OSHA Inspection: KEAL CASES, INCORPORATED

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $1320.00 · Current $400.00 Reduced

Hazardous substances 00402590

General-duty citation text

29 CFR 1910.106(d)(2)(i): Approved containers and/or portable tanks were not used for the storage of flammable liquids:     Foam Shop, in the spray booth, extremely flammable Crown Lacquer Thinner used by employees for cleaning spray guns was stored overnight in a loosely covered coffee can, exposing employees to the hazards of fire.

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 00402590

General-duty citation text

29 CFR 1910.107(e)(2): The quantity of flammable liquids or liquids with a flashpoint greater than 199.4 degrees F (93 degrees C) kept in the vicinity of spraying operations were not a minimum required for operations or they exceeded a supply for one day or one shift:   Foam Shop, in the spray booth, where employees were using extremely flammable Crown Lacquer Thinner to clean the spray gun, the manufacturer's 5-gallon can and a loosely covered coffee can containing thinner were stored overnight, exposing employees to the hazards of fire.

Issued

2014-09-17 00:00:00

Abate by

2014-11-04 00:00:00

Penalty

Initial $1320.00 · Current $400.00 Reduced

General-duty citation text

29 CFR 1910.106(d)(5)(vi)(a): When the storage building was located 50 feet (15.2 m) or less from a building or line of adjoining property that could be built upon, the exposing wall was not a blank wall having a fire-resistance rating of at least 2 hours:    Flammable liquid storage building, where employees were storing extremely flammable liquids and dispensing flammable liquids from 55-gallon drums including, but not limited to Solvent 210-66 and Wilsonart 950 and 951 Adhesives, the exposing wall on the dock side was not a blank wall in that the door opened to the dock, and the building was constructed of wood and OSB, exposing employees to the hazards of fire.

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 004020372460

General-duty citation text

29 CFR 1910.107(e)(4): The withdrawal of flammable liquids or liquids with a flashpoint greater than 199.4 degrees F (93 degrees C) from containers and the filling of containers, including portable mixing tanks, was not done only in a suitable mixing room or in a spraying area when the ventilating system was in operation:   Flammable liquid storage building, where employees were dispensing extremely flammable liquids including, but not limited to Solvent 210-66 and Wilsonart 950 and 951 Adhesives from 55-gallon drums for use on the assembly line, only general dilution ventilation in the form of an open door and open floor holes was provided, exposing employees to the hazards of fire.

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.107(e)(9):  Flammable liquids for use in spraying operations were transferred from one container to another without both containers being effectively bonded and grounded to prevent discharge sparks of static electricity:   Flammable liquid storage building, where employees were dispensing extremely flammable liquids including, but not limited to Solvent 210-66 and Wilsonart 950 and 951 Adhesives from 55-gallon drums for use on the assembly line, drums were not grounded and containers were not bonded to drums during filling operations, exposing employees to the hazards of fire.

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $1320.00 · Current $400.00 Reduced

Hazardous substances 00402590

General-duty citation text

29 CFR 1910.107(g)(2): All spraying areas were not kept as free from the accumulation of deposits of combustible residues as practical, with cleaning conducted daily if necessary:    (a) Foam Shop, in the spray booth, where employees were spray finishing caster boards with flammable Black Gloss Q.D. Enamel, residue from overspray was allowed to accumulate on the walls and floor and on wood tables and stands, exposing employees to the hazards of fire.    (b) Foam Shop, at the assembly line, where employees were spraying wood cases and foam lining with flammable 950 Adhesive and 951 Adhesive, residue from overspray was allowed to accumulate on paper and cardboard coverings for the work bench and room divider, exposing employees to the hazards of fire.

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.107(g)(3): Rags or waste impregnated with finishing material were not deposited in approved metal waste cans immediately after use:  Foam Shop, where employees on the assembly line were using extremely flammable petroleum distillates to clean flammable Wilsonart 950 and 951 contact adhesive overspray off cases, contaminated shop cloths were discarded in open wood bins with foam scraps and other waste materials, exposing employees to the hazards of fire.

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $2640.00 · Current $800.00 Reduced

General-duty citation text

29 CFR 1910.303(b)(2): Listed or labeled electrical equipment was not used or installed in accordance with instructions included in the listing or labeling:    (a) Foam Shop, a Bosch 1575A hand foam cutter was mounted to the underside of a table with the blade(s) passing through a hole in the table, the switch locked in the "On" position, and the power cord plugged into an outlet receptacle that was wired to a toggle switch on the operator's side of the table, exposing employees to the hazards of being struck by the blades if inadvertently activated.     (b) Foam Shop, on the floor near the Ingersoll-Rand drill press, a four-plex junction box that was powering equipment including, but not limited to an outlet receptacle box mounted under the Bosch foam cutter table, the drill press, and 2 cell phone chargers was lying on the floor in lieu of mounting the box, exposing employees to the hazards of electric shock.

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.305(g)(1)(iv)(A): Flexible cords and/or cables were used as a substitute for the fixed wiring of a structure:  Foam Shop, fixed equipment including but not limited to an Ingersoll-Rand Drill Press and a Bosch 1575A hand foam cutter installed for use as a "table saw" were powered by a series of electrical installations that were connected by flexible cords in lieu of fixed wiring, exposing employees to the hazards of fire.

