Activated carbon or charcoal manufacturing · Kentucky

Big Sandy Plant

Catlettsburgh, KY · ~205 workers · 3 years of OSHA Injury Tracking Application data.

A
Excellent Safety Record
1.0
Avg TCR
3.3
Industry avg
0
Fatalities
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The verdict

Big Sandy Plant runs at 30% of its industry's injury rate - far safer than the typical Activated carbon or charcoal manufacturing workplace, earning a grade A.

Big Sandy Plant: 1.0 TCR = 30% of Activated carbon or charcoal manufacturing BLS 3.3 · 3y Form 300A (see methodology below)

Big Sandy Plant safety composite

Big Sandy Plant scores strongest on total case rate (tcr) (safer than 83% of same-industry peers) and weakest on dart rate (safer than 49%), blended into one 0-100 breakdown against same-industry peers. A missing measure drops out and redistributes its weight rather than deflating the score. This is a per-dimension breakdown, distinct from the single letter grade above it (which weights TCR alone against the BLS industry benchmark).

C

63/100

Percentile-weighted across 3 of 3 measures

Total Case Rate (TCR)
B 0.98 per 100 workers

Safer than 83% of industry peers

DART rate
D 0.81 per 100 workers

Safer than 49% of industry peers

Fatalities
D 0

Safer than 51% of industry peers

Benchmarked live against every credibly-rated employer in the same NAICS industry code in the current OSHA extract (a segment must have at least 8 rated peers to benchmark). Not a legal or compliance determination; PlainSafetyScore's own weighting (TCR 40%, DART 35%, fatalities 25%).

Big Sandy Plant held a steady TCR band

Big Sandy Plant's TCR held near 0.0 from 0.9 in 2022 to 0.8 in 2024. Peak filing year was 2023 at 1.3 TCR. In 2024, DART was 0.83× this establishment's average TCR (severity share of cases).

2022=0.9 · 2023=1.3 · 2024=0.8

OSHA ITA Form 300A scorecard

Establishment book 325998 · Catlettsburgh, KY AT/BELOW-IND · MID

Grade A · TCR 1.0 · 30% of ind

  • DART 0.8 DART
  • RANK #3/6
  • PHOTO Henkel US Operations…
  • BOOK 3y book
  • INJ 7 inj
  • SIZE ~205 FTE

Nearest TCR peer: Henkel US Operations Corporation (0.0 TCR gap)

Read with this employer → · Industry book → · Kentucky employers → · Look up another →

Big Sandy Plant in the TCR neighbourhood

Average Total Case Rate among this establishment and nearest same-industry peers

TCR

What this shows Big Sandy Plant averages 1.0 TCR (30% of the Activated carbon or charcoal manufacturing BLS benchmark).

Source U.S. Department of Labor, OSHA Injury Tracking Application (Form 300A) As of 2026-08-25

Big Sandy Plant TCR series: 2022=0.9 · 2023=1.3 · 2024=0.8 · BLS 3.3

Where Big Sandy Plant falls in its industry

485 Activated carbon or charcoal m establishments

Safer than 83% of graded establishments in this industry, whose median TCR is 2.5.

More dangerous than peersSafer than peers

Narrower to Kentucky alone (the establishments it most directly competes with for workers and contracts): ranked #3 safest of 6 Activated carbon or charcoal m employers in Kentucky.

Big Sandy Plant (205 employees, TCR 1.0) among 29 same-industry peers, split at the industry median of 62 employees and a TCR of 2.5 2×2 strategic matrix plotting 30 entities by Average employees (X) and Total Case Rate (Y), with a crosshair dividing the plot into four quadrants. Larger & higher-riskSmaller & higher-riskLarger & saferSmaller & safer than peers 05001,0001,500 051015 Average employees Total Case Rate Big Sandy Plant
Big Sandy Plant (205 employees, TCR 1.0) among 29 same-industry peers, split at the industry median of 62 employees and a TCR of 2.5

Big Sandy Plant has more employees than the Activated carbon or charcoal manufacturi median and a lower injury rate than the industry's median TCR of 2.5. Workforce size and injury rate do not always move together within the same industry -- some of its smaller peers run higher rates than its larger ones, and vice versa.

Year-by-Year Safety Data

Year TCR DART Injuries Illnesses Fatalities
2024 0.8 0.8 2 0 0
2023 1.3 0.8 3 0 0
2022 0.9 0.4 2 0 0

OSHA ITA peer cross-reference

Establishment peer ledger

325998 · KY · Catlettsburgh

485 Activated carbon or charcoal manufacturing employers nationwide with a credible TCR · 7,805 rated employers in Kentucky with headcount on file · 4 cross-state NAT-TCR peers · 4 cross-state NAT-SIZE peers. Closest matches by relationship code are listed below.

Rel Establishment Metric
NAICS-TCR Henkel US Operations Corporation 1.0 TCR
NAICS-TCR Lubrizol Corporation - Bayport 1.0 TCR
NAICS-TCR Water Technologies and Solutions : New Philadelphia, OH, USA 1.0 TCR
NAICS-TCR Normerica Ind. Dyersburg 1.0 TCR
STATE-SIZE BOGE Rubber & Plastics USA LLC 205 FTE
STATE-SIZE Meijer Store 0151 205 FTE
STATE-SIZE Fruit of the Loom, Bowling Green Distribution Center 205 FTE
STATE-SIZE DCM : 5531-00 Ford-LOC/Louisville, KY 205 FTE
NAT-TCR MFAC, LLC warehouse 1.0 TCR
NAT-TCR Yokohama Dallas Distribution Center 1.0 TCR
NAT-TCR Store 1733 1.0 TCR
NAT-TCR Nor Am - Kansas City Mo - Cb 1.0 TCR
NAT-SIZE Planning and Development Services 205 FTE
NAT-SIZE Apple Valley High School 205 FTE
NAT-SIZE Silgan Dispensing Systems Thomaston 205 FTE
NAT-SIZE Flowers Bakery of Suwanee 205 FTE

Rel codes: NAICS-TCR · STATE-SIZE · CITY-NEAR · NAT-TCR/NAT-SIZE cross-state. Read with this employer →

Data Source: OSHA Injury Tracking Application (ITA), mandatory establishment-level injury/illness reports. Grades compare employer Total Case Rate (TCR) to BLS IIF industry benchmarks. Data covers years reported by this establishment: 2024, 2023, 2022. This is publicly available government data - not a legal determination of workplace conditions.

Read our methodology - how this data is sourced, computed, and verified.

Data sourced from official public datasets. See our methodology for details.