle strain in employees lower back left side.

Operator received an alarm in the ccr indicating that coal mill vent doors opened. No personnel injuries or property damages. No sounds heard from workers in burner building or ccr. kiln operating parameters, coal mill inlet and outlet temperatures were normal at the time of the event. Small amount of smoldering coal was found to be present in the inlet duct.

Coal Thayer belt tripped causing coal mill to become lean. Mitchell IN was receiving a winter storm, the combination of ice and snow that built up on the vent might have caused a delay in when pressure was released. Vents are set to release at 1 psi. Some smoldering coal in the duct work on the bottom just right inside of door during investigation

Employee was bent over pushing the crusher door shut when he felt a twinge in his lower back. Went home iced it and when he woke up this morning he couldn't stand up straight.

Employee was changing the laminating rings on the east crane west bridge drive when removing the guard the guard bumped the motor causing the end of the expanded metal to cut through glove into employees left palm, causing a 1 inch cut which needed 4 stitches.

Employee was using an utility knife to open a tube of caulk. While cutting through the tip of the tube the knife came through and cut his knee. Was taken to IU Health Clinic and was given 4 stitches and returned to work.

Employee was lifting and cleaning 40lb jacks in the mill building and while employee was picking up one of the jacks he felt a pop in his stomach/belly button area. No witnesses don't know if proper lifting was used. Employee was diagnosed with an abdominal strain and put on restrictions

4:30pm we received an alarm that the East&West explosion vents on the #1 coal mill had opened. No personnel injuries or property damages. It was discovered that an accumulation of smoldering coal dust was foiund at the bottom of the mill. This was determined to be the source of the ignition. All parameters of the coal mill circuit were normal leading up to the vent doors opening.

Two co-workers and I were up on the burner floor adjusting the coal pipe on #3 Kiln. I had a 36"" pipe wrench and was trying to adjust the turn buckle. While doing so the wrench slipped and I felt a pop in my left shoulder causing a burning sensation and pain.

The employee was descending a ladder and lost his footing causing him to fall. The employee twisted his left knee causing a strain. The employee was placed on restricted duty.

During the heat up of the #3 kiln an ignition of natural gas occurred in the electrostatic precipitator. This event caused one of the sixteen explosion vents to open. No persons were injured or equipment was damaged.

The employee was kneeling down on his knees on a grating floor installing a tipping valve. The employee experienced fluid build-up on his right knee. The fluid build on the right knee had to be drained of fluid on May 29, 2012. The employee was placed on a work restriction at that time.

The employee squatted over to pick up a small 2 gallon bucket of trash when he felt pain in his right testicle. The employee was seen at a local clinic and diagnosed with a strain and placed on a work restriction.

Two contractor employees were riding the cement silos passenger elevator at the end of their shift. The elevator stopped due to an interlock switch problem. The two men were stuck in the elevator for approximately 1 hour until repairs were made. The elevator was equipped with a functional telephone.

The employee was adjusting the right hand arm rest forward in the CAT 990 Loader. Her hand slipped off of the arm rest causing her right hand to go forward and striking a control lever with her right hand ring finger. The employee developed a ganglion cyst on her knuckle which had to be surgically removed on 4/6/2012 making the accident reportable.

On Wednesday, January 11th the #2 kiln and coal mill system were being shutdown to replace the tangential primary airline. The kiln operator began to lower coal feed rate tonnage as is normal procedure in order to empty the coal mill. When the coal mill feed rate was finally showing zero tons per hour the kiln operator received an alarm that the west explosion vent opened.

The employee was lifting an inspection cover to inspect the #3 kiln feed screw/belt system when he bumped his head against a counterweight that was hanging off of the plug screw flapper gate arm assembly. The counterweight fell and struck the employee's left hand causing a laceration.

At 8:35 pm the kiln operator received an alarm that the #1 coal mill system vents opened. The kiln and coal mill system were shutdown. During the investigation it was discovered that the coal mill inlet duct was hot (surface steel). An accumulation of coal dust had accumulated at the inlet duct and began to smolder causing an ignition source in the system.

