OSHA Inspection: ALEXANDER TANK COMPANY

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $9,054 · Current $6,380 Reduced

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1): The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to the hazards of being struck by falling and/or flying object from uninspected hoists and tank pressure testing:    a) On or about March 29, 2018, throughout the fabrication shop, employees were using hoists on a daily basis to lift metal plates and tanks of various sizes and weights in the process of manufacturing the tanks. The tanks being manufactured ranged in size and capacity from 200 barrel to 500 barrel tanks. The hoists were not being maintained under a preventative maintenance program and frequent and periodic inspections were not being conducted where deficiencies were identified. Hoists include, but are not limited to:  a) Roll Bending area: CM Lodestar XL 5 ton orange hoist.   b) Roll Bending area: Harrington 2 ton hoist located above the Roundo bending machine.  c) Roll Bending area: Harrington 5 ton hoist.   d) Middle of the shop to the side of the Roundo bending machine: Harrington 1 ton hoist.  e) Entrance to fabrication shop: Harrington 1 ton hoist.  f) Behind the winch area in the middle of shop: Harrington 2 ton hoist used on a daily basis.    g) Behind the winch area in middle of the shop on the same rail: Harrington 2 ton hoist.  h) In the back of the fabrication shop, at the last welding station for the larger tanks: Harrington 5 ton hoist.  i) In the back of the fabrication shop and on the same rail as the Harrington 5 ton: JET hoist.  j) In the back of the fabrication shop, at the last welding station for the smaller tanks: Harrington 3 ton.  k) In the maintenance shop there are three hoists: Harrington 5 ton, Harrington 3 ton, and Harrington 1 ton.  l) Located in front of the fabrication shop floor, there is a winch that is being used to lift the tank lids. This winch came originally from a 5 ton truck.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $3,880 · Current $3,880

General-duty citation text

29 CFR 1910.22(d)(1): The employer did not ensure that walking-working surfaces were inspected, regularly and as necessary, and maintained in a safe condition:    On or about January 31, 2018, at the paint storage building, the wooden back porch had fallen through, where boards had deteriorated from weather. Employees use the back porch to gain access to the building to get paint supplies from the receiving area to exit the building, exposing employees to the hazards of falling through the back porch.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $7,760 · Current $3,173 Reduced

General-duty citation text

29 CFR 1910.23(b)(8): The employer did not ensure ladders were used only for the purposes for which they were designed:    a) On or about January 30, 2018, in the fabrication shop, an employee was utilizing a portable, free-standing step ladder to gain access to an elevated tank up to approximately 36 inches high. The employee climbs the ladder and subsequently steps off the side of the ladder to access the opening of the tank, exposing the employee to a fall hazard.     b) On or about January 30, 2018, in the sand blasting and paint areas, employees utilize portable, free-standing step ladders to access tanks, up to approximately 54 inches high, by stepping off the side of the ladders into the openings of the tanks, exposing employees to a fall hazard.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $9,054 · Current $3,172 Reduced

General-duty citation text

29 CFR 1910.28(b)(1)(i): The employer did not ensure that each employee on a walking-working surface with an unprotected side or edge that is 4 feet (1.2m) or more above a lower level was protected from falling by guardrail systems, safety net system, or personal fall arrest system:    a) On or about January 30, 2018, at the sand hopper, employees climb the fixed ladder and walk across an unguarded platform to dispense sand into a sand pot exposing employees to a fall hazard of approximately 12 feet.     b) On or about January 30, 2018, in the fabrication shop, employees climb on the top of the finished tanks to unhook the tank from the hoist. They climb out of a scissor lift and walk on the tank to unhook the hoist exposing employees to a fall hazard up to approximately 25 feet.       c) On or about March 27, 2018, in the yard where tanks are stored, employees climb on the tanks to hook and unhook the tank for the crane operator.  They use a boom lift to gain access and walk across the tops of the tanks exposing employees to fall hazards up to approximately 15 feet.    d) On or about January 30, 2018, employees were using a JLG scissor lift to work on tanks and to gain access to the top of the tanks to unhook them. The top rail was missing from the scissor lift and the mid rail chain was not being used exposing employees to a fall hazard up to approximately 20 feet.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $9,054 · Current $6,345 Reduced

