OSHA Inspection: ROCK LAKE INCORPORATED

Issued

2016-09-28 00:00:00

Abate by

2016-10-18 00:00:00

Penalty

Initial $1817.00 · Current $1500.00 Reduced

General-duty citation text

29 CFR 1910.303(g)(2)(i): Except as elsewhere required or permitted by Subpart S of Part 1910, live parts of electric equipment operating  at 50 volts or more were not guarded against accidental contact by use of approved cabinets or other forms of approved enclosures or by any of the means identified in paragraphs (A), (B), (C), and (D) of 29 CFR 1910.303(g)(2)(i):    a) Bridge saw adjacent to production saw line, un-taped wire nut connections on live conductors in excess of 120 VAC were not enclosed by approved enclosure, thus exposing employees to electrical shock hazard, on or about, August 12, 2016.    ABATEMENT CERTIFICATION REQUIRED

Issued

2016-09-28 00:00:00

Abate by

2016-11-02 00:00:00

Penalty

Initial $1817.00 · Current $1500.00 Reduced

General-duty citation text

29 CFR 1910.104(b)(10): The employer did not maintain the equipment and functioning of each charged bulk oxygen system in a safe operating condition in accordance with the requirements of this section. Wood and long dry grass was not cut back within 15 feet of any bulk oxygen storage container:    a) Bulk oxygen tank and plumbing, a leak was present which resulted in liquid oxygen pooling on the ground and vapor cloud in the immediate area, on or about August 12, 2016.    b) Bulk oxygen tank, wood pallets were stored and grass was not trimmed within 15 feet of the tank, on or about, June 30, 2016.    ABATEMENT CERTIFICATION REQUIRED

Issued

2016-09-28 00:00:00

Abate by

2016-11-02 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.110(b)(6)(vi): Readily ignitable material such as weeds and long dry grass were not removed within 10 feet of any container.  a) Propane tank storage, wood pallets, weeds and plastic fabric tarps were located within 10 feet of containers, on or about, June 30, 2016.  ABATEMENT CERTIFICATION REQUIRED

Issued

2016-09-28 00:00:00

Abate by

2017-07-31 00:00:00

Penalty

Initial $3634.00 · Current $2800.00 Reduced

Hazardous substances 9010

General-duty citation text

29 CFR 1910.1000(c): An employee(s) was exposed to Silica, Crystalline Quartz, (respirable) in excess of the 8-hour time weighted average limits listed in Table Z-3:    a) Production building, a thermaling operator and helper was exposed to Silica, Crystalline Quartz, (respirable) at an 8 hour time weighted average of 1.74 milligrams per cubic meter of air (mg/M3) while thermaling stone and helping line operators.  The exposure was 2.98 times the Permissible Exposure Limit of 0.584 mg/M3.  The PEL was established to prevent silicosis.  The exposure was established over 463 minutes of personal sampling conducted on August 12, 2016.  Zero exposure was assumed for the unsampled period of time.    b) Production building, a saw line operator was exposed to Silica, Crystalline Quartz, (respirable) at an 8 hour time weighted average of 0.74 milligrams per cubic meter of air (mg/M3) while cutting stone.  The exposure was  1.97 times the Permissible Exposure Limit of 0.361 mg/M3.  The PEL was established to prevent silicosis.  The exposure was established over 462 minutes of personal sampling conducted on August 12, 2016.  Zero exposure was assumed for the unsampled period of time.    c) Production building, a saw line operator was exposed to Silica, Crystalline Quartz, (respirable) at an 8 hour time weighted average of 0.61 milligrams per cubic meter of air (mg/M3) while cutting stone. The exposure was  1.75 times the Permissible Exposure Limit of 0.350 mg/M3.  The PEL was established to prevent silicosis.  The exposure was established over 460 minutes of personal sampling conducted on August 12, 2016.  Zero exposure was assumed for the unsampled period of time.    d) Production building, a saw line operator was exposed to Silica, Crystalline Quartz, (respirable) at an 8 hour time weighted average of 0.54 milligrams per cubic meter of air (mg/M3) while cutting stone. The exposure was  1.69 times the Permissible Exposure Limit of 0.319 mg/M3.  The PEL was established to prevent silicosis.  The exposure was established over 463 minutes of personal sampling conducted on August 12, 2016.  Zero exposure was assumed for the unsampled period of time.      ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED

