OSHA Inspection: MITSUI ZINC POWDER, LLC.

Issued

Aug 16, 2012

Abate by

Aug 23, 2012

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1):  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 the employer failed to make necessary repairs, resulting in the operation of the crane with defective or missing parts affecting the safe operation of the crane and likely to result in serious injury or death to employees in the event of a crane malfunction or failure:    a) 6 Ton Wright Underhung Bridge Crane, Wright Underhung Wire Rope Hoist (Model number C4W07), Furnace Bay, 302 Frankfort Road, Monaca, Pennsylvania, 15061:  Observed on or about May 30, 2012, maintenance and repairs had not been conducted to repair defects identified during an inspection of the crane which was conducted on October 26, 2011 resulting in the operation of the crane with serious defects, including:    1.  The runway festoon cables and carriers are damaged and in need of replacement.    2.  The stationary junction box door needs to be reinstalled.    3.  A pendant warning label needs to be installed and the cord is damaged slightly and should be replaced.    4.  The pendant direction markings need to be repaired.    5.  The bridge drive wheels and wheel shaft need realigned in the drive assembly.    6.  The bridge brakes are not functioning properly and need readjusted.    7.  The west bridge drive, drives the crane in one direction only and doesn't drive in the other direction.      8.  The bridge festoon needs new flat cables, carriers, junction box and tow arm due to damage.    9.  The south trolley brake needs a new friction disc and the brake hub realigned with the disc.     10.  The hoist wire rope needs to be replaced due to several kinks, broken wires, and areas of birdcaging.    11. The runway festoon tow arm needs to be relocated to the other end of the truck.    12. The hoist hook safety latch was missing.

Issued

Aug 16, 2012

Abate by

Aug 23, 2012

Penalty

Initial $1,600 · Current $1,600

General-duty citation text

29 CFR 1910.22(a)(2):  Floor(s) of workroom(s) were not maintained in a clean and, so far as possible, a dry condition:    a) Melt Floor, north roof vent, 302 Frankfort Road, Monaca, PA 15061:  Observed on or about June 1, 2012, an exhaust lid was stuck open.  The open lid permitted rain water to accumulate on the shop floor  during periods of heavy rain.  Employees using the slab feeder while water is present are exposed to the hazard of electric shock.

Issued

Aug 16, 2012

Abate by

Aug 23, 2012

Penalty

Initial $1,200 · Current $1,200

General-duty citation text

29 CFR 1910.37(b)(2):  Each exit was not clearly visible and marked by a sign reading "Exit":    a) Front Office, visitor phone area, 302 Frankfort Road, Monaca, PA 15061:  An exit leading from the front offices to the parking lot was not marked with a sign reading "Exit."  Employees working in the area are exposed to burn and smoke inhalation hazards in the event of a fire.

Issued

Aug 16, 2012

Abate by

Aug 23, 2012

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.147(c)(1): The employer did not establish a program consisting of an energy control procedure and employee training to ensure that before any employee performed any servicing or maintenance on a machine or equipment where the unexpected energizing, start up or release of stored energy could occur and cause injury, the machines or equipment would be isolated, and rendered inoperative in accordance with 29 CFR 1910.147(c)(4):     a) Production Facility, 302 Frankfurt Road, Monaca, Pennsylvania 15061:  Observed on or about May 30, 2012, the employer did not have an energy control program.  Employees engaged in maintenance work on a variety of machines including, but not limited to, a slab feeder and the Rotex screeners, were exposed to the hazards associated with the unexpected energizing or startup of the equipment.

Issued

Aug 16, 2012

Abate by

Aug 23, 2012

Penalty

Initial $2,400 · Current $2,400

General-duty citation text

29 CFR 1910.151(c):  Where employees were exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body were not provided within the work area for immediate emergency use:    a) Production Facility, 302 Frankfurt Road, Monaca, Pennsylvania 15061:  Observed on or about May 30, 2012, employees working with injurious corrosive materials such as ammonium chloride and nitric acid were not provided with suitable facilities for quick flushing of the eyes and body within the work area for immediate emergency use.  Employees were exposed to an eye injury hazard while working with the corrosive materials.