General-duty citation text

29 CFR 1910.30(a)(1): The employer did not provide training for each employee exposed to fall hazards and who use personal fall protection systems or is required to be trained as specified else where in this subpart prior to May 17, 2017:    On or about January 30, 2018, employees were performing tasks throughout the facility while being exposed to fall hazards without the employer providing fall protection training to recognize and eliminate those hazards, exposing the employees to fall hazards up to approximately 25 feet.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $5,174 · Current $5,174

General-duty citation text

29 CFR 1910.106(e)(2)(iv)(d): Flammable liquids were not drawn from or transferred into vessels, containers, or portable tanks within a building only through a closed piping system, from safety cans, by means of a device drawing through the top, or from a container or portable tanks by gravity through an approved self-closing valve:    On or about January 31, 2018, near the paint storage area, employees were dispensing paint thinner from a 55 gallon drum of a flammable liquid into smaller metal containers to clean the nova-plate paint hopper and air guns. The 55 gallon drum was not equipped with a self-closing valve, exposing employees to the hazards of fire.    On or about January 30, 2018, in the paint storage building, spray paint area and paint thinner dispensing area, ignition sources such as electrical heaters, kerosene heaters, open barrel burning and cigarette smoking were present where flammables were stored and dispensed, exposing employees to the hazards of fire.    On or about January 31, 2018, near the paint storage area, employees were transferring flammable paint thinner into small metal containers to use at the paint hopper. The smaller metal cans and 55 gallon drum were not bonded, exposing employees to the hazards of fire.

Issued

Jul 24, 2018

Abate by

Oct 17, 2018

Penalty

Initial $9,054 · Current $6,345 Reduced

General-duty citation text

29 CFR 1910.146(c)(4): When the employer decided that its employees would enter permit spaces, the employer did not develop and implement a written permit space entry program that complied with 29 CFR 1910.146:    On or about January, 30, 2018, employees were required to enter permit required confined spaces to perform painting and sand blasting operations inside new and refurbished tanks that had not been evaluated by the employer for permit required confined spaces, exposing employees to inhalation hazards.    On or about January 30, 2018, employees were required to conduct spray painting, sand blasting and welding operations inside permit required confined spaces without training being provided by the employer on how to perform the required duties safely, exposing employees to hazards such as, but not limited to inhalation hazards.

Issued

Jul 24, 2018

Abate by

Oct 17, 2018

Penalty

Initial $6,467 · Current $6,467

General-duty citation text

29 CFR 1910.147(c)(1): The employer did not establish a program consisting of an energy control procedure, employee training and periodic inspections to ensure that before any employee performed any servicing or maintenance on a machine or equipment where the unexpected energizing, startup or release of stored energy could occur and cause injury, the machine or equipment shall be isolated from the energy source and rendered inoperative:    On or about February 6, 2018, the employer did not develop and implement an energy control program where authorized and affected employees were operating and maintaining machines throughout the plant, exposing employees to unexpected startup hazards such as, but not limited to electric shock, being caught in and struck by moving parts.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $9,054 · Current $6,345 Reduced

General-duty citation text

29 CFR 1910.151(c): Where employees were exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body were not provided within the work area for immediate emergency use:     On or about January 30, 2018, at the paint mixing area, employees mix epoxy paints which are corrosive to tissue. There was no eyewash station installed for quick flushing of the eyes, exposing employees to the hazards of corrosive chemical splashes to the eyes.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $3,880 · Current $3,880

General-duty citation text

29 CFR 1910.157(c)(1): Portable fire extinguishers were not mounted, located and identified so that they were readily accessible without subjecting the employees to injuries:    On or about March 22, 2018, in the assembly building, employees are expected to utilize fire extinguishers in the event of a fire and two fire extinguishers in this building were not mounted. Employees are using a plasma cutter and performing welding operations in this building exposing employees to the hazards of fire and smoke due to a delay in locating fire extinguishers.    On or about January 30, 2018, throughout the plant, employees performing spray painting and welding operations are expected to use fire extinguishers in the event of a fire. The employees are not trained on how to use the fire extinguishers exposing employees to fire hazards.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $5,174 · Current $5,174