Issued

2016-09-28 00:00:00

Abate by

2017-07-31 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9010

General-duty citation text

29 CFR 1910.1000(e): Feasible administrative or engineering controls were not determined and implemented to achieve compliance with the limits prescribed in 29 CFR 1910.1000(a) through (d):    a) Production building, a thermaling operator and helper was exposed to Silica, Crystalline Quartz, (respirable) at an 8 hour time weighted average of 1.74 milligrams per cubic meter of air (mg/M3) while thermaling stone and helping line operators.  Feasible administrative or engineering controls were not implemented to reduce the employees exposure, August 12, 2016.    b) Production building, a saw line operator was exposed to Silica, Crystalline Quartz, (respirable) at an 8 hour time weighted average of 0.74 milligrams per cubic meter of air (mg/M3) while cutting stone.  Feasible administrative or engineering controls were not implemented to reduce the employees exposure, August 12, 2016.     c) Production building, a saw line operator was exposed to Silica, Crystalline Quartz, (respirable) at an 8 hour time weighted average of 0.61 milligrams per cubic meter of air (mg/M3) while cutting stone. Feasible administrative or engineering controls were not implemented to reduce the employees exposure, August 12, 2016.    d) Production building, a saw line operator was exposed to Silica, Crystalline Quartz, (respirable) at an 8 hour time weighted average of 0.54 milligrams per cubic meter of air (mg/M3) while cutting stone. Feasible administrative or engineering controls were not implemented to reduce the employees exposure, August 12, 2016.      ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED      General methods of control would include, but are not limited to the following:     1. Install exhaust ventilation in the building wall in the area were thermalling is performed.  A pusher fan system mounted in the ceiling near to the thermaling, may assist in directing the dust towards the exhaust fans.     2. Install rubber sheet or fabric bristle skirting on the lower portion of the saw blade enclosure. The skirting should be as close to the stone surface as possible and should direct airflow and mist towards the rear and downward.  No part of the skirting should produce buffeting which may direct dust outwards towards the operators.    Abatement Schedule     Step 1 A written detailed plan of abatement shall be submitted to the Area Director outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposures to hazardous substances as referenced in this citation. This plan shall include, at a minimum, target dates for the following actions which must be consistent with the abatement dates required by this citation:     (1)  Evaluation of engineering/administrative control options;     (2)  Selection of optimum control methods and completion of design;     (3)  Procurement, installation and operation of selected control measures;     (4)  Testing and acceptance or modification/redesign of controls.     All proposed control measures shall be approved for each particular use by a competent industrial hygienist or other technically qualified person.        Step 2  Abatement shall have been completed by the implementation of feasible engineering and /or administrative controls upon verification of their effectiveness in achieving compliance.      Date by Which Violation Must be Abated:    STEP - 1     (15 days)       Date by Which Violation Must be Abated:    STEP - 2     (60 days)

