OSHA Inspection: AUSTIN POWDER COMPANY

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $4,400 · Current $2,640 Reduced

General-duty citation text

29 CFR 1910.22(a)(2): The floor of every workroom shall be maintained in a clean and, so far as possible, a dry condition. Where wet processes are used, drainage shall be maintained and false floors, platforms, mats, or other dry standing places should be provided where practicable:  a.    In the Mix Plant, hydraulic leak on the West side of the building, thereby exposing employees to a slip/fall hazard.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $4,400 · Current $2,640 Reduced

General-duty citation text

29 CFR 1910.24(i): "Vertical clearance." Vertical clearance above any stair tread to an overhead obstruction shall be at least seven feet measured from the leading edge of the tread:  a.     Emulsion Building: A pipe was installed four feet over the crossover stairway, exposing employees were exposed to a struck-by hazard.

Issued

Jun 6, 2013

Abate by

Jun 6, 2013

Penalty

Initial $7,000 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.110(d)(3)(i):  The filling pipe inlet terminal shall not be located inside a building. For containers with a water capacity of 125 gallons or more, such terminals shall be located not less than ten feet from any building (see paragraph (b)(6)(ii) of this section), and preferably not less than five feet from any driveway, and shall be located in a protective housing built for the purpose:  a.     At the front of the main garage where semi-trucks were parked, there were two large 500 water gallon liquid petroleum tanks which were located within five feet of the maintenance building and not in a protective enclosure.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.110(d)(7)(iv)(d): Container is located so as not to be subject to vehicular damage, or is adequately protected against such damage:  a.  At the front of the main garage, there were two large 500 water gallon liquid petroleum tanks located where they could be struck by vehicular traffic.  The employer did not provide suitable protection around the tanks to protect employees from a fire/explosion hazard.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $7,000 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.132(a):  Application. Protective equipment, including personal protective equipment for eyes, face, head, and extremities, protective clothing, respiratory devices, and protective shields and barriers, shall be provided, used, and maintained in a sanitary and reliable condition wherever it is necessary by reason of hazards of processes or environment, chemical hazards, radiological hazards, or mechanical irritants encountered in a manner capable of causing injury or impairment in the function of any part of the body through absorption, inhalation or physical contact:  a.  For the Mix Plant where employees connected to a fall protection system when working on the top of the ammonia nitrate tank, the employer did not perform a hazard assessment to determine if the fall protection system was in proper working order, thereby exposing employees to a fall hazard.  b.  Maintenance Department work platform above locker rooms: employees on the work platform were not protected against falling to the lower level more than eight feet below.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $7,000 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures shall be developed, documented and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered by this section.  Note: Exception: The employer need not document the required procedure for a particular machine or equipment, when all of the following elements exist: (1) The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees; (2) the machine or equipment has a single energy source which can be readily identified and isolated; (3) the isolation and locking out of that energy source will completely deenergize and deactivate the machine or equipment; (4) the machine or equipment is isolated from that energy source and locked out during servicing or maintenance; (5) a single lockout device will achieve a locker-out condition; (6) the lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance; (7) the servicing or maintenance does not create hazards for other employees; and (8) the employer, in utilizing this exception, has had no accidents involving the unexpected activation or reenergization of the machine or equipment during servicing or maintenance:  a.  In the facility, employees, who were affected by and authorized to perform lock-out/tag-out, were not provided clear procedures documented and utilized for control of potentially hazardous energy when employees working around or working on equipment such as, but not limited to, the emulsion packer, detonator rewinder, and mixers which could restart, thereby exposing the employees to a struck-by hazard.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $5,500 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.151(c):  Where the eyes or body of any person may be exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body shall be provided within the work area for immediate emergency use:  a.     In the boiler room of the weigh building where potassium hydroxide was used as a corrosive from five gallon containers for boiler water treatment, the employer did not provide an emergency eyewash, thereby exposing employees to an eye contact hazard.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $5,500 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.157(g)(3):  The employer shall provide employees who have been designated to use firefighting equipment as part of an emergency action plan with training in the use of the appropriate equipment:  a.     At the plant employees in non-explosive areas, who would attempt to extinguish an incipient stage fire, were not provided training in the use of the portable fire extinguishers, thereby exposing them to a fire hazard.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $4,400 · Current $2,640 Reduced

