OSHA Inspection: AMERICAN TESTING LABORATORIES, INC.

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $3,500 · Current $1,925 Reduced

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, in that employees were exposed to struck by hazards:    On or about 03/11/14 and at times prior thereto employees walking/working in proximity of storage racks throughout the Plant building were exposed to be struck-by and/or crushed by metal racks and stored materials in the event of a collapse of the free standing. unanchored metallic storage racks. The employer failed to ensure that all metal rack columns were anchored to the floor.    Among other methods, one feasible and acceptable method to correct the hazards is to follow the Rack Manufacturers Institute installation instructions and the American National Standards Institute (ANSI) Standard MH16.1-2012 (a revision of  MH16.1-2008): Specifications for the Design, Testing and Utilization of Industrial Steel Storage Racks, which includes, among others, the following:  a. Section 1.4.7 Column Base Plates and Anchors:  The bottom of all columns shall be furnished with column base plates, as specified in 7.1.  All rack columns shall be anchored to the floor with anchor bolts, which shall be designed in accordance with Section 7.3, to resist applicable forces as described in Section 2.1 or 2.2    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $3,500 · Current $1,925 Reduced

General-duty citation text

29 CFR 1910.22(a)(1): All places of employment, passageways, storerooms or service rooms were not kept clean and orderly or in a sanitary condition.    a) Saw Room - On or about 03/11/14 and at times prior thereto the employer did not establish and implement a cleaning policy and schedule for the removal of combustible saw dust accumulated on the floor and  on elevated areas of the equipment and building, in order to prevent employee exposure to fire and combustible dust deflagrations/explosions.      In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $2,100 · Current $1,155 Reduced

General-duty citation text

29 CFR 1910.134(e)(1): The employer did not provide a medical evaluation to determine the employee's ability to use a respirator, before the employee was fit tested or required to use the respirator in the workplace:    (a) Plant -  On or about 03/11/14 and at times prior thereto employees sprayed Kleiberit 430.6 Supratherm  polyurethane dispersion adhesive on agglomerated wood panels and wore half face respirators with organic cartridges and N-95 pre-filters. The employer did not provide medical questionnaires to determine the ability of workers to wear the selected respiratory protection equipment.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(f)(1): The employer did not ensure that employee(s) required to use a tight-fitting facepiece respirator passed the appropriate qualitative fit test (QLFT) or quantitative fit test (QNFT):  (a) Plant -  On or about 03/11/14 and at times prior thereto employees sprayed Kleiberit 430.6 Supratherm  polyurethane dispersion adhesive on agglomerated wood panels and wore half face respirators with organic cartridges and N-95 pre-filters. The employer did not provide fit-testing of the respirators.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(k)(1): The employer did not provide respirator training that would ensure each employee could demonstrate knowledge of items in section (i)-(vii):  (a) Plant - On or about 03/11/14 and at times prior thereto employees sprayed Kleiberit 430.6 Supratherm  polyurethane dispersion adhesive on agglomerated wood panels and wore half face respirators with organic cartridges and N-95 pre-filters. The employer did not provide training in relation to the selection, use, care, and limitations of respiratory protection equipment.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $3,500 · Current $1,925 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section:    a) Facility - On or about 03/11/14 and at times prior thereto employees performed lockout/tagout  during repairs and servicing of equipment including (but not limited to)  the Picture Frame Molding Laminators (4 units), Prisma CE saw, Prisma Maxi Saw,  Weinig Hydromat 23 C moulder, Fletcher Edge Former, and Giben Automatic Edgebander KG-368j, and additional equipment described in the Horton Components Fixed Asset Summary Report, updated February 2014, which require lockout/tagout. The employer did not develop, document, and utilize individual written lockout/tagout procedures to protect the workers during repairs/maintenance of machinery.      b) Facility - On or about 03/11/14 and at times prior thereto employees performed lockout/tagout  during repairs and servicing of equipment including (but not limited to)  the Flat Line Laminator, Almex Thermolaminator (2 units), Komo Router (Model VR 510 Mach II S, 480 V, 60 Hz.), Bulleri Brevetti Router (Model FPM 2313 NTL, 480 V, 60 Hz.), Komo Router (Model Fusion 510, S.N. 01134-12, 480 V, 60 Hz.), and Fletcher Edge Former. The employer did not utilize the corresponding individual written lockout/tagout procedures to protect the workers during repairs/maintenance of machinery.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition documentation demonstrating that abatement is complete must be included with your certification. This documentation may include, but is not limited to, evidence of purchase or repair of the equipment, photographic or video evidence of abatement, or other written records.