Issued

2016-09-28 00:00:00

Abate by

2016-11-21 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9010

General-duty citation text

29 CFR 1910.134(a)(1): When effective engineering controls were not feasible or while they were being instituted, appropriate respirators were not used pursuant to the requirements of 29 CFR 1910.134:      a) Production building, a thermaling operator and helper was exposed to Silica, Crystalline Quartz, (respirable) at an 8 hour time weighted average of 1.74 milligrams per cubic meter of air (mg/M3) while thermaling stone and helping line operators.   The employee did not wear respiratory protection, August 12, 2016.    b) Production building, a saw line operator was exposed to Silica, Crystalline Quartz, (respirable) at an 8 hour time weighted average of 0.74 milligrams per cubic meter of air (mg/M3) while cutting stone. The employee did not wear respiratory protection, August 12, 2016.    c) Production building, a saw line operator was exposed to Silica, Crystalline Quartz, (respirable) at an 8 hour time weighted average of 0.61 milligrams per cubic meter of air (mg/M3) while cutting stone.  The employee did not wear respiratory protection, August 12, 2016.    d) Production building, a saw line operator was exposed to Silica, Crystalline Quartz, (respirable) at an 8 hour time weighted average of 0.54 milligrams per cubic meter of air (mg/M3) while cutting stone.   The employee did not wear respiratory protection, August 12, 2016.    ABATEMENT DOCUMENTATION REQUIRED

Issued

2016-09-28 00:00:00

Abate by

2017-03-31 00:00:00

Penalty

Initial $3634.00 · Current $2800.00 Reduced

Hazardous substances 81108111

General-duty citation text

29 CFR 1910.95(b)(1): When employees were subjected to sound exceeding those listed in Table G-16, feasible administrative or engineering controls were not utilized:    a) Production building, a thermaling operator and helper was exposed to  continuous noise levels at 403% of the allowable eight (8)-hour time weighted sound level of 90 decibels (dBA).  The equivalent dBA level of 403% is approximately 99.6 dBA.  The sampling was performed for 464 minutes on August 12, 2016. (Zero exposure was assumed for the unsampled period of time.)   Feasible administrative or engineering controls were not utilized to reduce sound levels.    b) Production building, a saw line operator was exposed to  continuous noise levels at 301% of the allowable eight (8)-hour time weighted sound level of 90 decibels (dBA).  The equivalent dBA level of 301% is approximately 97.5 dBA.  The sampling was performed for 464 minutes on August 12, 2016. (Zero exposure was assumed for the unsampled period of time.)   Feasible administrative or engineering controls were not utilized to reduce sound levels.    c) Production building, a saw line operator was exposed to  continuous noise levels at 278% of the allowable eight (8)-hour time weighted sound level of 90 decibels (dBA).  The equivalent dBA level of 278% is approximately 97.1 dBA.  The sampling was performed for 460 minutes on August 12, 2016. (Zero exposure was assumed for the unsampled period of time.)   Feasible administrative or engineering controls were not utilized to reduce sound levels.    d) Production building, a saw line operator was exposed to  continuous noise levels at 216% of the allowable eight (8)-hour time weighted sound level of 90 decibels (dBA).  The equivalent dBA level of 216% is approximately 95.1 dBA.  The sampling was performed for 463 minutes on August 12, 2016. (Zero exposure was assumed for the unsampled period of time.)   Feasible administrative or engineering controls were not utilized to reduce sound levels.      ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED      GENERAL METHODS OF CONTROL APPLICABLE IN THESE CIRCUM STANCES INCLUDE, BUT ARE NOT LIMITED TO THE FOLLOWING:    i) Rotate the thermaling operator to jobs in the facility such as stacker on a routine basis such that thermaling work does not exceed 4 hours per day.    ii) Train employees to avoid standing with their heads very close to the production saws during the normal gear driven travel across the bridge/arm.    iii) Install commercially available laminate core blades on the production saws.    iv) Install rubber sheet or bristle skirting on the lower guards of the production saws.  The skirting should be as close to the stone surface as possible.     v) At saw #3, install a hold-down device on the stone such that the small sliver which is cut off the main piece does not vibrate at such a high rate and produce high noise.      Abatement Schedule      Step 1  As an interim protective measure and when administrative or engineering controls fail to reduce sound levels to within the levels of Table G 16, effective hearing protection shall be provided and used by all exposed employees. In addition, an effective hearing conservation program in accordance with 29CFR 1910.95(c) through (n) shall be maintained.    Step 2   A written detailed plan of abatement shall be submitted to the Area Director outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposures to noise as referenced in this citation. This plan shall include, at a minimum, target dates for the following actions which must be consistent with the dates required by this citation:    (1)  Evaluation of engineering control options;    (2)  Selection of optimum control method and completion of design;    (3)  Procurement, installation and operation of selected control measures;    (4)  Testing and acceptance or modification/redesign of controls;    All proposed control measures shall be evaluated for each particular use by a competent industrial hygienist or other technically qualified person. 30 day progress reports are required during the abatement period.    Step 3   Abatement shall have been completed by the implementation of feasible engineering and/or administrative controls upon verification of their effectiveness in achieving compliance.      Date by Which Violation Must be Abated:    STEP - 1     00/00/00 (15 days)    Date by Which Violation Must be Abated:    STEP - 2     00/00/00 (30 days)    Date by Which Violation Must be Abated:    STEP - 3     00/00/00 (60 days)