The employee was pulling on a vacuum hose which had filled with material in order to empty it. As the employee was backing up and pulling the vacuum hose tore and the employee fell backwards to the ground. The employee fell into a steel beam pier causing pain in his lower back.

The employee was using a shear machine to cut a piece of plate steel. The employee inserted the piece of steel into shear and it lifted up pinching his right hand small finger between the steel plate and the guard/barrier. The employee sustained a fracture and two lacerations requiring stitches.

The employee was operating a skid steer loader when he had dust enter into his left eye. The following day the employee was assisting in the stemming of a production shot when he received dust in his left eye.

The employee stepped out of a maintenance truck at the east end of the material storage building to begin work on the east OH crane bucket. The employee slipped on wet cement kiln dust that was on the ground and twisted his right knee. The employee was referred to physical therapy which began on August 9, 2011.

At 1:34am the #1 coal mill was operating normally when the kiln operator received an alarm that one of the two explosion vents opened. Hot material was inside the mill inlet ductwork. The coal system was flooded with water.

At 3:03am the #2 coal mill experienced an airlock which stopped coal feed to the coal mill. When the coal feed stopped the coal mill exit temperature began to slightly rise from 127 degrees F to 131 degrees F. Both rupture vents opened due to an ignition of coal dust in the system.

The #3 Coal Mill went down loaded due to a high mill exit temperature. Upon restart some 3 1/2 hours later and ignition occurred inside the mill circuit causing one of the coal mill vents to open.

At 9:28pm the control room operator received an alarm that the East rupture vent door for the #1 coal mill system was open. The primary air fan belts had slipped causing the primary air to slow and then resume normal speed. This caused a low sweeping velocity in the piping and was likely the ignition source.

The employee was cleaning under the west truck load-out scale, when a foreign body entered his right eye causing irritation. The employee was sent for medical treatment for the removal of the foreign body.

At 5:11 pm on Monday, October 25th the Kiln Operator received an alarm that the west explosion vent door opened. It apprears that a backpressure/ignition resulted from the waste(excess) air valve to the firing hood being completely closed.

The employee was attempting to remove a chunk of limestone from the #2 Raw Mill feed table. The employee was rolling the chunk off the table and then lifted it, twisted and tossed the chunk to the ground. The employee reported on Wednesday, October 20, his next scheduled work day severe pain in his lower back.

At approximately 8:30AM the #2 coal mill system lost coal feed and the coal mill explosion vents were ruptured.

An ignition of coal dust occurred inside of the #2 coal mill system which caused the two explosion vents to open and relieve pressure. A hot ember or material entered the coal mill causing the ignition.

The employee was working at the bottom of cement silo #15 when he reached to grab a hammer off the flange. When he dragged the hammer toward him he pulled some dust off which entered his left eye. The employee was given an RX for his eye.

The employee was assisting a co-worker to position a removable section of floor grating back into position. The floor grating was setting in position to cover the floor opening, but injured employee place his foot on the corner of the grating to further position it when it tipped down. The employee lost his balance and fell approximately 9 1/2 feet to the lower level.

The employee was attempting to loosen an oil filter on a Chevy Pick-up truck while lying on his back. The filter wrench slipped causing his right shoulder to jerk back. He struck his shoulder on the truck framework. An MRI was later conducted. On 6/25/2010 the company was notified of a tear in the employee's rotator cuff and bi-cep.

At approximately 7:41am the rupture vents on the #2 coal system opened due to an ignition of coal dust inside the coal grinding circuit. Prior to the ignition the coal weigh belt stalled causing a reduced amount of coal feed into the grinding mill which resulted an elevated temperature at the mill exit. There were no personnel injuries or equipment damages.

The #2 coal weigh belt stalled due to a drive sprocket catching on a guard. During the period of time the coal mill was starved of coal feed and explosion occurred inside of the #2 coal mill sytem. Both rupture vents opened to vent pressure. No equipment damages or personnel injuries occurred.

At approx. 11:33 pm an explosion occurred inside the #2 coal mill system resulting in the opening of both explosion vents. There were no personnel injuries or equipment damages at a result of the accident. Metallic objects were found in the coal mill which created an ignition source.

