OSHA Inspection: CLEARY PALLET SALES, INC.

Issued

Jun 29, 2018

Abate by

Aug 20, 2018

Penalty

Initial $5,691 · Current $3,983 Reduced

General-duty citation text

29 CFR 1910.95(c)(1): The employer did not administer a continuing, effective hearing conservation program, as described in paragraphs (c) through (o) of this section, where employee noise exposures equaled or exceeded an 8 hour time weighted average sound level (TWA) of 85 decibels measured on the A scale (slow response), or equivalently, a dose of fifty percent:    On or about January 26, 2018, employees were exposed to elevated noise levels while repurposing wood pallets. The employer did not administer a continuing, effective hearing conservation program where employee noise exposures equaled or exceeded an 8 hour time weighted average sound level (TWA) of 85 decibels:    1) An employee using a band saw to disassemble wooden pallets was exposed to an 8-hour TWA noise level of 96.6 dBA measured on the A scale with a dose of 249% during a 320 minute sampling period assuming zero exposure for the unsampled 160 minutes.    2) An employee using a table saw to disassemble wooden pallets  in the saw room was exposed to an 8-hour TWA noise level of 87.7 dBA measured on the A scale with a dose of 72.9% during a 315 minute sampling period assuming zero exposure for the unsampled 165 minutes.    Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jun 29, 2018

Abate by

Aug 20, 2018

Penalty

Initial $5,691 · Current $3,983 Reduced

General-duty citation text

29 CFR 1910.134(d)(1)(iii): When the employer was unable to identify or reasonably estimate the employee exposure, the employer did not consider the atmosphere to be Immediately Dangerous to Life or Health(IDLH):    1) On January 2, 2018, the employer failed to estimate employee exposure to carbon monoxide (CO) in the production areas. Despite alarms from CO detectors, the employer failed to consider the workplace atmosphere to be IDLH. Employee(s) were exposed to CO levels exceeding the 8-hour time weighted average (TWA) of 50 ppm.    2) On January 3, 2018, the employer failed to estimate employee exposure to carbon monoxide (CO) in the production areas. Despite alarms from CO detectors, the employer failed to consider the workplace atmosphere to be IDLH. Employee(s) were exposed to CO levels exceeding the 8-hour time weighted average (TWA) of 50 ppm.    3)On January 4, 2018, the employer failed to estimate employee exposure to carbon monoxide (CO) in the production areas. Despite alarms from CO detectors, the employer failed to consider the workplace atmosphere to be IDLH. Employee(s) were exposed to CO levels exceeding the 8-hour time weighted average (TWA) of 50 ppm.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jun 29, 2018

Abate by

Aug 20, 2018

Penalty

Initial $4,065 · Current $2,845 Reduced

General-duty citation text

29 CFR 1910.304(f)(1)(iv): Overcurrent devices for circuits rated 600 volts, nominal, or less, were located in the vicinity of easily ignitable material:    On or about January 3, 2018, the employer did not ensure that circuit breaker panelboards in the pallet disassembly area were mounted in locations where, in the course of their operation, they would be safe from igniting accumulations of wood dust.    Abatement certification is required for this item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

Jun 29, 2018

Abate by

Aug 20, 2018

Penalty

Initial $5,691 · Current $1,992 Reduced

General-duty citation text

29 CFR 1910.1200(e)(1): The employer did not develop, implement, and/or maintain at the workplace a written hazard communication program which describes how the criteria specified in 29 CFR 1910.1200(f), (g), and (h) will be met:     On or about January 2, 2018, the employer did not develop a written hazard communication program when employees were working with hazardous chemicals such as, but not limited to, propane and carbon monoxide.    All provisions of 29 CFR 1910.1200(e) through (h) must be covered in a written hazard communication program. Key elements include, but are not limited to the following:    1) Chemical inventory list  2) Safety Data Sheets (SDS)  3) Labeling of containers  4) Employee information and training     Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jun 29, 2018

Abate by

Aug 20, 2018

Penalty

Initial $0 · Current $0

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 January 2, 2018, the employer did not provide employees with effective information and training on the hazardous chemicals in their work areas at the time of their initial assignment or whenever a new hazardous chemical was introduced to the work area. Employees working in the production area worked with hazardous chemicals such as, but not limited to, propane and carbon monoxide.   Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jun 29, 2018

Abate by

Aug 20, 2018

Penalty

Initial $71,135 · Current $49,795 Reduced

General-duty citation text

29 CFR 1910.178(p)(1): Powered industrial truck(s) found to be in need of repair, defective, or in any way unsafe had not been taken out of service until restored to safe operating condition(s):    On or about January 3, 2018 through January 5, 2018, the employer did not remove from service three powered industrial trucks that were found to be in need of repair. After being instructed by the fire department and the gas utility company to service and/or repair the forklifts, the employer continued to operate one Yale and two Clark forklifts while they were in need of repairs including, muffler replacement, spark plug replacement, and fuel mixing diaphragm replacement and adjustments. Operators and other employees were exposed to fire and respiratory hazards.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jun 29, 2018