Issued

2016-09-28 00:00:00

Abate by

2017-03-31 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 81108111

General-duty citation text

29 CFR 1910.95(c)(1): The employer did not administer a continuing, effective hearing conservation program as described in 29 CFR 1910.9(c) through (o) whenever employee noise exposures equal or exceed an 8-hour time-weighted average sound level of 85 decibels measured on the A scale, or equivalently a dose of fifty percent:    a) Production building, a thermaling operator and helper was exposed to  continuous noise levels at 403% of the allowable eight (8)-hour time weighted sound level of 90 decibels (dBA).  The equivalent dBA level of 403% is approximately 99.6 dBA.  The sampling was performed for 464 minutes on August 12, 2016. (Zero exposure was assumed for the unsampled period of time.)   A continuing, effective hearing conservation program as described in 29 CFR 1910.95(c) through (n) was not instituted.    b) Production building, a saw line operator was exposed to  continuous noise levels at 301% of the allowable eight (8)-hour time weighted sound level of 90 decibels (dBA).  The equivalent dBA level of 301% is approximately 97.5 dBA.  The sampling was performed for 464 minutes on August 12, 2016. A continuing, effective hearing conservation program as described in 29 CFR 1910.95(c) through (n) was not instituted.    c) Production building, a saw line operator was exposed to  continuous noise levels at 278% of the allowable eight (8)-hour time weighted sound level of 90 decibels (dBA).  The equivalent dBA level of 278% is approximately 97.1 dBA.  The sampling was performed for 460 minutes on August 12, 2016. (Zero exposure was assumed for the unsampled period of time.)   A continuing, effective hearing conservation program as described in 29 CFR 1910.95(c) through (n) was not instituted.    d) Production building, a saw line operator was exposed to  continuous noise levels at 216% of the allowable eight (8)-hour time weighted sound level of 90 decibels (dBA).  The equivalent dBA level of 216% is approximately 95.1 dBA.  The sampling was performed for 463 minutes on August 12, 2016. (Zero exposure was assumed for the unsampled period of time.)   A continuing, effective hearing conservation program as described in 29 CFR 1910.95(c) through (n) was not instituted.      ABATEMENT CERTIFICATION REQUIRED    ABATEMENT NOTE:      A comprehensive, effective hearing conservation program consisting of the following elements shall be developed and implemented for all employees whose exposure equals or exceeds 85 dBA on an 8-hour time weighted average:    1. Initial exposure monitoring and periodic reassessment of employees to determine noise exposures.    2. Establishment and maintenance of an annual audiometric testing program for all employees who work in the facility.    3. Provision and enforcement of hearing protection devices for all employees who work in the facility.    4. Institution of an initial training program for all employees, as well as annual refresher training, including information on the hazards of noise, purpose of audiometric testing, and proper use of hearing protectors.    5. Maintenance of records as they relate to employee exposure measurements, medical examinations, and training.