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.305(g)(1)(iv)(D): Flexible cords and cables were used where attached to building surfaces:  Foam Shop, above the Ingersoll-Rand Drill Press, a 4-plex outlet receptacle mounted on an overhead structural beam was connected to a four-plex junction box on the floor with a 12/3 Type SOW-A flexible cord that was wrapped around the overhead beam for support and dropped along a vertical steel beam to the j-box on the floor, which employees were using to plug in equipment including, but not limited to the drill press, Bosch 1575A hand foam cutter, and two cell phone chargers, exposing employees to the hazards of electrical shock.

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $1320.00 · Current $400.00 Reduced

Hazardous substances 00402460

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:    Foam Shop, at the assembly line, where employees were spraying wood cases and pre-cut foam with flammable 950 Adhesive and 951 Adhesive, electrical equipment and installations including, but not limited to portable pedestal fans, outlet receptacles and switches, and foam cutting saws were not approved for hazardous locations where flammable vapor-air mixtures may exist within 20 feet of spraying areas under normal operating conditions.

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $1320.00 · Current $400.00 Reduced

Hazardous substances 00402590

General-duty citation text

29 CFR 1910.1200(f)(6): The employer did not ensure that each container of hazardous chemicals in the workplace was labeled, tagged or marked with the information specified under paragraphs (f)(6)(i) through (ii) of this section:    (a) Foam Shop, in the spray booth, extremely flammable Crown Lacquer Thinner was stored in an unlabeled coffee can and used by employees for cleaning the spray gun, exposing employees to the hazards of chemicals.     (b) Foam Shop, in the flammable liquid storage cabinet beside the spray booth, the 55-gallon drum containing flammable Capitol Paint Mfg. Corp. Black Gloss Q.D. Enamel (mixed xylenes) was supplying the spray gun used by employees to paint caster boards and was installed so that no identity or hazard warnings were visible other than a red Flammable label, exposing employees to the hazards of chemicals.     (c) Foam Shop, outside the spray booth, employees were spraying foam case lining with flammable Wilsonart 950 Adhesive and 951 Adhesive from unlabeled spray pots, exposing employees to the hazards of chemicals.    (d) Foam Shop, glue line work bench, a 1-gallon can with manufacturer's label for Nazdar SW37 Universal Screen Wash contained Tem-Tex Solvents extremely flammable Solvent 210-66 and was used by employee(s) to clean adhesive overspray off cases, exposing employees to the hazards of chemicals.

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 00402590

General-duty citation text

29 CFR 1910.1200(g)(1): The employer did not have a material safety data sheet for each hazardous chemical which they used:   Foam Shop, where employees were spraying caster boards with flammable Capitol Paint Mfg. Corp. Black Gloss Q.D. Enamel (mixed xylenes), the employer did not have a Material Safety Data Sheet (MSDS), exposing employees to the hazards of chemicals.

Issued

2014-09-17 00:00:00

Penalty

Initial $2640.00 · Current $800.00 Reduced

Hazardous substances 004016602590

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:    Foam Shop, on or about March 26, 2014 and in times prior thereto and thereafter employee(s) were required to wear 3M 5300 Organic Vapor/P95 half-facepiece respirators while working in the spray booth without ensuring each was medically evaluated prior to using the respirator, exposing employee(s) to an additional burden to their cardiopulmonary systems.    Keal Cases Incorporated was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.134(e)(1), which was contained in OSHA inspection number 848523, citation number 1, item number 3a, and was affirmed as a final order on April 2, 2013 with respect to a workplace located at 1100 West Old Settlers Blvd., Round Rock, TX 78680.

Issued

2014-09-17 00:00:00

Penalty

Initial $2640.00 · Current $800.00 Reduced

Hazardous substances 166025909685

General-duty citation text

29 CFR 1910.134(f)(2): Employee(s) using tight-fitting facepiece respirators were not fit tested prior to initial use of the respirator, and at least annually thereafter:    Foam Shop, on or about March 26, 2014 and in times prior thereto, employees were required to wear 3M 5300 Organic Vapor/P95 half-facepiece respirators while working in the spray booth without ensuring each employee was fit tested prior to use and at least annually thereafter, exposing employees to chemical inhalation hazards.    Keal Cases Incorporated was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.134(f)(2), which was contained in OSHA inspection number 848523, citation number 1, item number 3b, and was affirmed as a final order on April 2, 2013 with respect to a workplace located at 1100 West Old Settlers Blvd., Round Rock, TX 78680.

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.37(b)(6): Each exit sign was not illuminated to a surface value of at least five foot-candles (54 lux) by a reliable light source and was not distinctive in color:  Foam Shop, east wall beside the spray booth, the exit sign above the side-hinged swinging door to the outside was not illuminated, exposing employees to the hazards of fire.

Issued

2014-09-17 00:00:00

Abate by

2014-09-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 00402590

General-duty citation text

29 CFR 1910.134(g)(1)(i)(A): Respirators with tight-fitting facepieces were worn by employees who had facial hair that came between the sealing surface of the facepiece and the face or that interfered with valve function:  Foam Shop, on or about March 26, 2014 and in times prior thereto, employees were required to wear 3M 5300 Organic Vapor/P95 half-facepiece respirators while spraying caster boards with flammable Black Gloss Q.D. Enamel, and the employer did not ensure that employee(s) did not have facial hair that interfered with the face-to-facepiece seal of the respirator, exposing employees to the hazards of chemical inhalation.