Abate by

Aug 20, 2018

Penalty

Initial $71,135 · Current $49,865 Reduced

General-duty citation text

29 CFR 1910.1000(a)(2): Employee(s) were exposed to an airborne concentration of carbon monoxide listed in Table Z-1 in excess of the 8 hour Time Weighted Average concentration of 50 ppm:    1) On or about January 2, 2018, the employer did not ensure that employee(s) exposed to carbon monoxide did not exceed 50 ppm for an 8-hour time weighted average (TWA). An employee sorting boards in the saw room was exposed to carbon monoxide at an 8-hour TWA of 513.4 ppm, approximately 10.27 times the permissible exposure limit of 50 ppm. The carbon monoxide level was derived from blood carboxyhemoglobin levels.    2) On or about January 2, 2018, the employer did not ensure that employee(s) exposed to carbon monoxide did not exceed 50 ppm for an 8-hour time weighted average (TWA). An employee disassembling pallets in the shop area was exposed to carbon monoxide at an 8-hour TWA of 344.4 ppm, approximately 6.89 times the permissible exposure limit of 50 ppm. The carbon monoxide level was derived from blood carboxyhemoglobin levels.     3) On or about January 2, 2018, the employer did not ensure that employee(s) exposed to carbon monoxide did not exceed 50 ppm for an 8-hour time weighted average (TWA). An employee sorting boards in the saw room was exposed to carbon monoxide at an 8-hour TWA of 214.9 ppm, approximately 4.30 times the permissible exposure limit of 50 ppm.  The carbon monoxide level was derived from blood carboxyhemoglobin levels.    4) On or about January 4, 2018, the employer did not ensure that employee(s) exposed to carbon monoxide did not exceed 50 ppm for an 8-hour time weighted average (TWA). An employee sorting boards in the saw room was exposed to carbon monoxide at an 8-hour TWA of 113.4 ppm, approximately 2.27 times the permissible exposure limit of 50 ppm.  The carbon monoxide level was derived from blood carboxyhemoglobin levels.    5) On or about January 4, 2018, the employer did not ensure that employee(s) exposed to carbon monoxide did not exceed 50 ppm for an 8-hour time weighted average (TWA). An employee assembling pallets in the shop area was exposed to carbon monoxide at an 8-hour TWA of 235.8 ppm, approximately 4.72 times the permissible exposure limit of 50 ppm.  The carbon monoxide level was derived from blood carboxyhemoglobin levels.     6) On or about January 4, 2018, the employer did not ensure that employee(s) exposed to carbon monoxide did not exceed 50 ppm for an 8-hour time weighted average (TWA). An employee assembling pallets in the shop area was exposed to carbon monoxide at an 8-hour TWA of 225 ppm, approximately 4.50 times the permissible exposure limit of 50 ppm.  The carbon monoxide level was derived from blood carboxyhemoglobin levels.    7) On or about January 4, 2018, the employer did not ensure that employee(s) exposed to carbon monoxide did not exceed 50 ppm for an 8-hour time weighted average (TWA). An employee disassembling pallets in the shop area was exposed to carbon monoxide at an 8-hour TWA of 214.1 ppm, approximately 4.28 times the permissible exposure limit of 50 ppm. The carbon monoxide level was derived from blood carboxyhemoglobin levels.    8) On or about January 4, 2018, the employer did not ensure that employee(s) exposed to carbon monoxide did not exceed 50 ppm for an 8-hour time weighted average (TWA). An employee sorting boards in the saw room was exposed to carbon monoxide at an 8-hour TWA of 174.6 ppm, approximately 3.49 times the permissible exposure limit of 50 ppm. The carbon monoxide level was derived from blood carboxyhemoglobin levels.     9) On or about January 4, 2018, the employer did not ensure that employee(s) exposed to carbon monoxide did not exceed 50 ppm for an 8-hour time weighted average (TWA). An employee sorting boards in the saw room was exposed to carbon monoxide at an 8-hour TWA of 70.9 ppm, approximately 1.42 times the permissible exposure limit of 50 ppm. The carbon monoxide level was derived from blood carboxyhemoglobin levels.    10) On or about January 4, 2018, the employer did not ensure that employee(s) exposed to carbon monoxide did not exceed 50 ppm for an 8-hour time weighted average (TWA). An employee sorting boards in the saw room was exposed to carbon monoxide at an 8-hour TWA of 107.2 ppm, approximately 2.14 times the permissible exposure limit of 50 ppm. The carbon monoxide level was derived from blood carboxyhemoglobin levels.    11) On or about January 4, 2018, the employer did not ensure that employee(s) exposed to carbon monoxide did not exceed 50 ppm for an 8-hour time weighted average (TWA). An employee working in the front office was exposed to carbon monoxide at an 8-hour TWA of 108.0 ppm, approximately 2.16 times the permissible exposure limit of 50 ppm. The carbon monoxide level was derived from blood carboxyhemoglobin levels.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jun 29, 2018

