€280,000

Government safety organizations around the globe for the most part have been established to assure safe and healthful working conditions for working men and women by setting and enforcing standards and by providing training, outreach, education and assistance. The Aluminium Plant Safety Blog has posted stories of government safety organizations fining aluminium companies after onsite inspections. We do this not to shame the aluminium company (though we omit the company name and location) nor the industry, but to make aware of the hazards that are identified in an aluminium company. We challenge the reader afterwards to take this post and walk through your plant(s) and look for any of the below mentioned safety hazards. Here is a recent story.

An inspection at an aluminum plant found over 40 violations, according to the U.S. Department of Labor's Occupational Safety and Health Administration.

OSHA proposed €280,000 in penalties for the aluminum company. The citations and proposed penalties resulted from an April investigation launched in the wake of an on-the-job injury to a crane operator in March, 2015.

OSHA said it found violations including damaged electrical equipment, damaged crane control boxes and lack of saw guards. Other issues included unguarded floor openings and machines, as well as a lack of training and failure to report the crane incident in a timely manner, the agency said.

“The number of safety violations found at (the aluminum) plant is completely unacceptable,” OSHA’s regional administrator said in a prepared statement. “This employer blatantly ignored known safety requirements, causing a preventable worker injury. This company is now paying a hefty price for its negligence. The hazards identified in the investigation should be immediately addressed to prevent future incidents and ensure worker safety.”

The company was cited for the following hazards:

• For every pit and/or trap door floor opening, while the cover was not in place, was not constantly attended by someone or was not protected on all exposing sides by removable standard railings.

• An attendant was not present and guardrails were not in use while the door to the butt chute pit was open, on or about.

• Every floor hole into which persons can accidentally walk were not guarded:

• Employees worked in the vicinity of the rack lift location where there were unguarded floor holes while working with small racks which was observed.

• Open-sided floors and/or platforms four feet or more above adjacent floor or ground level were not guarded with standard railings (or equivalent) and toeboards:

• Employees worked on open sided floors or platforms between 52 and 60 inches in height which were not guarded by standard rail (or equivalent- chains) were observed.

• Employees worked on open sided floors eight to ten feet around the furnace which were not guarded by standard rail (or equivalent- chains) were observed.

• The anchoring of posts and framing of members for railings of all types were not of such construction that the completed structure was not capable of withstanding a load of at least 200 pounds applied in any direction at any point on the top rail:
• Employees loaded trailers or placed orders to be loaded on loading docks at a height of approximately 52 up to 60 inches where vertical posts were not attached or anchored to the loading dock and capable of withstanding 200 pounds of force which was observed.
• "Railings and handrails." Standard railings were not provided on the open sides of all exposed stairways and stair platforms. Stair railings and handrails were not installed in accordance with the provisions of 1910.23.
• Employees used a stairway for access and egress to and from the building which was not provided with railings on its open side and was observed.
• Exit accesses(es) were not at least 28 inches (71.1 cm) wide at all points.
• Exit access was 11 inches wide was observed.

• Exit route(s) were not kept free and unobstructed:
• Shipping Area: The exit door was blocked by a motor was observed.
• A reel of steel taping was placed in front of the door, which would not allow the door to open in the event of an emergency was observed.
• The exit door was blocked by stored dies was observed.

• Before entry was authorized (confined space), the employer did not document the completion of measures required by 29 CFR 1910,146(d)(3) by preparing an entry permit:
• Entry permits were not filled out prior to foundry employees entering the areas under the furnaces was observed.
• Entry permits were not filled out prior to foundry employees entering the casting pit, was observed

• The employer did not provide training so that all employees whose work was regulated by 29 CFR 1910.146 (permit required confined spaces) acquired the understanding, knowledge, and skills necessary for the safe performance of the duties assigned under 29 CFR 1910.146:
• Permit required confined space training had not been provided to employees who enter permit required confined spaces which include but are not limited to areas beneath the furnaces and the casting pit was observed.