Issued

Aug 16, 2012

Abate by

Sep 7, 2012

Penalty

Initial $1,600 · Current $1,600

General-duty citation text

29 CFR 1910.303(b)(6):  Conductors and equipment were located where they were exposed to gases, fumes, vapors, liquids, or other agents that have a deteriorating effect on the conductors or equipment:    a) Rotex floor, 302 Frankfort Road, Monaca, PA 15061:  Observed on or about May 30, 2012, hydraulic oil from the Line #1 alloy furnace was leaking and accumulating on electrical cabinets located in a room adjacent to Rotex screener room.  Employees working in the area of the electrical cabinets were exposed to a fire hazard.

Issued

Aug 16, 2012

Abate by

Aug 23, 2012

Penalty

Initial $1,600 · Current $1,600

General-duty citation text

29 CFR 1910.303(b)(7)(iv):  Damaged parts that may adversely affect the safe operation or mechanical strength of the equipment, such as parts that are broken, bent, cut, or deteriorated by corrosion, chemical action, or overheating were not repaired or replaced:    a)  Melt Room, 302 Frankfort Road, Monaca, PA 15061:  Observed on or about May 30, 2012, the conduit on a Bulletin brand 801 limit switch was torn away.  The conductors inside were exposed.  Employees working on the Melt Floor were exposed to the hazards of fire and electric shock.    b)  Inductor Floor, 302 Frankfort Road, Monaca, PA 15061:  Observed on or about May 30, 2012, 110 volt conductors leading into a bypass solenoid were exposed due to a corroded conduit.  Employees working in the area were exposed to the hazard of fire and electric shock.    c)  Inductor Floor, 302 Frankfort Road, Monaca, PA 15601:  Observed on or about May 30, 2012, the conductors leading into a 460 volt impeller motor were exposed due to broken and corroded conduit.  Employees working in the area were exposed to the hazards of fire and electric shock.    d)  Inductor Floor, 302 Frankfort Road, Monaca, PA 15061:  Observed on or about May 30, 2012, metal conduit carrying conductors from the bypass button located near the dross box were separated exposing the conductors inside.  A portion of the conduit was hanging on the conductors.  The conductors were exposed to the sharp edges of the broken conduit.  Employees working in the area of the conduit were exposed to the hazards of fire and electric shock.

Issued

Aug 16, 2012

Abate by

Aug 23, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(b)(2):  Pull boxes, junction boxes, and fittings were not provided with covers approved for the purpose:    a)  Inductor floor, 302 Frankfort Road, Monaca, PA 15061:  Observed on or about May 30, 2012, the #2 Alloy Furnace bypass solenoid was missing a cover.  The 110 Volt conductors inside were exposed.  Employees working in the area of the bypass solenoid were exposed to the hazard of electric shock.

Issued

Aug 16, 2012

Abate by

Aug 23, 2012

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.305(g)(2)(ii): Flexible cords were not used only in continuous lengths without splice or tap:    a)  Slab Feeder Area, 302 Frankfort Road, Monaca, PA 15061:  Observed on or about May 30, 2012, an energized flexible cable used to supply 120 Volt power to the slab feeder foot pedal was not used in a continuous length without splice.  Employees using the foot pedal to operate the slab feeder were exposed to the hazard of electric shock.    b) Slab Feeder Area, 302 Frankfort Road, Monaca, PA 15061:  Observed on or about May 30, 2012, an energized flexible cable used to supply 110 Volt power to the slab feeder pendant was not used in a continuous length without splice.  Employees using the pendant to operate the slab feeder were exposed to the hazard of electric shock.

Issued

Aug 16, 2012

Abate by

Aug 23, 2012

Penalty

Initial $1,200 · Current $1,200

General-duty citation text

29 CFR 1910.305(g)(2)(iii): Flexible cords were not connected to devices and fittings so that tension would not be transmitted to joints or terminal screws:               a)  Rotex room, 302 Frankfort Road, Monaca, PA 15061:  Observed on or about May 30, 2012, a flexible cord which supplied power to a Rotex Ultrasonex system was not equipped with strain relief to prevent tension from being transmitted to joints or terminal screws.  Employees engaged in the use and maintenance of the Rotex Ultrasonex were exposed to the hazard of electric shock.

Issued

Aug 16, 2012

Abate by

Aug 23, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.22(a)(1):  All places of employment, passageways, storerooms, and service rooms were not kept clean and orderly and in a sanitary condition:    a) Inductor and Melt Rooms, 302 Frankfort Road, Monaca, PA 15061:  Observed on or about May 30, 2012, metal residue accumulated on electrical equipment including electrical boxes and conduit.  The accumulated material could interfere with the safe operation of the machines and electrical equipment in the area of the debris.