The employee was standing next to a co-worker when the co-worker opened a port on a chute that contained hydrated lime. The hydrate lime dust came out of the port and entered the employee's eyes causing burns. The employee was given prescription medication for his eye injuries.

The two explosion vent for the #1 kiln coal mill system opened due to a coal dust ignition inside of the #1 kiln booster fan/ductwork. A Hot Spot was found in the bottom of the fan housing.

While trying to start the #3 coal mill in order to empty it the pressure relief vents opened. An ignition of coal dust occurred in the coal mill system ductwork. Ignition source was in the system recirculation duct.

The #3 coal mill shutdown automatically when a high temperature occured. The coal mill was loaded. After approximately three hours the coal mill was started to try to empty the coal when an unplanned ignition of dust occured resulting in the two explosion vents opening.

The employee was removing a circle cutting attachment from the end of the plasma cutting torch head.EE had gripped the attachment with his left hand and the torch handle with his right hand.EE accidentally pushed the trigger on the torch turning the plasma cutter on. He received a third degree burn to his left hand palm.

The #3 coal mill system explosion vents opened at 8:06 PM due to an increased pressure created by an ignition of coal dust. High coal mill temperatures occured prior to the event which resulted in coal burning in the inlet duct of the coal mill. There were no personnel injuries or equipment damages.

The employee was welding on a screw conveyor for the #3 kiln system when he received flash burns to both of his eyes.

The employee placed a clinker sample ladle under the head pulley of the #3 kiln transfer pan conveyor to obtain a sample. The ladle was caught by the conveyor severing the employee's right hand ring finger between the ladle handle and the framework.

The employee was working in the machine shop trying to move an overhead crane wheel that was lying on the floor when he felt pain in his left hip and lower back. The employee was given a prescription on 7/21/08 to begin physical therapy on 7/24/08.

At 7:10pm a plant-wide power outage occurred. The #2 coal mill shutdown loaded with coal. The operator then bumped the coal mill to empty it and an explosion occurred. The booster fan sustained damages and the explosion vents opened.

Due to heavy rains the Limestone Quarry crusher building was flooded. All power was shut off and pumping of the water has began. An adjacent creek overflowed its bank causing the flooding of the building.

An unplanned ignition of coal dust occurred in the #2 kiln coal mill circuit causing the two explosion vent panels to open and vent pressure. No personnel injuires or property damages.

A second unplanned ignition of coal dust occurred in the #2 coal mill circuit while trying to re-start the coal mill. There were no personnel injuires or property damages.

An unplanned ignition of coal dust occurred in the panels to open and vent pressure. The ignition of coal dust caused the explosion vent panels to open and vent pressure. There were no personnel or equipment damages. The investigation as to the cause of this event is ongoing.

The employee was working from a ladder when the ladder slipped out from under him and he fell approximately 4 feet to the catwalk. While falling his right forearm sustained three lacerations from contact with a guard. The employee received sutures.

At approximately 1 pm a grease fire occurred on the #3 clinker cooler clinker breaker's north bearing. Due to excess heat from the cooler the grease caught fire. The fire was extinguished several times and flared back up. The fire was extinguished on and off for approxiamtely 50 minutes.

The employee was spraying graphite on a kiln roller. The employee's left hand index finger contacted a conduit bracket on the kiln and caused a laceration. The laceration required 5 stitches.

The employee was walking across the raw mill feed table floor when he tripped over a rope that was being used to secure an extension ladder. The employee fell and injured his right knee. An MRI revealed a tear in the right knee tissue.

The #3 coal mill system went down loaded with coal due to a secondary firing fan motor failure at 7:45AM. The motor was replaced, and when the operator began to ""bump"" the coal mill empty several hours later an explosion occurred in the coal mill circuit causing the pressure relief explosion vent to rupture. No employee injuries or equipment damages occured.

The #3 coal mill was slowly being brought back up to full production rate when an explosion occurred in the coal mill circuit causing the pressure relief explosion vent to rupture. The shift supervisor had opened and then closed the tramp iron tipping valve to make sure it was operating correctly and appproximately 10 seconds later the explosion occurred.