General-duty citation text

29 CFR 1910.176(b): Secure storage. Storage of material shall not create a hazard. Bags, containers, bundles, etc., stored in tiers shall be stacked, blocked, interlocked and limited in height so that they are stable and secure against sliding or collapse:  a.    In the Mix Plant warehouse, 15 Austrite shopper bags were not securely stacked, causing the pallets to slide, thereby exposing employees to a struck-by hazard.  b.     In the emulsion one warehouse, boxes were stacked until needed for the production line.  There were unsecured pallets sitting on the stacked boxes, which would fall from the pile, thereby exposing employees to a struck-by hazard.  c.      In the box warehouse where boxes were assembled, stapled and stacked for the Production Department, the boxes stacked on the pallets were not secured from falling and were not evenly stacked, in that there were materials falling off the pallets, thereby exposing employees to a struck-by hazard.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $4,400 · Current $2,640 Reduced

General-duty citation text

29 CFR 1910.178(l)(4)(ii): Refresher training in relevant topics shall be provided to the operator when:  29 CFR 1910.178(l)(4)(ii)(B): The operator has been involved in an accident or near-miss incident:  a.     In the doorway between the North and South mix warehouse, the beam support for the building had been struck by a powered industrial truck and severely damaged. The employee involved in the accident had not received refresher training.

Issued

Jun 6, 2013

Abate by

Jun 6, 2013

Penalty

Initial $7,000 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.212(a)(1):  Types of guarding. One or more methods of machine guarding shall be 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. Examples of guarding methods are-barrier guards, two-hand tripping devices, electronic safety devices, etc.:  a.    In the overspin building, employees were exposed to being struck-by the rotating parts between each "overspin  machine" unit that were not guarded.   b.     In the emulsion building, employees were exposed to a caught-in hazard where the front and back of the cartridge packer/chub packer machine was open and not guarded.  c.     In the emulsion building, there were openings along the back and front of the transfer conveyor presented unguarded rotating parts that ran along the aisle where employees worked. Employees were exposed to caught-in hazards.  d.     In booster pour building 1, there are six kettles in this building where employees were exposed to a struck-by hazard from unguarded rotating paddles while dipping a container into the kettles.   e.      In booster pour building 2, there are six kettles in this building where employees were exposed to a struck-by hazard from unguarded rotating paddles while dipping a container into the kettles.  f.       In booster pour building 3, there are six kettles in this building where employees were exposed to a struck-by hazard from unguarded rotating paddles while dipping a container into the kettles.