General-duty citation text

29 CFR 1910.178(a)(4): Modifications and additions which affect capacity and safe operation of powered industrial truck were performed by the employer without the manufacturer's prior written approval:    On or about March 23, 2018, and at times prior thereto, the employees installed shop made fork extension attachments. They use the extensions when they are transporting the low profile tanks, which measure approximately 15 feet wide and 16 feet high. The forklift is a Hyster, H360XL. Employees are exposed to hazards such as, but not limited to being crushed by the load or the forklift tipping over.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $5,174 · Current $5,174

General-duty citation text

29 CFR 1910.178(l)(1)(i): The employer did not ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph (l):    On or about January 30, 2018, employees are required to operate forklifts to move material and products such as tanks throughout the facility without being trained by the employer, exposing employees to hazards such as, but not limited to being struck by falling tanks and/or crushed by the forklift in the event of a tip over.    On or about March 23, 2018, employees were operating the Hyster Model H360XL forklift to transport tanks. The operator could not see around the tanks, exposing employees to the hazard of being struck by the forklift.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $9,054 · Current $6,345 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 March 22, 2018, employees were operating the Hyster Model H360XL forklift that was in need of repairs and was not taken out of service until such repairs were made, exposing employees to the hazard of being struck by the forklift.     Deficiencies include, but are not limited to:      1. The hydraulic/ram to move the forks from left to right does not work.  2. Diesel was leaking from the forklift.   3. Fuel gauge is broken.   4. Air brakes do not maintain pressure.   5. Seat for operator is deficient in that the operator can not be seated level on the seat to operate the forklift.   6. The back-up alarm is not operational.  7. Forklift is hard to start so operators will not shut it down; instead they leave the forklift running.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $9,054 · Current $6,345 Reduced

General-duty citation text

29 CFR 1910.180(d)(2)(ii):Periodic inspection(s), 1-12 month interval, or as specifically recommended by the manufacturer was not conducted:    a) On or about April 10, 2018, the HIAB 622 load crane, periodic inspections were not performed on the crane, exposing employees to the hazards of being struck by falling tanks weighing approximately 10,500 pounds.    b) On or about March 23, 2018, the Terex 230, 30 ton mobile crane, periodic inspections were not performed on the crane exposing employees to the hazards of being struck by falling tanks weighing approximately 10,500 pounds.    c)b) On or about March 23, 2018, for the Terex 230, 30 ton mobile crane, monthly inspections on the running ropes were not performed on the crane exposing employees to the hazards of being struck by falling tanks weighing approximately 10,500 pounds.

Issued

Jul 24, 2018

Abate by

Oct 17, 2018

Penalty

Initial $7,760 · Current $6,345 Reduced

General-duty citation text

29 CFR 1910.184(f)(1): Wire-rope slings did not have permanently affixed and legible identification markings as prescribed by the manufacturer that indicated the recommended safe working load for the type(s) of hitch(es) used, the angle upon which it is based, and the number of legs if more than one:    a) On or about March 23, 2018, at the Terex mobile crane, wire rope slings were being used with no weight limits on them. The operator was lifting tanks ranging in weight from approximately 9,000 pounds to 10,500 pounds exposing employees to the hazards of being struck by a falling tank.     b) On or about April 10, 2018, at the HIAB crane, a wire rope sling was being used and the weight limit was not legible. The operator was lifting tanks ranging in weight from approximately 9,000 pounds to 10,500 pounds exposing employees to the hazard of being struck by a falling tank.    c)  On or about March 23, 2018, at the Terex mobile crane, wire rope slings had five or more broken strands in one rope lay. The wire rope sling was being used to lift tanks that weigh approximately 8,300 pounds exposing employees to the hazard of being struck by a falling tank.

Issued

Jul 24, 2018

Abate by

Nov 17, 2018

Penalty

Initial $7,760 · Current $6,345 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:    On or about January 30, 2018, in the fabrication shop, the Roundo three roll bending machine used to bend steel was not guarded exposing employees to the hazards of being caught-in the machine.