A short occurred causing the two 24 volt power supplies to trip out. When the power supplies tripped this faulted the power to the analog control loops to several field devices. The coal mill weigh belt stopped and the two tempering air dampers stopped. An explosion occured in the #3 coal mill or ductwork causing the explosion vent to rupture as designed.

Chain Fall Pulley accident - got finger caught in chain.

The employee was using a utiity knife to cut a fan belt when the blade contacted the palm of his left hand cuasing a laceration. The laceration required 13 stiches.

The employee was pushing a two wheeled cart in the storeroom when he slipped on the metal casing surrounding an ""in-floor"" scale. The employee fell to the ground and when trying to catch himself he injured his right shoulder. The employee had surgery to repair a right rotator cuff tear on 11/13/2006.

The employee, a mechanic, reached into the engine compartment of the CAT 950G front-end loader to check the tension on the alternator belt. At the same time the loader operator tried to start the loader. The injured employee's left hand index, middle, and ring fingers were pulled between the belt and sheave resulting in fractures and lacerations of these fingers.

Reported 9/5/06 - Helping load a shot and twisted knee.

The employee was using a utility knife to cut the string off of a roll of vacuum hose when the knife contacted his left hand small finger causing a laceration. The laceration required four stiches.

The employee was lifting an oil filter when his left forearm came in contact with the sharp side of an air compressor housing. This caused a laceration to the employee's left forearm requiring three stiches.

The #2 coal mill system was being ""jogged"" in order to empty the mill of coal. The mill had gone down fully loaded at 4pm on 7/6/06. When jogging the mill an ignition occurred in the ductwork, mill, or cyclone causing the rupture disc to rupture.

The #2 coal mill drive shaft coupling broke causing the coal mill and coal mill system fan to stop. Due to the coal mill system fan stopping the primary air fan intake air became very hot (>300 F) and ignited the pulverized coal dust in the fan or ductwork causing an overpressure in the system and rupturing the coal mill rupture disc. There were no personal injuries.

The #2 coal mill system rupture disc was ruptured due to an overpressure inside the coal mill, duct work, or coal cyclone. This was caused by an unplanned ingnition of coal dust. There were no personal injuries or property damage associated with this incident.

The employee fell off of a bicycle and tried to catch himself with his right arm. The employee sustained a shoulder injury. An MRI was conducted on the right shoulder. The MRI results were received on 6/20/2006 and revealed a rotator cuff tear.

At approximately 6 AM a belt conveyor caught fire due to contact with hot clinker. The belt fire lasted more than thirty minutes.

At approximately 11:39 PM the rupture disc burst on the #3 coal mill system. An overpressure (deflagration) occurred in the coal mill, cyclone, or ductwork causing the disc to rupture. No personnel or equipment damage occurred.

The employee was using a knife to remove old electrical tape for the wiring on a fan. The employees knife slipped off of the electrical tape and punctured his right thigh requiring three stitches.

A Contractor employee was striking an oxy/fuel torch when an unplanned ignition of acetylene gas occurred near the #2 clinker cooler. There were no personal injuries or equipment damage. The contractor is Huelsman-Sweeney Construction.

The employee was ascending a stairway when he missed a step and fell forward, catching himself against a handrail. The strain from catching himself on the handrail allegedly caused two hernias. The employee underwent surgical repair for the hernias on 2/2/2006.

Two employees were changing two 12 volt batteries on a welder. The employee removed the ground cable from both batteries first. The employee then removed the positive cable from one battery and were attempting to remove the positive cable from the second battery when that battery exploded.

On Friday, April 22, beginning at approx. 6 pm, three power outages occured. Upon restarting of the #3 kiln coal firing system, an explosion occured within the mill or ductwork. The safety rupture disc burst as designed. No personal injuires or property damages were sustained.

EE was raking up cuttings with a hoe and said that he had pulled a muscle in his shoulder.

The employee's right hand index finger was caught between the handle of a mallet and a brick shim causing a small laceration requiring three stitches. The employee was laying brick inside the #2 kiln.

A fire occured inside of the Hydraulic Roll Crusher building and the basement area below the Hydraulic Roll Crusher building. The fire was extinguished by a local fire department. There were no personal injuires, but property damage did occur.

