OSHA Inspection: WEINMANN, INC.

Issued

Aug 25, 1995

Abate by

Oct 30, 1995

Penalty

Initial $7,000 · Current $7,000

Issued

Aug 25, 1995

Abate by

Oct 30, 1995

Issued

Aug 25, 1995

Abate by

Oct 30, 1995

Issued

Aug 25, 1995

Abate by

Oct 30, 1995

Penalty

Initial $7,000 · Current $7,000

Issued

Aug 25, 1995

Abate by

Oct 30, 1995

Issued

Aug 25, 1995

Abate by

Oct 30, 1995

Issued

Aug 25, 1995

Abate by

Oct 30, 1995

Issued

Aug 25, 1995

Abate by

Aug 30, 1995

Penalty

Initial $7,000 · Current $7,000

Issued

Aug 25, 1995

Abate by

Aug 30, 1995

Penalty

Initial $7,000 · Current $7,000

Issued

Aug 25, 1995

Abate by

Aug 30, 1995

Penalty

Initial $7,000 · Current $7,000

Issued

Aug 25, 1995

Abate by

Nov 30, 1995

Penalty

Initial $2,500 · Current $2,500

Issued

Aug 25, 1995

Abate by

Aug 30, 1995

Penalty

Initial $7,000 · Current $7,000

Issued

Aug 25, 1995

Abate by

Aug 30, 1995

Penalty

Initial $7,000 · Current $7,000

Issued

Aug 25, 1995

Abate by

Aug 30, 1995

Issued

Aug 25, 1995

Abate by

Nov 8, 1995

Penalty

Initial $7,000 · Current $7,000

Issued

Aug 25, 1995

Abate by

Nov 8, 1995

Penalty

Initial $7,000 · Current $7,000

Issued

Aug 25, 1995

Abate by

Nov 8, 1995

Issued

Aug 25, 1995

Abate by

Aug 30, 1995

Penalty

Initial $70,000 · Current $56,000 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The
employer did not furnish
employment and a place of employment which were free from recognized
hazards that were
causing or likely to cause death or serious physical harm to employees in
that employees were
exposed to:
........the hazards of fire and or explosion due to the unsafe methods of
operating,
collecting and storing of aluminum dust and the residue mixture of polish
and cotton generated
during the production process of aluminum alloy bicycle rims.
General methods of abatement applicable in these circumstances include,
but are not limited to,
the following:
1) Exhaust aluminum dust to an approved dust collection system located
outdoors as defined in
sections 2-1.5, 2-1.6 and 2-3.1 of the 1993 version of NFPA 65.
* 2-1.5; Dry-type dust collectors shall be located outside of buildings.
* 2-1.6; All dust collection systems shall be installed in accordance with
NFPA
91, Standards for Exhaust Systems for Air Conveying of Materials.
* 2-3.1; The exhaust vent shall terminate outside the building and be
securely
fastened. ....
2) Design and install local exhaust systems that meet the minimum
operating parameters and
safety guidelines established in sections 2-2.1 through 2-2.6 in the 1993
version of NFPA 65 in
areas where aluminum dust is being generated.  These areas include
polishing, brushing, and
grinding stations.
* 2-2.1; Ducts shall be designed to maintain a velocity of not less than
4500
ft/min(1372.5 m/min.) to ensure the transport of both coarse and fine
particles
and to ensure reentrainment if, for any reason, the particles can fall out
before
delivery to the collector (for example, in the event of power failure).
* 2-2.2; Ducts shall be designed to handle a volumetric flow rate
sufficient to
maintain a dust loading safely below the lower explosive limit.
* 2-2.3; Ducts shall be as short and as straight as possible.
* 2-2.4; Ducts shall have as few bends and irregularities as possible so
that free
airflow is not interfered with.
* 2-2.5; Ducts shall be of conductive material construction and shall be
carefully
fabricated and assembled with smooth interior surfaces and with internal
lap joints
facing the direction of airflow.  There shall be no unused capped outlets,
pockets,
or other dead-end spaces that might allow accumulations of dust.  Duct
seams
shall be oriented in a direction away from normal working personnel. *
2-2.6; Duct systems, dust collectors, and dust-producing machinery shall be
bonded and grounded to minimize accumulation of static electric charge.
3) Use separate dust collection systems for grinding operations and
polishing/buffing operations
as described in section 2-1.3 of the 1993 version of NFPA 65.  Dedicate
dust collection systems
for aluminum or aluminum alloy dust only as described in section 2-1.7 of
the 1993 version of
NFPA 65.
* 2-1.3;  Grinding operations shall not be served by the same dust
collection
system as buffing and polishing operations.
* 2-1.7; Dust collection systems shall be dedicated to collection of
aluminum or
aluminum alloy dust only.  Grinders, buffers, and associated equipment
with dust
collectors utilized for processing aluminum shall be provided with a
placard
indicating, "Warning-Aluminum Metal Only-Fire or explosion can result with
other metals."
4) Once the decision is made to install either a wet-type or dry-type dust
collection
system, all
requirements in sections 2-3 or 2-4 in the 1993 edition of NFPA 65 must be
met.
WET TYPE
* 2-3.1; The exhaust vent shall terminate outside the building and be
securely
fastened.  The duct shall be as short and as straight as possible, and
shall be
designed to withstand the same explosion pressure as the wet collector.
* 2-3.2; The exhaust vent shall be inspected and cleaned frequently to
prevent
buildup of highly combustible deposits of metal dusts on the interior
surfaces of
the duct.
