OSHA Inspection: ESSROC CEMENT CORPORATION

Issued

Apr 29, 2016

Abate by

May 19, 2016

Penalty

Initial $5,000 · Current $3,000 Reduced

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:    On or about November 10, 2015, there was an elevated walkway approximately 40 feet long on the second level at the side of the number 1 rotating ball mill. The elevated walking/working surface and surrounding floor area were wet and slippery from the pulverized cement powder/dust and the rain water that was coming through the roof.

Issued

Apr 29, 2016

Abate by

May 19, 2016

Penalty

Initial $7,000 · Current $5,000 Reduced

General-duty citation text

29 CFR 1910.146(e)(1): Before entry was authorized, the employer did not document the completion of measures required by 29 CFR 1910.146(d)(3) by preparing an entry permit:    On or about November 6, 2015, an employee was exposed to potentially hot cement dust, a hazardous atmosphere and possible engulfment because of the inwardly converging walls that were internally configured such that an entrant could be trapped or asphyxiated while performing an auger replacement task inside of the dust collection system.

Issued

Apr 29, 2016

Abate by

Jul 30, 2016

Penalty

Initial $7,000 · Current $5,000 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:    On or about November 10, 2015, the employer had not established a written specific lockout/tagout procedure for work such as but not limited to the broom, shovel and wheel barrow clean up of the pile of pulverized cement powder. The powder spills out of the ventilation system at the seal of the Unidan air slide spitzer box for the number 1 ball mill.

Issued

Apr 29, 2016

Abate by

May 19, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d)(4)(ii): Lockout devices utilized were not affixed in a manner that held the energy isolating device in a safe or off position:  On or about November 10, 2015, The employer did not ensure employees were locked out while cleaning up piles of cement powder at the number 1 ball mill air slide spitzer box. The ratchet tool over the handle end used for racking the  4160 volt main breaker in the motor control center was deficient for controlling the electrical energy source. The ratchet handle could be locked in position but the socket segment of the ratchet could be by-passed and rotated with pliers.

Issued

Apr 29, 2016

Abate by

May 19, 2016

Penalty

Initial $7,000 · Current $5,000 Reduced

General-duty citation text

29 CFR 1910.179(j)(4)(iii): Standby crane(s) were not inspected at least semi-annually in accordance with the requirements of 1910.179(j)(2) and 1910.179(m)(2)(a):     On or about November 10, 2015, The employer did not ensure their overhead cranes received semi-annual inspection. The P&H 10 ton overhead crane and the Wright 10 ton overhead crane were available for use as standby cranes for changing large motors, adding steel balls to the ball mills and adding oil to the gear boxes.

Issued

Apr 29, 2016

Abate by

May 19, 2016

Penalty

Initial $35,000 · Current $6,000 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, rotating parts, flying chips and sparks:    1. On or about November 10, 2015, the dryer operation rotating cylindrical barrel that was approximately 12 feet wide by 60 feet long had two idler rollers to stabilize the rotating barrel on the north side. The two idler rolls were approximately 12 inches in diameter by 18 inches wide. The ingoing nip points of the rollers were not guarded.     2. On or about November 10, 2015, the number 1 ball mill had a rotating horizontal drive shaft approximately 12 inches in diameter and 10 feet long with a 5 foot diameter coupling between the gear box and air slide spitzer box ventilation system. The guard railing system on both sides was inadequate in that the guard railing barriers did not extend to the associated machinery and had entry gates in the centers on each side that did not have interlocks. The openings were between 10 and 20 inches at both ends of each side. The large rapid rotating drive shaft and coupling were not guarded.    3. On or about November 10, 2015, the number 1 ball mill was a rotating metal barrel 32 feet long and 9.5 feet in diameter with multiple threaded bolt ends protruded from the outside of the barrel approximately 1.5 inches. The rapid rotating ball mill was 17 inches from the top hand rail of the elevated walkway and the bolts that protruded through the outside walls of the barrel were not guarded.        ESSROC READY MIX, CORPORATION WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR IT'S EQUIVALENT STANDARD 29 CFR 1910.212(a)(1), WHICH WAS CONTAINED IN OSHA INSPECTION 407102, CITATION NUMBER 1, ITEM NUMBER 2, AND WAS AFFIRMED AS A FINAL ORDER ON SEPTEMBER 11, 2012, WITH RESPECT TO A WORKPLACE LOCATED AT LOT 3 ORDERS LANE WINFIELD, WV 25213.