Issued

Jul 24, 2018

Abate by

Oct 17, 2018

Penalty

Initial $7,760 · Current $6,345 Reduced

General-duty citation text

29 CFR 1910.212(a)(3)(ii): Point(s) of operation of machinery were not guarded to prevent employee(s) from having any part of their body in the danger zone(s) during operating cycle(s):    a) On or about March 22, 2018, in the assembly department at the cutting and press area, the Bantam iron worker used to cut metal channel for the stairs and to punch holes, was not guarded. Employees were exposed to the hazards of being struck by the unguarded shear and punch operations.    b) On or about March 22, 2018, in the assembly building, the rotating flywheel on the Bantam iron worker was not guarded. Employees use the iron worker to cut steel for stairs. Employees were exposed to the hazard of being struck by the rotating flywheel.    c) On or about March 22, 2018, in the assembly building, the rotating belts on the Bantam iron worker were not guarded. Employees use the iron worker to cut steel for stairs. Employees were exposed to the hazard of being caught-in the rotating belts.    d) On or about March 22, 2018, in the assembly building, the rotating pulleys on the Bantam iron worker were not guarded. Employees use the iron worker to cut steel for stairs. Employees were exposed to the hazard of being caught-in the rotating pulleys.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $7,760 · Current $6,345 Reduced

General-duty citation text

29 CFR 1910.252(b)(2)(iii): Workers and other persons adjacent to the welding area were not protected from the rays by noncombustible or flameproof screens or shields:    On or about January 30, 2018, in the fabrication shop, employees were welding at numerous work stations and were not utilizing welding screens.  Employees working in the maintenance area and walking through the fabrication shop were exposed to the hazards of ultraviolet (uv) radiation to the eyes.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $3,880 · Current $3,880

General-duty citation text

29 CFR 1910.253(b)(2)(ii): Assigned storage spaces for cylinders were not located away from elevators, stairs, or gangways where cylinders could not be knocked over or damaged by passing or falling objects, or subject to tampering by unauthorized persons:    a) On or about January 30, 2018, between the maintenance and fabrication shop, an empty compressed gas cylinder of oxygen was not secured, exposing employees to the hazards of being struck by flying pressurized cylinders in the event of damage to the cylinder.     b) On or about January 31, 2018, in fabrication shop an empty compressed gas cylinder of argon was not secured, exposing employees to the hazards of being struck by flying pressurized cylinders in the event of damage to the cylinder.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $9,054 · Current $6,345 Reduced

General-duty citation text

29 CFR 1910.254(b)(4)(iv): Terminals for welding leads were not protected from accidental contact by personnel or metal objects:    On or about March 29, 2018, employees are required to utilize a step ladder to gain access to the Miller welder inside the fabrication shop. The employees climb the ladder to operate the power switch daily which places them in direct proximity to the un-guarded terminals, exposing employees to an electrical shock hazard.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $6,467 · Current $6,467

General-duty citation text

29 CFR 1910.254(d)(8): Welding cables with splices within 10 feet (3 m) of the holder were used:    a) On or about March 22, 2018, in the testing area, a 240 volt Miller welder cable was spliced within approximately 8 feet of the holder. Employees use the welder to make repairs to the tank, exposing employees to an electrical shock hazard.    b) On or about March 22, 2018, located outside between the assembly and fabrication shop, a 240 volt Miller welder cable was repaired with electrical tape.  Employees use the welder to make repairs to the tank, exposing employees to an electrical shock hazard.     c) On or about March 29, 2018, inside the fabrication shop, at the Miller welder, on the ground lead (electrode) which still can carry DC voltage, the internal conductor was exposed where they made a splice to add more cable, exposing  employees to an electrical shock hazard.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $9,054 · Current $6,345 Reduced

General-duty citation text

29 CFR 1910.303(f)(2): Each service, feeder, and branch circuit, at its disconnecting means or overcurrent device, was not legibly marked to indicate its purpose, nor located and arranged so the purpose was evident:    In the following instances each circuit breaker and/or box was not labeled as to the equipment it controlled, exposing employees to the hazards associated with delays in turning off equipment and/or turning off the wrong equipment.    a) On or about January 30, 2018, in the fabrication  shop near the maintenance shops, the breaker boxes were not labeled to identify each breaker's purpose. The breakers control the lights, receptacles and welders in the shop areas.     b) On or about February 6, 2018, at the entrance of the fabrication shop, the breaker box was not labeled to identify each breaker's purpose. The breakers control the lights, receptacles and welders in the shop area.       c) On or about March 22, 2018, in the paint storage building, the breaker box was not labeled to identify each breaker's purpose. The breakers control the lights and receptacles.     d) On or about March 22, 2018, in the assembly building, the breaker box was not labeled to identify each breaker's purpose. The breakers control the lights and receptacles, iron workers and plasma cutter.    e) On or about February 6, 2018, in the fabrication shop, employees were working around an area where there was an energized 240 volt conductor lying on the floor with the outer sheath pulled back and the copper end unprotected, exposing employees to the hazard of an electrical shock.    f) On or about March 29, 2018, in the fabrication shop, on the 110 volt 5 ton winch used to lift tanks lids, the electrical control panel covers were missing , leaving unprotected conductors open to contact, exposing employees to the hazards of electrical shock.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $3,880 · Current $3,880