* 2-3.3; The dust collector shall be arranged so that contact between dust
particles and parts moving at high speeds is prevented.  The blower for
drawing
the dust-laden air into the collector shall be located on the clean air
side of the
collector.
* 2-3.4; The dust collector shall be arranged so that the dust-laden air
stream
shall be thoroughly scrubbed by the liquid to achieve the desired
efficiency.
* 2-3.5; Sludge shall be removed from the collector on a regular schedule
to
ensure proper and safe operation of the equipment.  Sludge shall be
disposed of
in accordance with the requirements of 2-3.7.
* 2-3.6; The sump of water wet-type dust collectors shall be ventilated at
all
times.  When the dust collector is not in operation, this ventilation
shall be
provided by an independent blower or by an unimpeded gravity vent.  Gravity
vents shall be provided with means to automatically open when the dust
collectoris shut down.
DRY TYPE
* 2-4.1; Electrostatic collectors shall not be used.
* 2-4.2; Dust-collecting filter medium made from synthetic fabrics that
accumulate high static charges shall not be used.
* 2-4.3; Special care shall be taken to ensure the internal cleanliness of
dry
dustcollection
systems at all times and to avoid the accumulation of material
except
in the discharge hoppers of the dust collectors.  Accumulation or
condensation of
water shall be prevented.
* 2-4.4; Dust shall be removed from dry collectors at least once each day
and at
more frequent intervals if conditions warrant.  Extreme care shall be
taken in
removing dust from the collectors to avoid creating dust clouds.  The
material
shall be discharged into metal containers that shall be promptly and
tightly
covered to avoid the creation of airborne "fugitive dust."  Waste material
shall
be mixed with an inert material, such as dry sand, in a volume ration of 5
parts
inert material to 1 part metal dust, and disposed in accordance with
local, state,
and federal regulations.
* 2-4.5; Dry dust collectors where an explosion hazard exists shall be
provided
with explosion vents.  Extreme care shall be taken in the selection of the
type and
location of vents or weak sections of the collector to minimize injury to
personnel
and blast damage to nearby equipment or structures.  Explosion vents shall
be
positioned so that a potential blast shall not be directed towards any
combustible
or frangible structure.
* 2-4.6; Where repairs on dry dust collectors are necessary, the
collectors shall
be emptied and residual accumulations of dust thoroughly removed.  (see
section
3-01.)  Ductwork leading into the collector shall be disconnected and
blanked
off
before repair work shall be permitted to be started.
* 2-4.7; The interior of hoods and ducts shall be regularly cleaned
wherever there
is a possibility of buildup of wax, lint, aluminum fines, or other
combustible
material.
* 2-4.8; The dust collector shall be arranged so that contact between dust
particles and parts moving at high speeds shall be prevented.  The blower
for
drawing the dust -laden air into the collector shall be located on the
clean air side
of the collector.
5) If a wet-type dust collector is used, disposal of sludge accumulations
from this type of
collector shall be in accordance with all sections specified in section
2-3.7 of the 1993 version
of NFPA 65.
* 2-3.7.1; Sludge from water wet-type dust collectors shall be removed at
least
once each day or more frequently if conditions warrant.
* 2-3.7.2; Covered, vented metal containers, preferably holding not more
than
50 lb(22.7 kg) each, shall be used to transport the collected sludge for
disposal.(see A-2-3.5.)
* 2-3.7.3; Sludge shall be disposed of using the following method:
* 2-3.7.4; Sludge shall be permitted to be mixed with sand in a ration of
at least
5 parts sand to 1 part sludge, and then shall be discarded in accordance
with
local, state, and federal requirements.
* 2-3.7.5; Smoking or open flames shall be prohibited in the disposal area
and
throughout the disposal process.
6) Establish a written housekeeping program for any and all accumulations
of aluminum dust.
This written program shall include at a minimum; employee training, daily
visual checks by
employees and management to assure that good housekeeping is being
maintained, all guidelines
established in section 3-1 in the 1993 version of NFPA 65.
* 3-1.1; This chapter shall be applied to new and existing facilities.
* 3-1.2; Good housekeeping shall be practiced in the entire work area.
Dust shall
not be allowed to accumulate on floors, exposed building structural
members,
piping, conduit, or ductwork.
* 3-1.3; Cleaning shall be done with a soft brush or squee-gee and pickup
shall
be done with non-sparking conductive scoops.  Synthetic fiber bristle
brushes and
plastic or other nonconductive scoops shall not be used because of their
tendency
to accumulate strong static electric charges.
* 3-1.4; Only vacuum cleaners specifically approved for use with reactive
combustible metal dusts shall be used to pick up small quantities of loose
dust.
Standard commercial industrial vacuum cleaners shall not be used, as they
are not
safe for use with combustible metals.
* 3-1.4.1; All spills shall first be cleaned by scooping and mild brushing.