Abate by

Aug 20, 2018

Penalty

Initial $0 · Current $0

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):  1) On or about January 2, 2018, the employer failed to implement an effective combination of engineering and work practice controls to reduce and maintain employee(s) exposures to carbon monoxide to or below 50 parts per million or less.     a) An employee sorting boards in the saw room area was exposed to carbon monoxide at an 8-hour TWA of 513.4 ppm, approximately 10.27 times the permissible exposure limit.  b)  An employee disassembling pallets in the shop area was exposed to carbon monoxide at an 8-hour TWA of 344.4 ppm, approximately 6.89 times the permissible exposure limit.  c) An employee sorting boards in the saw room was exposed to carbon monoxide at an 8-hour TWA of 214.9 ppm, approximately 4.30 times the permissible exposure limit.    2) On or about January 4, 2018, the employer failed to implement an effective combination of engineering and work practice controls to reduce and maintain employee(s) exposures to carbon monoxide to or below 50 parts per million or less.     a) An employee sorting boards in the saw room was exposed to carbon monoxide at an 8-hour TWA of 113.4 ppm, approximately 2.27 times the permissible exposure limit.    b) An employee assembling pallets in the shop area was exposed to carbon monoxide at an 8-hour TWA of 235.8 ppm, approximately 4.72 times the permissible exposure limit.   c) An employee assembling pallets in the shop area was exposed to carbon monoxide at an 8-hour TWA of 225 ppm, approximately 4.50 times the permissible exposure limit.    d) An employee disassembling pallets in the shop area was exposed to carbon monoxide at an 8-hour TWA of 214.1 ppm, approximately 4.28 times the permissible exposure limit.  e) An employee sorting boards in the saw room was exposed to carbon monoxide at an 8-hour TWA of 174.6 ppm, approximately 3.49 times the permissible exposure limit.   f) An employee sorting boards in the saw room was exposed to carbon monoxide at an 8-hour TWA of 70.9 ppm, approximately 1.42 times the permissible exposure limit.  g) An employee sorting boards in the saw room was exposed to carbon monoxide at an 8-hour TWA of 107.2 ppm, approximately 2.14 times the permissible exposure limit.  h) An employee working in the front office was exposed to carbon monoxide at an 8-hour TWA of 108.0 ppm, approximately 2.16 times the permissible exposure limit.  Methods of engineering and work practice controls include but are not limited to:    1. Seek the expertise of a competent individual such as an engineer or certified industrial hygienist to assess existing controls and work practices, obtain recommendations to improve existing controls and work practices, and prepare documentation for the successful installation of recommended equipment or modifications.    2. Repair, replace or otherwise tune, by a professional service, any and all propane-powered forklifts, ensuring compliance with current and/or applicable emission controls criteria and standards for Powered Industrial Vehicles.  Implement and adhere to a forklift preventative maintenance schedule.    3. Assess production necessities and necessities as well as the spatial arrangement of the various work stations to optimize and reduce the duration of time propane-powered forklifts are operated indoors.    4. Replace propane-powered forklifts with electric / battery-powered forklifts and/or bulk moving equipment.    5. Repair, replace or otherwise tune any and all natural gas-powered space-heating equipment, ensuring compliance with current and/or applicable emission controls criteria and standards.  Ensure proper ventilation of exhaust gas to the outdoors.    6. Install improved mechanical ventilation in the work areas.     7. Evaluate employee work practices.  Develop policies geared towards minimizing use of forklifts in enclosed areas and minimize idling of forklifts.    ABATEMENT NOTE:    STEP 1: Effective training on the recognition, signs and symptoms of Carbon Monoxide shall be provided to affected employees along with development of policies geared towards minimizing the idling of forklifts.      Abatement Date: 15 days from the citation issuance date    STEP 2: A written, detailed plan of abatement shall be submitted to the Area Director outlining a schedule for the implementation of engineering controls and work practice measures to control employee exposures to carbon monoxide, as referenced in the citation.  This plan shall include, at a minimum, target dates for the following action, which much be consistent with the dates required by this citation:    (1) Evaluation of engineering and work practices. (2) Selection of the optimum combination of engineering controls and work practices. (3) Installation and operation of the optimum engineering controls and work practices. (4) Testing and acceptance, or modification/redesign of engineering controls and work practices.    Abatement Date: 60 days from the citation issuance date    STEP 3: Abatement shall have been completed by the implementation of feasible engineering / administrative controls and/or work practice changes, upon verification of their effectiveness in achieving compliance    Abatement Date: 90 days from the citation issuance date.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jun 29, 2018

Abate by

Aug 20, 2018

Penalty

Initial $9,756 · Current $6,830 Reduced

General-duty citation text

29 CFR 1910.178(l)(4)(iii): An evaluation of each powered industrial truck operator's performance was not being conducted at least once every three years:    On or about January 2, 2018, the employer did not ensure that each powered industrial truck operator was evaluated on their competency to operate a powered industrial truck safely at least once every 3 years.      Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).    The employer was previously cited for a violation of this occupational safety and health standard, which was contained in OSHA inspection number 942954, citation number 1, item number 2 and was affirmed as a final order on December 3, 2013, with respect to a workplace located at 32570 Genoa Road in Genoa, Illinois 60135.