General-duty citation text

29 CFR 1910.304(f)(1)(iv): Overcurrent devices for circuits rated 600 volts, nominal, or less, were not readily accessible to each employee or authorized building management personnel:    On or about January 30, 2018, a disconnect and two breaker boxes between the fabrication and maintenance shops were blocked by steel tables that were placed in front of them. The boxes did not have sufficient space for prompt access in front of them, exposing employees to hazards such as, but not limited to, delay in turning power off to a circuit.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $3,880 · Current $3,880

General-duty citation text

29 CFR 1910.305(b)(1): Conductors entering boxes, cabinets, or fittings were not protected from abrasions:    a) On or about March 22, 2018, at the breaker box in the paint storage area, an energized 120 volt non-metallic (NM) sheathed cable was installed without protection from abrasions through an opening on a breaker box, exposing employees to an electrical shock hazard.    b) On or about January 30, 2018, a receptacle box located between the maintenance and fabrication shops had an opening not effectively closed where a knockout plug was missing, exposing employees to an electrical shock hazard.     c) On or about January 30, 2018, breaker box located in the center of the fabrication shop had openings not effectively closed where multiple knockout plugs were missing, exposing employees to an electrical shock hazard.      d) On or about March 22, 2018, two receptacle boxes which had knock out holes that were not effectively closed were being used along the conveyor on the bending line, exposing employees to an electrical shock hazard.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $6,467 · Current $6,467

General-duty citation text

29 CFR 1910.305(b)(2)(i): Pull boxes, junction boxes, and fittings were not provided with covers approved for the purpose:    a) On or about February 6, 2018, in the fabrication shop, the employees are welding tanks using welding machines supplied by power from two 240 volt junction boxes without cover plates located  approximately 4 and 4.5 feet off the ground, exposing employees to an electrical shock hazard.    b) On or about February 6, 2018, in the fabrication shop, a 240 volt junction box located in the middle of the aisle did not have cover plate, exposing employees to an electrical shock hazard.    c) On or about January 30, 2018, in the fabrication shop, a 110 volt light switch located near the back welding station did not have a cover plate on it, exposing employees to an electrical shock hazard.    d) On or about March 22, 2018, in the sand blasting area, a 110 volt receptacle was missing the cover plate, exposing employees to an electrical shock hazard.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $3,880 · Current $3,880

General-duty citation text

29 CFR 1910.305(g)(2)(ii): Flexible cords were not used only in continuous lengths without splice or tap:    a) On or about March 22, 2018, in the spray paint area, a 110 volt extension cord which had two splices was being used by employees to supply power to a heater, exposing employees to an electrical shock hazard.    b) On or about January 30, 2018, a receptacle box located between the maintenance and fabrication shops had an opening not effectively closed where a knockout plug was missing, exposing employees to an electrical shock hazard.     c) On or about January 30, 2018, breaker box located in the center of the fabrication shop had openings not effectively closed where multiple knockout plugs were missing, exposing employees to an electrical shock hazard.      d) On or about March 22, 2018, two receptacle boxes which had knock out holes that were not effectively closed were being used along the conveyor on the bending line, exposing employees to an electrical shock hazard.    e) On or about March 22, 2018, in the spray paint area, a 110 volt extension cord which was not equipped with a grounding pin was used to supply power to a heater, exposing employees to an electrical shock hazard.

Issued

Jul 24, 2018

Abate by

Sep 17, 2018

Penalty

Initial $1,294 · Current $1,294

General-duty citation text

29 CFR 1910.303(b)(8)(i): Electrical equipment was not firmly secured to the surface on which it was mounted:    On or about March 22, 2018, in the spray paint area, a 110-volt receptacle at the end of a line of conduit was pulled away from the wall on which it was mounted and tied with string to hold it up, exposing employees to an electrical shock hazard.