* 3-1.5; The vacuum cleaner, its piping, suction hose, and tools shall be
electrically conductive and shall be  grounded to prevent static electric
sparks.
The vacuum cleaning tools shall be made of conductive non-sparking
materials.* 3-1.6; The use of compressed air for cleaning of the structure
and clothing shall
not be permitted except for certain areas impractical or impossible to
clean
otherwise, and done under carefully controlled conditions, with all
potential
ignition sources prohibited in or near the area and the equipment shut
down.
7) Eliminate all ignition sources in areas where Aluminum dust is present.
This would include
but is not limited to all sources listed in section 3-4 of the 1993
version of NFPA 65.
* 3-4.1; No open flames shall be allowed in areas where aluminum dust or
sludge
is produced or handled.  No smoking shall be allowed in such areas.
* 3-4.2; Grinding wheels shall not be dressed while on a spindle connected
to an
aluminum-dust collection system.
* 3-4.3; Propellant-actuated tools shall not be used in buildings where
aluminum
dust is created or handled.
* 3-4.4; Electric or gas welding or cutting or maintenance operations that
could
produce hot particles, such as drilling, sawing, or chipping shall not be
permitted
in areas where an aluminum dust hazard exists unless the following
precautions
are taken:
* 3-4.4.1; All machinery in the area where such operations are to
be performed shall be shut down.
* 3-4.4.2; All ductwork of dust collections systems shall be
cleaned and the dust collectors shall be emptied and cleaned.
* 3-4.4.3; All accumulations of aluminum dust shall be thoroughly
cleaned and removed from the area.  The area shall also be free of
all solvents and solvent vapors.
* 3-4.5; Smoking or open flames shall be prohibited in the disposal area
and
throughout the disposal process.
8) Installation of electrical equipment inside the polishing booths shall
be in accordance with
applicable sections of the National Electric Code 502 for Class 2, Group
E, Division 1 locations.
This electrical equipment would include but is not limited to motors,
wiring, switches, lighting
fixtures, receptacles and relay systems. In addition to meeting the
requirements established in
NEC 502, all guidelines listed in section 3-2 in the 1993 version of NFPA
65
shall also be
complied with.
* 3-2.1; All electrical equipment and wiring shall be in accordance with
NFPA
70, National Electrical Code where Class 1 or 2 locations, as defined in
Article
500-5 or 500-6 of NFPA 70, National Electrical Code exist, equipment shall
be
approved for such usage.  Exception:  Control equipment meeting
therequirements of NFPA 496, Standard for Purged and Pressurized
Enclosures for
Electrical Equipment, need not comply with 3-2.1 when equipment is approved
for such usage.
* 3-2.2; All electrical equipment shall be inspected and cleaned at
regular intervals.
* 3-2.3; All electrical equipment shall be adequately grounded by permanent
ground wires to minimize accumulation of static electric charges.
9) Install motors and electrical control equipment designed for operating
at 60 cycles.
10) Provide Class D portable fire extinguishers as required in section
5-1.1 of the 1993 version
of NFPA 65.  Provide portable fire extinguisher training to employee's
expected to fight Class
D fires.
* 5-1.1; Only fire extinguishers approved for Class D fires shall be
permitted in
areas where aluminum dusts are present.  Exception:  If Class A, B, or C
extinguishers are in the area, a conspicuous sign shall be posted adjacent
to these
extinguishers stating: "These extinguishers are not for use on aluminum
dust
fires."
11) Install an automatic power disconnect for the local exhaust systems
which would disable
their operation in the event of a fire.  This is in accordance with
section 5-3 of the 1993 version
of NFPA 65.
* 5-3; Equipment shutdown.  In the event of fire, all fans and machinery,
including dust collection systems, shall be shut down.  Drafts shall be
avoided
wherever possible.
12) Employees who work around areas in the plant where they can come into
contact with
aluminum dust as part of their routine duties are prohibited from wearing
clothes made of
synthetic fabrics and trousers which have cuffs as defined in section 5-4
in the 1993 version of
NFPA 65.
* 5.4; Work Clothing.  Work clothing shall be made of smooth,
hard-finished,
closely woven fabric and shall not be made of synthetic fabrics, which
tend to
accumulate static electric charges.  Trousers shall have no cuffs where
dust might
accumulate.
13) Conduct an engineering study on the feasibility of lowering the high
temperatures generated
by brushing/polishing wheels when they make contact with aluminum alloy
bicycle
rims.
14) Comply with all other sections of NFPA 65 1993 version which relate to
any other specific
application in the manufacturing of aluminum bicycle rims at Weinmann, Inc.
DISCLAIMERS:
a) The employer is not limited to the abatement methods suggested by OSHA.
b) The methods explained are general and may not be effective in all cases.
c) The employer is responsible for selecting and carrying out an
appropriate
abatement method.

Issued

Aug 25, 1995

Abate by

Nov 8, 1995

Penalty

Initial $70,000 · Current $56,000 Reduced