• The employer who had designated rescue and emergency services did not inform each rescue team or service of the hazards they may confront when called to perform rescue at the site:
• The local Fire Department, who the employer designated to perform permit required confined space rescue, was not informed of the hazards they may confront when called to perform rescue at the facility where employees performed cleaning and maintenance of the areas beneath the casting pit was observed.
• The local Fire Department, who the employer designated to perform permit required confined space rescue, was not informed of the hazards they may confront when called to perform rescue at the facility where employees performed cleaning and maintenance of the areas beneath the holding furnace was observed. 
• The local Fire Department, who the employer designated to perform permit required confined space rescue, was not informed of the hazards they may confront when called to perform rescue at the facility where employees performed cleaning and maintenance of the anodizing tanks was observed.

• Procedures did not clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, and the means to enforce compliance including, but not limited to, 29 CFR 1910.147(c)(4)(ii)(A), (c)(4)(ii)(B), (c)(4)(ii)(C) and (c)(4)(ii)(D):
• A specific energy control procedure was not documented to be utilized for maintenance to shut down an aluminum press was observed.

• The energy control procedures did not clearly and specifically outline the steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy.
• Energy control procedure for the furnace did not include procedures on the placement of blocking devices to prevent the furnace from drifting down while employees entered the pit to clean was observed.

• All energy isolating devices that were needed to control the energy to the machine or equipment was not physically located and operated in such a manner as to isolate the machine or equipment from the energy source:
• Blocking devices were not installed to prevent the furnace from drifting down while employees entered the pit to clean were observed.

• Each authorized employee did not affix a personal lockout or tagout device to the group lockout device before working on the machine or equipment:
• Each employee working in a crew under the melting/holding furnace did not apply a personal lock was observed

• Portable fire extinguishers were not kept in their designated places at all times except during use:
• Portable fire extinguishers were missing from designated areas was observed.
• Portable fire extinguishers were not visually inspected at least monthly:
• Two Amerex portable fire extinguishers were not subject to a monthly inspection
• Portable fire extinguishers were not provided with a monthly inspection

• Portable fire extinguishers were not subjected to an annual maintenance check

• The educational program to familiarize employees with the general principles of fire extinguisher use and the hazards involved with incipient stage firefighting was not provided to all employees upon initial employment, and at least annually thereafter:
• Employees who were expected to use a portable fire extinguisher in the event of an incipient stage fire were not provided with training upon initial hiring and at least annually thereafter.

• The employer did not ensure that all nameplates and markings were in place:
• Employees were operating a forklift with an attachment which did not have all nameplates and markings in place for purposes including but not limited hoisting aluminum furnace doors was observed.
• Employees were operating a forklift with an attachment which did not have all nameplates and markings in place for purposes including but not limited to loading scrap aluminum into furnaces was observed.
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• Multiple conductor cable was used with a suspended pushbutton station, but the station was not supported in some satisfactory manner that protected the electrical conductors against strain:
• The pendant control box was lacking strain relief where the drop cord met the box was observed.

• A complete periodic inspection of crane(s) had not been conducted in the past 12 months:
• A complete inspection of cranes had not been completed since 2013.

• Monthly inspections of hooks, with a certification record which includes the date of inspection, the signature of the person who performed the inspection and the serial number, or other identifier, of the hook inspected, were not performed:
• Monthly inspections with written certifications were not performed on the hook used to rig loads throughout the facility.

• Monthly inspections of hoist chains, with a certification record which includes the date of inspection, the signature of the person who performed the inspection and an identifier of the chain which was inspected, were not performed:
• Monthly inspections with written certifications were not performed on the chains used to rig loads throughout the facility was observed

• Thorough monthly inspections of rope conditions, with written, dated and signed reports, were not performed on the running ropes:
• Monthly inspections with written certifications were not performed on the running ropes used throughout the facility.

• One or more methods of machine guarding was not provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks:
• Employees operated a horizontal band saw to cut materials such as but not limited to metal and plastic with approximately five inches of the unused portion of the blade exposed.
• Employees operated a belt sander to fabricate parts without a guard to protect employees from flying chips or particles.
• Employees operated lathe machines without a guard to protect from the rotating action of the chuck and part.
• Employees used a milling machine and a Victor milling machine without a guard to protect from the rotating action of the chuck to fabricate parts
• Employees used an metal cutting saw with insufficient chip guarding
• Employees operated a drill Press without a guard to protect from the rotating action of the chuck to fabricate aluminum products.
• Employees took measurements of aluminum extruded products at the aluminum press which was not guarded to prevent employees from having any part of their body in the danger zone during the operating cycle.