At 8:59 am there was an ingnition of coal dust within the #2 coal mill ductwork system. There were no personal injuries or equipment damage. The safety rupture disc worked as designed and relieved pressure from the system created by the explosion. Foreign metal found in the coal mill is the suspected ignition source.

The employee was using a utility knife to cut a section of skirt rubber. As the employee attempted to cut the rubber the utility knife slipped and contacted his left forearm causing a laceration. The employee required 5 stitches.

At 5:30 pm an ignition of coal dust occurred within the #3 kiln coal firing system causing the pressure relief vent to burst. No personal injuries or property damage resulted from this occurrance.

AT 7:50PM AN IGNITION OF COAL DUST OCCURED WITH THE #3 KILN COAL FIRING SYSTEM. THE PRESSURE RELIEF VENT WAS RUPTURED AS IS DESIGNED TO DO. THE IGNITION SOURCE IS NOT KNOWN AT THIS TIME. A FUEL BLEND OF RECYCLED PAPER PRODUCT & COAL WAS BEING USED. NO INJURIES OR PROPERTY DAMAGE.

A NEW OXYGEN BOTTLE WAS CONNECTED TO A REGULATOR. A MILLWRIGHT CRACKED THE OXYGEN BOTTLE VALVE. FLAMES BEGAN COMING OUT OF THE REG.BODY (THRU VENT HOLES). THE FLAMES BURNED APPROX. 40 SECONDS & THEN SELF-EXTINGUISHED. THE VALVE ON OXYGEN BOTTLE WAS THEN CLOSED. A REGULATOR BURN-OUT. NO INJURIES.

AT APPROX. 9:30 PM ON MAY 6, 2004, DAMAGE WAS DISCOVERED ON THE #2 KILN ELECTOSTATIC PRECIPITATOR (ESP). INITIAL INVESTIGATION REVEALS THAT AN EXPLOSION MAY HAVE OCCURED INSIDE THE #2 ESP. THE INVESTIGATION IS CONTINUING AT THIS TIME. INVESTIGATION REPORT WILL BE SENT TO VICENNNES UPON COMPLETION.

The employee was using a ratchet to loosen a bolt on a coupling when the ratchet slipped off of the bolt causing his right index finger to be pinched between the ratchet handle and a section of angle iron below. The employee recieved a small fracture and three stiches as a result.

The employee was using a 12 gauge shotgun to shoot a large clinker ball. The employee was standing outside of the clinker cooler shooting through a port hole. When the gun fired the recoil caused the hammer to puncture the employee's right hand between the thumb and index finger. The employee recieved five stitches.

The employee dismounted a forklift and attempted to pull a section of screw conveyor onto the forks. The screw struck her in the knee and she stepped backwards into a pothole cuasing her left knee to suddenly shift. An MRI was performed and revelead an medial meniscus tear.

The employee was positioning a steel casting inside the discharge end of the #1 kiln. The casting shifted and the employee cuaght it with his left arm. His left shoulder was suddenly pushed backward causing pain. The employee had an MRI on 4/6/04 revelaing a rototor cuff tear. The employee had surgery on the shoulder on 4/14/04.

AT APPROXIMATELY 11:05 PM THE #1 KILN COAL FIRING SYSTEM EXPERIENCED ON EXPLOSION IN THE ENCLOSED DUCT WORK OR COAL MILL CAUSING THE PRESSURE RELIEF RUPTURE DISK TO BURST. THIS RUPTURE DISK IS DESIGNED TO RELIEVE SYSTEM PRESSURE IN THE EVENT OF AN EXPLOSION.

The employee's left hand ring finger was caught between a pipe wrench and a vise grip causing a laceration. The laceration required seven stiches.

THE EMPLOYEE WAS ENTERING A HOPPER ACCESS DOOR BELOW THE #1 FINISH MILL DUST COLLECTOR. WHEN HE ENTERED HE WAS ON HIS KNEES IN THE DOOR FRAME. HE LOST HIS BALANCE AND FELL FORWARD AGAINST THE OPPOSITE SIDE WALL. HE CAUGHT HIMSELF WITH HIS RIGHT ARM. EMPLOYEE SUSTAINED A RIGHT ROTATOR CUFF TEAR AND REQUIRED SURGERY. THE FIRST LOST WORK DAY WAS 1/14/04.