Issued

Jun 6, 2013

Abate by

Jun 6, 2013

Penalty

Initial $5,500 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.213(i)(1):  All portions of the saw blade shall be enclosed or guarded, except for the working portion of the blade between the bottom of the guide rolls and the table. Bandsaw wheels shall be fully encased. The outside periphery of the enclosure shall be solid. The front and back of the band wheels shall be either enclosed by solid material or by wire mesh or perforated metal. Such mesh or perforated metal shall be not less than 0.037 inch (U.S. Gage No. 20), and the openings shall be not greater than three-eighths inch. Solid material used for this purpose shall be of an equivalent strength and firmness. The guard for the portion of the blade between the sliding guide and the upper-saw-wheel guard shall protect the saw blade at the front and outer side. This portion of the guard shall be self-adjusting to raise and lower with the guide. The upper-wheel guard shall be made to conform to the travel of the saw on the wheel:  a.     In the maintenance department, the blade guard on the Wilton band saw was maladjusted and the unused portion of the blade was not guarded, thereby exposing employees to amputation hazards from the revolving blade.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $5,500 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.219(c)(2)(i): All exposed parts of horizontal shafting seven (7) feet or less from floor or working platform, excepting runways used exclusively for oiling, or running adjustments, shall be protected by a stationary casing enclosing shafting completely or by a trough enclosing sides and top or sides and bottom of shafting as location requires:  a.     Extruder section, at the start of the take up reel there was an unguarded horizontal shaft which was not completely enclosed, thereby exposing employees to a caught-in hazard.  b.     Extruder operation, at the end of the take up reel, there was an unguarded horizontal shaft which was not completely enclosed, thereby exposing employees to a caught-in hazard.   c.      Sizer room, there was an unguarded horizontal shaft that was not completely enclosed thereby exposing employees to a caught-in hazard.  d.      Emulsion building, the horizontal drive shaft for the mixer was not completely enclosed, thereby exposing employees to a caught-in hazard.  e.      Pre mix side, the horizontal drive shaft to the hydraulic water pump was not completely enclosed, thereby exposing employees to a caught in hazard.  f.       Booster Building production 1 scrubber room, there was a horizontal shaft which was not completely enclosed, thereby exposing employees to a caught-in hazard.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $5,500 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.219(d)(1): Guarding. Pulleys, any parts of which are seven (7) feet or less from the floor or working platform, shall be guarded in accordance with the standards specified in paragraphs (m) and (o) of this section. Pulleys serving as balance wheels (e.g., punch presses) on which the point of contact between belt and pulley is more than six feet, six inches (6 ft. 6 in.) from the floor or platform may be guarded with a disk covering the spokes:  a.  Extruder operation, at the end of the take up reel where both belt runs were less than 42 inches from the floor, the belt/pulley was not completely enclosed, thereby exposing employees to a caught-in hazard.  b.  Sizer room, the end of the take up reel had a belt/pulley assembly which was not completely enclosed,  where both belt runs were less than 42 inches from the floor, thereby exposing employees to a caught-in hazard.  c.  Booster production building 2 scrubber room, there was an unguarded belt/pulley on the Leeson motor for the power washer where both runs were less than 42 inches from the floor, thereby exposing employees to a caught-in hazard.  d.  Weigh building scrubber room, there was an unguarded belt/pulley assembly where both runs were less than 42 inches from the floor, which was not completely enclosed on the Leeson power wash, thereby exposing employees to a caught-in hazard.  e.  Winder building, there were five (5) Leeson machines with unguarded belts/pulley assemblies where both belt runs were less than 42 inches from the floor and which were not completely enclosed, thereby exposing employees to a caught-in hazard.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.219(e)(1)(i):  Where both runs of horizontal belts are seven (7) feet or less from the floor level, the guard shall extend to at least fifteen (15) inches above the belt or to a standard height, except that where both runs of a horizontal belt are 42 inches or less from the floor, the belt shall be fully enclosed in accordance with paragraphs (m) and (o) of this section:  a.  In the extruder operation at the end of the take up reel where both belt runs were less than 42 inches from the floor the belt/pulley was not completely enclosed, thereby exposing employees to a caught-in hazard.  b.  In the sizer room the end of the take up reel had a belt/pulley assembly which was not completely enclosed, where both belt runs were less than 42 inches from the floor, thereby exposing employees to a caught-in hazard.  c.  In the booster production building 2 scrubber room, there was an unguarded belt/pulley on the Leeson motor for the power washer where both runs were less than 42 inches from the floor thereby exposing employees to a caught-in hazard.  d.  In the weigh building scrubber room, there was an unguarded belt/pulley assembly where both runs were less than 42 inches from the floor which was not completely enclosed on the Leeson power wash, thereby exposing employees to a caught-in hazard.  e.  In the winder building, there were five (5) Leeson machines with unguarded belts/pulleys assemblies where both belt runs were less than 42 inches from the floor and which were not completely enclosed, thereby exposing employees to a caught-in hazard.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $4,400 · Current $2,640 Reduced

General-duty citation text

29 CFR 1910.219(i)(2): Couplings. Shaft couplings shall be so constructed as to present no hazard from bolts, nuts, setscrews, or revolving surfaces. Bolts, nuts, and setscrews will, however, be permitted where they are covered with safety sleeves or where they are used parallel with the shafting and are countersunk or else do not extend beyond the flange of the coupling.   a.     Mix plant, the guard on the back of the machine over the coupler to the Heet packer was not secured over the coupler to protect employees from protruding screws on the coupler and  to prevent accidental contact, employees were exposed to a caught-in hazard.   b.     Mix plant,  the guard over the coupler to the Bowie machine was not secured and had properly installed over the coupler to prevent accidental contact to the coupler, employees were exposed to a caught-in hazard.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $4,400 · Current $2,640 Reduced

General-duty citation text

29 CFR 1910.219(m)(2)(i): Expanded metal, sheet or perforated metal, and wire mesh shall be securely fastened to frame:  a.  in the mix plant, the guard on the back of the Heet Packer over the coupler was not secured to prevent accidental displacement, exposing employees to a caught-in hazard.  b.  In the mix plant, the guard over the coupler to the Bowie machine was not secured to the machine and was becoming displaced from movement of the coupler, thereby exposing employees to a caught-in hazard.  c.  At the rear of the emulsion maintenance dike area, the guard over the coupler on the transfer pump was not secured to the machine to prevent accidental displacement, exposing employees to a caught-in hazard.