• Machine(s) designed for fixed location(s) were not securely anchored to prevent walking or moving:
• Employees were exposed pedestal grinders which was not securely anchored to prevent moving
• Employees were exposed to a pedestal grinder-buffer which was not securely anchored to prevent moving

• Radial saw(s) were not provided with an adjustable stop to prevent the forward travel of the blade beyond the position necessary to complete the cut in repetitive operations:

• Radial saw(s) were not installed in a manner so as to cause the cutting head to return gently to the starting position when released by the operator:
• Employees were operating radial saws that were not installed so as to cause the cutting head to return to the starting position when released

• Pulley(s) with part(s) seven feet or less from the floor or work platform were not guarded in accordance with the requirements specified in 29 CFR 1910.219(m) and (o):
• Employees operated a Wales drilling machine  with the pulleys unguarded at approximately 65 inches observed

• Horizontal belts which had both runs seven feet or less from the floor level were not guarded with a guard that extended to at least fifteen inches above the belt:
• Employees operated a Drilling Machine with the belts unguarded at approximately 65 inches observed.

• Sprocket wheels and chains which were seven 7 feet or less above floors or platforms were not enclosed:
• Employees worked near unguarded sprocket and chain wheels, below waist level less than seven feet above the floor on the aluminum press, which were not enclosed in the stretcher area.

• Compressed air used for cleaning purposes was not reduced to less than 30 p.s.i.:

• Workers and other persons adjacent to the welding area were not protected from the rays by noncombustible or flameproof screens or shields:

• Inside of buildings, cylinders were not stored in a well-protected, well ventilated, dry location, at least 20 (6.1 m) feet from highly combustible materials such as oil or excelsior. Cylinders were not stored in definitely assigned places away from elevators, stairs, or gangways. Assigned storage spaces were not located where cylinders would not be knocked over or damaged by passing or falling objects, or subject to tampering by unauthorized persons:

• Oxygen cylinders were stored near highly combustible material, especially oil and grease; or near reserve stocks of carbide and acetylene or other fuel-gas cylinders, or near another substance likely to cause or accelerate fire; or in an acetylene generator compartment:

• Electric equipment shall be firmly secured to the surface on which it is mounted.

• Listed or labeled electrical equipment was not used or installed in accordance with instructions included in the listing or labeling:

• Sufficient access and working space was not provided and maintained about all electric equipment (operating at 600 volts, nominal, or less to ground) to permit ready and safe operation and maintenance of such equipment:

• Overcurrent devices for circuits rated 600 volts, nominal, or less, were not readily accessible to each employee or authorized building management personnel and were located in the vicinity of easily ignitable material.

• Live pairs of electric equipment operating at 50 volts or more were not guarded against accidental contact by use of approved cabinets or ether forms of approved enclosures or by any of the means identified in paragraphs (A), (B), (C), and (D) of 29 CFR 1910.303(g)(2)(i):

• Flexible cords and cables were not protected from accidental damage, as might be caused, for example, by sharp corners, projections, and doorways or other pinch points:

• Lamps for general illumination were not protected from accidental contact or breakage by a suitable fixture or lamp holder with a guard:

• Cabinets, cutout boxes, fittings, boxes, and panel board enclosures were not weatherproof in wet locations:

• The exposure determination did not include a list of all job classifications in which all employees in those job classifications had occupational exposure:

• Hepatitis B vaccination was not made available within 10 working days of initial assignment to all employee(s) with occupational exposure.

• The employer did not ensure that each employee with occupational exposure participated in a training program.

• Electrical equipment had damaged parts that may adversely affect safe operation or mechanical strength of the equipment, such as parts that are broken, bent, cut, or deteriorated by corrosion, chemical action, or overheating.

The APSB has posted incidents (not involving this company) involving a majority of the violations listed above. Each and every one of these violations could result in a worker injury or fatality. We hope that the above mentioned violations are corrected. 

So after reading this article what should you do? 

A. Laugh and say "I am sure glad I don't work there".

B. Print this article out and use these violations for a quick inspection of your facility.

C. Print this article out and place it in your boss’s mailbox.

The answer is B. You should print this article out and use these violations for a quick inspection on your plant. Record your findings and make corrections as needed. 

Feel free to contact the APSB if you have any questions on remedies for the cited violations in this post. 

Please comment.