Issued

Jul 30, 2014

Abate by

Oct 1, 2014

Penalty

Initial $3,500 · Current $1,925 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(ii): 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) Facility - On or about 03/11/14 and at times prior thereto employees performed lockout/tagout  during repairs and servicing of equipment including (but not limited to)  the Flat Line Laminator, Almex Thermolaminator (2 units), Komo Router (Model VR 510 Mach II S, 480 V, 60 Hz.), Bulleri Brevetti Router (Model FPM 2313 NTL, 480 V, 60 Hz.), Komo Router (Model Fusion 510, S.N. 01134-12, 480 V, 60 Hz.), and Fletcher Edge Former.     The procedures did not specify the  minimum necessary information including (but not limited to) :      The types and magnitudes of the  energies involved.      The identification/location of the energy controls (panels, valves).      The required protective hardware required for each energy at each machine.      The procedural steps (specific for each machine) for shutting down , isolating, blocking and securing equipment for the control of hazardous energy.      A description of residual energy.    Specific requirements for testing and verifying the effectiveness of the isolation or lockout/tagout.      Notification of affected employees when the energy is interrupted and restarted.    Workers were exposed to electrical energy, vacuum, compressed air, hydraulic energy, hot surfaces and fluids, potential (gravitational) energy, crushes and amputations. (Reference: 29 CFR 1910.147 Appendix A, Typical Minimal Lockout/tagout procedures).    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition documentation demonstrating that abatement is complete must be included with your certification. This documentation may include, but is not limited to, evidence of purchase or repair of the equipment, photographic or video evidence of abatement, or other written records.

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $3,500 · Current $1,925 Reduced

General-duty citation text

29 CFR 1910.147(c)(6)(i): The employer did not conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirement of this standard were being followed:    a) Facility - On or about 03/11/14 and at times prior thereto employees performed lockout/tagout during repairs and servicing of equipment including (but not limited to)  the Flat Line Laminator, Almex Thermolaminator (2 units), Komo Router (Model VR 510 Mach II S, 480 V, 60 Hz.), Bulleri Brevetti Router (Model FPM 2313 NTL, 480 V, 60 Hz.), Komo Router (Model Fusion 510, S.N. 01134-12, 480 V, 60 Hz.), and Fletcher Edge Former. The employer did not conduct periodic and at least annual inspections of the corresponding individual written lockout/tagout procedures.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition documentation demonstrating that abatement is complete must be included with your certification. This documentation may include, but is not limited to, evidence of purchase or repair of the equipment, photographic or video evidence of abatement, or other written records.

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $3,500 · Current $1,925 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i)(B): Affected employees were not instructed in the purpose and use of the energy control procedure:    a) Facility - On or about 03/11/14 and at times prior thereto employees performed lockout/tagout  during repairs and servicing of equipment including (but not limited to)  the Flat Line Laminator, Almex Thermolaminator (2 units), Picture Frame Molding Laminators (4 units), Komo Router (Model VR 510 Mach II S, 480 V, 60 Hz.), Bulleri Brevetti Router (Model FPM 2313 NTL, 480 V, 60 Hz.), Komo Router (Model Fusion 510, S.N. 01134-12, 480 V, 60 Hz.), Prisma CE saw, Prisma Maxi Saw,  Weinig Hydromat 23 C moulder, Fletcher Edge Former, and Giben Automatic Edgebander KG-368j. The employer did not provide training for affected employees in relation to the control of hazardous energy  and lockout/tagout.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition documentation demonstrating that abatement is complete must be included with your certification. This documentation may include, but is not limited to, evidence of purchase or repair of the equipment, photographic or video evidence of abatement, or other written records.

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $3,500 · Current $1,925 Reduced

General-duty citation text

29 CFR 1910.212(a)(1): 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, and rotating parts:    a) Warehouse, Flat Line - On or about 03/11/14 and at times prior thereto  the guard protecting the brake in the flat line laminator was loose and worn out. The brake was not protected, and  operators were exposed to nip points created by the rotating brake components and the stationary guard.     b) Warehouse, Flat Line - On or about 03/11/14 and at times prior thereto the squirrel cage rotor in the blower that cooled the laminated boards did not have a guard, exposing workers to amputations/lacerations.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition documentation demonstrating that abatement is complete must be included with your certification. This documentation may include, but is not limited to, evidence of purchase or repair of the equipment, photographic or video evidence of abatement, or other written records.

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $3,500 · Current $1,925 Reduced

General-duty citation text

29 CFR 1910.219(f)(3): Sprocket wheels and chains which were seven -7 feet or less above floors or platforms were not enclosed:    a) Flat Line - On or about 03/11/14 and at times prior thereto the flat line laminator had loose, worn out guard. The chain and sprocket  were not protected, and  operators were exposed to nip points, amputations and laceration hazards.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition documentation demonstrating that abatement is complete must be included with your certification. This documentation may include, but is not limited to, evidence of purchase or repair of the equipment, photographic or video evidence of abatement, or other written records.

