OSHA Inspection: GENTEX CORPORATION

Issued

Mar 30, 2015

Abate by

May 2, 2015

Penalty

Initial $7,000 · Current $7,000

Hazardous substances 2460

General-duty citation text

29 CFR 1910.106(e)(6)(i): Adequate precautions were not taken to prevent the ignition of flammable vapors from sources such as open flames; lightning; smoking; cutting and welding; hot surfaces; frictional heat; static, electrical, and mechanical sparks; spontaneous ignition, including heat-producing chemical reactions; and radiant heat:  a) Day Mix Room:  Employees poured a metal bucket that contained a liquid toluene/resin mix directly into the Day mixing tank that contained approximately 70 gallons of the flammable liquid, toluene.  The employer did not ensure that the metal bucket was bonded and/or grounded to prevent static discharge during the pouring of this liquid mixture, on or about 12/3/2014.  b) Day Mix Room:  Employees poured/dumped liquid and solid chemicals directly into the Day mixing tank that contained approximately 70 gallons of the flammable liquid, toluene.  The employer did not ensure that employees wore the available anti-static wrist grounding straps and/or other static control mechanisms (e.g., static dissipative footwear, anti-static or conductive clothing) to prevent static discharge from the body.  The employer did not ensure that the metal grounding plugs on the available anti-static wrist grounding straps were free from an accumulation of residue that would prevent successful metal to metal grounding, on or about 12/3/2014.  c) Day Mix Room:  Employees dumped non-conductive cardboard boxes and non-conductive paper bags that contained solid bulk and powdered chemicals directly into the Day mixing tank that contained approximately 70 gallons of the flammable liquid, toluene.  The employer did not ensure that employees used the available intermediate chemical load chute, with attached nitrogen inerting, on the Day mixer tank opening, to eliminate the explosive toluene vapors and prevent the ignition of flammable vapors, on or about 12/3/2014.  d) Day Mix Room:  Employees poured/dumped liquid and solid chemicals directly into the Day mixing tank that contained approximately 70 gallons of the flammable liquid, toluene.  The employer did not ensure that employees turned on the valve that provided nitrogen to inert the headspace of the Day mixer tank and chemical load chute, prior to chemical additions to the day mixer, to eliminate the explosive toluene vapors and prevent the ignition of flammable vapors, on or about 12/3/2014.  ABATEMENT CERTIFICATION REQUIRED

Issued

Mar 30, 2015

Abate by

May 2, 2015

Penalty

Initial $7,000 · Current $3,000 Reduced

Hazardous substances 2460

General-duty citation text

29 CFR 1910.132(a): Protective equipment was not used when necessary whenever hazards capable of causing injury and impairment were encountered:    a) Day Mix Room:  Employees poured/dumped liquid and solid chemicals directly into the Day mixing tank that contained approximately 70 gallons of the flammable liquid, toluene.  The employer did not ensure that these employees wore fire retardant full-body protection to protect them from the fire hazard created by ignition of flammable vapors, on or about 12/3/2014.    ABATEMENT CERTIFICATION REQUIRED