THE INJURED EMPLOYEE WAS LIFTING A DUST COLLECTOR CAGE AND BAG OUT OF THE TUBE SHEET IN THE N.E. COMPARTMENT OF THE #2 KILN CLINKER COOLER DIST COLLECTOR. AS HE LIFTED THE BAG AND CAGE UP WITH BOTH ARMS HE FELT A SHARP PAIN IN HIS RIGHT SHOULDER. THE EMPLOYEE BEGAN LOSING TIME FROM WORK SEPTEMBER 29, 2003.

THE EE WAS ASSISTING ANOTHER EMPLOYEE TO REMOVE A LARGE COOLING FAN RADIATOR FROM THE PRIMARY CRUSHER COOLING FAN SYSTEM. THE RADIATOR WAS ATTACHED TO A MOBILE CRANE FOR LIFTING. WHEN THE EE B EGAN PULLING ON THE SIDE OF THE RADIATOR HE FELT A SHARP PAIN IN HIS RIGHT ELBOW. THE EE REQUIRED SURGERY ON THE ELBOW & BEGAN LOSING TIME ON JULY 24, 2003.

THE EMPLOYEE WAS DESCENDING A 6 FOOT STEP LADDER AND WHEN HIS LEFT FOOT CONTACTED THE BOTTOM STEP IT SLIPPED OFF AND WENT TO THE GROUND. THE EMPLOYEE LOST HIS BALANCE AND TWISTED HIS LEFT KNEE . THE EMPLOYEE HAD SURGERY ON THE LEFT KNEE ON 8/13/03. EMPLOYEE BEGAN LOSING TIME ON 8/13/03.

THE EE WAS STANDING ON THE TOP STEP OF A PORTABLE STAIRWAY (APPROX 38"" ABOVE FLOOR LEVEL)THE EE WAS USING AN AIRLANCE TO CLEAN A CHOCKED HOPPER WHEN THE EE TURNED THE AIRLANCE ON HE LOST HIS BALANCE & FELL BACKWARDS DOWN TO THE FLOOR LEVELEE STRUCK HIS HEAD ON A STAIR CAUSING MOMENTARY LOSS OF CONSCIOUSNESS & A CONCUSSION EE BEGAN LOSING TIME 3/19/03

EE WAS WORKING CLOSE TO ROTATING EQUIPMENT. MISJUDGMENT RESULTED IN CONTACT WITH EQUIPMENT. THE EE WAS SHAKEN AND SCRAPED & A LITTLE SORE BUT NO MAJOR INJURIES. THE SCISSOR LIFT WAS DAMAGED - THE PLATFORM WAS TWISTED.

EE DROVE THE YARD MAIL TRUCK TO THE LIMESTONE QUARRY AND PARKED NEXT TO THE PRIMARY CRUSHER CONTROL ROOM TO DELIVER MAIL. WHEN THE EE STEPPED OUT OF DRIVER'S SIDE HE SLIPPED ON THE SNOW AND IC E CAUSING HIS RIGHT KNEE TO TWIST. THE EE BEGAN LOSING TIME FROM WORK ON 3-7-03. RIGHT KNEE REQUIRED SURGERY.

THE EMPLOYEE WAS WALKING FROM THE MAINTENANCE DEPARTMENT BUILDING TO A STORAGE BUILDING WHERE HE SLIPPED AND FELL ON A SNOW & ICE COVERED GRAVEL SURFACE. THE EMPLOYEE SUSTAINED INJURY TO THE L EFT KNEE. THE EMPLOYEE BEGAN LOSING TIME ON APRIL 3, 2003 AT WHICH TIME HE HAD SURGERY ON THE LEFT KNEE.

THE EE WAS DISMOUNTING THE ROAD GRADER WHEN SHE STEPPED OFF OF THE LOWER ACCESS STEP TO THE GROUND SHE FELL BACKWARDS TO THE GROUND. SHE TRIED TO CATCH HERSELF WITH BOTH HANDS AND ARMS. THE EE SUSTAINED A FRACTURE OF THE LEFT WRIST.