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $2,800 · Current $1,540 Reduced

General-duty citation text

29 CFR 1910.219(c)(4)(i): Unguarded projecting shaft end(s) did not present a smooth edge and end and projected more than one half the diameter of the shaft:     a) Warehouse, Flat Line Area - On or about 03/11/14 and at times prior thereto  the  unguarded 1.5 in. diameter  live shaft on the side of the flat line laminator did not have a smooth edge and protruded 4.0 in. from the bearing.     In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.219(c)(4)(ii): The unused keyway(s) of projecting shaft end(s) were not filled up or covered:   a) Warehouse, Flat Line Area - On or about 03/11/14 and at times prior thereto  the  unguarded 1.5 in. diameter  live shaft on the side of the flat line laminator protruded 4.0 in. from the bearing and the keyway was not filled or covered.  In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $2,100 · Current $1,155 Reduced

General-duty citation text

29 CFR 1910.305(b)(2)(i): Pull boxes, junction boxes, and fittings were not provided with covers approved for the purpose:    a) Warehouse - On or about 03/11/14 and at times prior thereto employees operated the  Nordson Durablue 10L   glue machine Model 1026754A,  S.N. AN04D02445, 240 V. The equipment did not have a cover to protect the conductors and terminals for the heating elements. Employees were exposed to potential contact with live parts.        In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $3,500 · Current $1,925 Reduced

General-duty citation text

29 CFR 1910.307(c): Equipment, wiring methods, and installations of equipment in hazardous (classified) locations were not intrinsically safe, approved for the hazardous (classified) location, or safe for the hazardous (classified) location:    a) Saw Room, Router Area - On or about 03/11/14 and at times prior thereto  the employer operated the Komo Router, Model VR 510 Mach II S, 480 V, 60 Hz, the Bulleri Brevetti Router, Model FPM 2313 NTL, 480 V, 60 Hz., and the Komo Router, Model Fusion 510, S.N. 01134-12, 480 V, 60 Hz.   Combustible (and explosive)  Class II saw dust was allowed to accumulate on the floor and on elevated areas of the equipment and building. Electrical equipment including (but not limited to) conduits, wall outlets, and safety switch boxes were not explosion proof.     In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $2,100 · Current $1,155 Reduced

General-duty citation text

29 CFR 1910.1200(h)(1): Employees were not provided effective information and training on hazardous chemicals in their work area at the time of their initial assignment and whenever a new hazard that the employees had not been previously trained about was introduced into their work area:    On or about 03/11/14 and at times prior thereto  workers came in contact with chemical including (but not limited to)  Compressed air, Permaset 422 EXP# 1NF Emulsion Adhesive (Tailored Chemical Products, Inc.), Liquefied Petroleum Gas in cylinders (LPG), Supratherm 430.6 Polyurethane Dispersion Adhesive (Kleiberit), HC Natural Versafil M6010055OH Wood Filler (RPM Wood Finishes Group, Inc.), and Dynalube Vacuum Pump Oil (Travani Pumps USA, Inc.). The employer did not provide training on the Hazard Communication Program, the "Right to Know", the nature and hazardous properties of the chemicals at the workplace, and the Global Harmonization System (GHS) (due December 1, 2013).    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.178(l)(6): The employer did not certify that each operator has been trained and evaluated as required by this paragraph (l):  (a) Plant and  Warehouse -  On or about 03/11/14 and at times prior thereto employees operated electric forklifts and LPG-powered forklifts, and the employer did not certify that the drivers were trained and evaluated in the safety operation of the forklifts.  In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(b)(7)(iv): There were damaged parts that may adversely affect safe operation or mechanical strength of electric equipment, such as parts that were broken, bent, cut or deteriorated by corrosion, chemical action, or overheating:  a) Warehouse, Flat Line Laminator - On or about 03/11/14 and at times prior thereto the flexible conduits for the wiring of the heaters were loose and disconnected from the junction boxes.  The internal conductors were exposed to damage and potential loss of insulation.  b) Warehouse, Flat Line Laminator - On or about 03/11/14 and at times prior thereto the conduit for the wiring of the emergency stop button was loose and separated from the box.  The internal conductors were exposed to damage and potential loss of insulation.  c) Warehouse, Flat Line Laminator - On or about 03/11/14 and at times prior thereto the flexible conduit for the wiring of the power transformer was loose and separated from the cabinet.  The internal conductors were exposed to damage and potential loss of insulation.  In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 30, 2014

Abate by

Sep 2, 2014

Penalty

Initial $0 · Current $0

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) Saw Shop -  On or about 03/11/14 and at times prior thereto the starter powering the dust blower for  the Komo Router (Model VR 510 Mach II S, 480 V, 60 Hz) had a damaged strain relief device. The outer jacket was broken and withdrawn, and the internal conductors and terminals were subjected to strain.   b) Warehouse - On or about 03/11/14 and at times prior thereto employees operated the automatic table to feed board to the conveyor of the Flat Line Laminator. The dual foot switch controlling the table had a damaged strain relief device. The outer jacket was broken, and the internal conductors and terminals were subjected to strain.   In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).