Issued

Jun 6, 2013

Abate by

Jun 6, 2013

Penalty

Initial $5,500 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.242(b): Compressed air used for cleaning. Compressed air shall not be used for cleaning purposes except where reduced to less than 30 p.s.i. and then only with effective chip guarding and personal protective equipment:  a.     In the East building, first bin, the compressed air "Number 29" was used to clean off the machines and was operated at 80 p.s.i., thereby exposing employees to an injury.  b.     In the East building, first bin, the compressed air nozzle used to clean machines on the backside of "Number 25" was operated at 78 p.s.i., thereby exposing employees to an injury.  c.      At the extruder operation, the compressed air used to clean machines on the extruder machine was operated at 80 p.s.i., thereby exposing employees to an injury.  d.      In the extruder operation, the compressed air used for cleaning the start-up/take up reel was operated at 65 p.s.i., thereby exposing employees to an injury.

Issued

Jun 6, 2013

Abate by

Jun 26, 2013

Penalty

Initial $5,500 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.303(f)(1):  Motors and appliances. Each disconnecting means required by this subpart for motors and appliances shall be legibly marked to indicate its purpose, unless located and arranged so the purpose is evident:  a.     At the rear of the emulsion building beside the dikes for bulk tanks, the disconnects to the electrical equipment in this area were not marked with the equipment it controlled, thereby exposing employees to a contact hazard.  b.     In the booster pour building 3 scrubber room, the disconnect in the room was not marked as to the equipment it controlled, thereby exposing employees to a contact hazard.

Issued

Jun 6, 2013

Abate by

Jun 16, 2013

Penalty

Initial $3,300 · Current $1,980 Reduced

General-duty citation text

29 CFR 1910.304(f)(1)(iv): Overcurrent devices shall be readily accessible to each employee or authorized building management personnel. These overcurrent devices may not be located where they will be exposed to physical damage or in the vicinity of easily ignitable material:  a.  On the South side of the mix plant, there were several 55 gallon drums of emulsifier stored in front of the energized electrical panel, thereby preventing easy access to operate the electrical equipment.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $7,000 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.305(d)(2): Panelboard enclosures. Panelboards shall be mounted in cabinets, cutout boxes, or enclosures designed for the purpose and shall be dead front. However, panelboards other than the dead front externally-operable type are permitted where accessible only to qualified persons:  a.  In the SPA electrical room, the front of the energized electrical panel had missing circuit breakers, thereby exposing employees to an electrocution hazard.  b.  In the maintenance department, the energized electrical panel box beside the doorway to the kitchen had a missing circuit breaker, thereby exposing employees to an electrocution hazard.  c.  At the P-10 dryer (outside light panel box), there was a two inch unused opening where employees could contact energized electrical parts, thereby exposing employees to an electrocution hazard.  d.  In the mix plant warehouse, there was an energized electrical panel used by employees to control lighting.  The electrical panel had missing circuit breakers, thereby exposing employees to an electrocution hazard.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(g)(2)(i): Except as elsewhere required or permitted by this standard, live parts of electric equipment operating at 50 volts or more shall be guarded against accidental contact by use of approved cabinets or other forms of approved enclosures or by any of the following means:  a.  In the SPA electrical room, the front of the energized electrical panel had missing circuit breakers, thereby exposing employees to an electrocution hazard.  b.  In the maintenance department, the energized electrical panel box beside the doorway to the kitchen had a missing circuit breaker, thereby exposing employees to an electrocution hazard.  c.  At the P-10 dryer (outside light panel box), there was a two inch unused opening where employees could contact energized electrical parts, thereby exposing employees to an electrocution hazard.  d.  In the mix plant warehouse, there was an energized electrical panel used by employees to control lighting.  The electrical panel had missing circuit breakers, thereby exposing employees to an electrocution hazard.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $7,000 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.333(a): "General." Safety-related work practices shall be employed to prevent electric shock or other injuries resulting from either direct or indirect electrical contacts, when work is performed near or on equipment or circuits which are or may be energized. The specific safety-related work practices shall be consistent with the nature and extent of the associated electrical hazards:  a.  The employer failed to employ safety related work practices consistent with the nature, extent of shock and arc-flash blast hazards encountered by employees, who performed troubleshooting and voltage testing on or near energized parts up to 480 VAC.  A flash hazard analysis was not conducted to determine the nature and extent of arc/fault hazards that would require the use of arc-rated personal protective equipment.

Issued

Jun 6, 2013

Abate by

Jun 6, 2013

Penalty

Initial $5,500 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.334(a)(2)(i): Portable cord and plug connected equipment and flexible cord sets (extension cords) shall be visually inspected before use on any shift for external defects (such as loose parts, deformed and missing pins, or damage to outer jacket or insulation) and for evidence of possible internal damage (such as pinched or crushed outer jacket). Cord and plug connected equipment and flexible cord sets (extension cords) which remain connected once they are put in place and are not exposed to damage need not be visually inspected until they are relocated:  a.  In the bulk emulsion building, the power cord to the A.O. Smith portable industrial fan was not inspected for defective wiring prior to use, thereby exposing employees a shock/electrocution hazard.

Issued

Jun 6, 2013

Abate by

Jun 6, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.304(g)(5): Grounding path. The path to ground from circuits, equipment, and enclosures shall be permanent, continuous, and effective:  a.     In the bulk emulsion building where an A.O. Smith fan was used for cooling purposes, the ground pin was missing, thereby exposing employees to a contact hazard.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $7,000 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.335(a)(1)(i):  Employees working in areas where there are potential electrical hazards shall be provided with, and shall use, electrical protective equipment that is appropriate for the specific parts of the body to be protected and for the work to be performed.  Note: Personal protective equipment requirements are contained in subpart I of this part:  a.  The employer did not ensure the use of electrical protective equipment necessary to protect employees from electrical shock, arc flash or arc blast, for employees who routinely performed work, such as testing, troubleshooting, voltage measuring, and other tasks, on or near energized parts up to 480 VAC or higher.

Issued

Jun 6, 2013

Abate by

Jun 6, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(5)(ii)(D):  Lock-out devices and tag-out devices shall indicate the identity of the employee applying the device(s):  a.     In the East building, the lock-out device attached to machine 26 was not identified as to who applied the lock to the machine.

Issued

Jun 6, 2013

Abate by

Jul 11, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(b)(1)(ii):  Unused openings in cabinets, boxes, and fittings shall be effectively closed:  a.    In the SPA electrical room, there were two unused openings in the top of the energized 240 volt electrical panel, thereby exposing employees to a contact hazard.  b.     On the East wall of the maintenance shop, the energized 240 volt three phase disconnect had an unused opening in the bottom of the disconnect, thereby exposing employees to a contact hazard.  c.     In the maintenance shop where employees repaired equipment and manufactured guards, the light switch beside the door to the propane tanks had a switch missing, leaving an unused opening in the energized light switch, thereby exposing the employees to a contact hazard.  d.     In the emulsion one warehouse, there was a 1 1/2 inch unused opening in the bottom of the 277/480 VAC energized electrical panel, thereby exposing employees to a contact hazard.  e.      In the truck garage where maintenance was performed on over the road equipment, on the North side door opener number 2, the 240 volt/three phase energized electrical disconnect had an unused opening in the bottom of the disconnect, thereby exposing employees to a contact hazard.  f.      In the truck garage where maintenance was performed on over the road equipment, on the South side door opener number 2, there was an unused opening in the top of the light switch (240 volt/three phase), thereby exposing employees to a contact hazard.  g.      In the emulsion box warehouse where storage was kept until needed, there was an unused opening on the side of the Atlas Copco 7 1/2 HP air compressor, thereby exposing employees to a contact hazard.  h.      In the emulsion box warehouse, there was an unused opening on the bottom of the energized disconnect to the SWF box machine, thereby exposing employees to a contact hazard.