OSHA Inspection: MENARD, INC.

Issued

Jul 25, 2018

Penalty

Initial $12,195 · Current $9,756 Reduced

General-duty citation text

29 CFR 1910.22(a)(1): Surface Conditions. The employer must ensure: (1) All places of employment, passageways, storerooms, service rooms, and walking-working surfaces are kept in a clean, orderly, and sanitary condition:    (a) Extrusion Plant Production Area, Building 11;  Excessive accumulations of combustible dust were located in several areas including, but not limited to, ledges, ducting, walls, overhead rafters, the mezzanine, piping, and equipment.    (b) Extrusion Plant Grinding Room, Building 11; Excessive accumulations of combustible dust were located in several areas including, but not limited to, ledges, ducting, walls, overhead rafters, piping, and equipment.    (c) Truss Plant Saw Areas, Building MM-9; Excessive accumulations of combustible dust were located in several areas including, but not limited to, ledges, ducting, walls, overhead rafters, racking, and equipment.

Issued

Jul 25, 2018

Abate by

Sep 13, 2018

Penalty

Initial $10,163 · Current $10,163

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 1910.95 (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) Countertops Plant; An employee working in laminate, finish line 0, was exposed to continuous noise levels at 62.02% of the allowable time-weighted average (TWA) sound action level of 83.4 dBA during the 578 minute sampling period conducted on February 28, 2018. The equivalent dBA level of 62.02% for 578 minutes is approximately 86.5 dBA. Zero exposure was assumed for the unsampled time period of 22 minutes.     NOTE: The 8-hour TWA sound level of 85 dBA prompts the requirement of a hearing conservation program (HCP), and shall be adjusted for work shifts less than or longer than 8 hours. Employees working in the Countertops Plant worked 10 hour shifts. When making the adjustment the following formula is used: Action Level (AL)= 90 + 16.61 x Log {50/{12.5[(hours)]}; therefore, the AL in which a HCP would be required is reduced to the AL of 83.4 dbA to account for employees extended exposure.

Issued

Jul 25, 2018

Abate by

Sep 13, 2018

Penalty

Initial $12,195 · Current $9,756 Reduced

General-duty citation text

29 CFR 1910.134(d)(1)(iii): The employer did not identify and evaluate the respiratory hazard(s) in the workplace; including a reasonable estimate of employee exposures to respiratory hazards and identification of the contaminant's chemical state and physical form:    (a) Concrete Plant; The employer did not identify and evaluate potential respirable dust and silica hazards when employees were performing tasks including, but not limited to, cleaning dried concrete out of the hoppers, off the side scrapers and mixer arms, as well as, changing the tumbler lining.    (b) Concrete Plant; The employer did not identify and evaluate potential respirable dust and silica hazards when employees were performing tumbling operations.

Issued

Jul 25, 2018

Abate by

Aug 22, 2018

Penalty

Initial $12,934 · Current $12,934

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:    (a) Truss plant, UltraDeck tabletop area; The energy isolation (lockout) procedure is not used during setup/adjustment operations on the multi-spindle (Desoutter) drill press.    (b) Laminate countertops plant, Lines 1 and 2; The energy isolation (lockout) procedure is not used during cleaning operations on the quad saw.

Issued

Jul 25, 2018

Abate by

Aug 22, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d)(3): All energy isolating devices that were needed to control the energy to the machine or equipment were not physically located and operated in such a manner as to isolate the machine or equipment from the energy source(s):    (a) Laminate countertop plant, Lines 1 and 2; Electrical and pneumatic sources of energy were not isolated during cleaning activities on the line 1 and 2 quad saw machines.

Issued

Jul 25, 2018

Abate by

Aug 22, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d)(4)(i): Lockout or tagout devices were not affixed to each energy isolating device by authorized employees:    (a) Truss plant, UltraDeck tabletop area; Lockout devices were not affixed to isolation points during setup/adjustment operations on the multi-spindle (Desoutter) drill press.    (b) Laminate countertops plant, Lines 1 and 2; Lockout devices were not affixed to isolation points during cleaning operations on the quad saw.

Issued

Jul 25, 2018

Abate by

Aug 22, 2018

Penalty

Initial $12,195 · Current $8,536 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:    Guarding was not provided for rotating parts, flying chips, and pinch points.    (a) Truss plant, Maintenance area; Guarding was not provided for the unused portion of blade on a horizontal bandsaw.    (b) Truss plant, Maintenance area; Guarding was not provided for rotating parts and flying chips on a drill press.     (c) Truss plant, UltraDeck tabletop area; Guarding was not provided for rotating parts and flying chips on a drill press.     (d) Extrusion plant, Extrusion line 2; Guarding was not provided to prevent access to pinch points on the in-feed side of pullers.    (e) Steel plant, Pro-snap roll forming machine; Guarding was not provided to prevent access to rotating parts of the coil unwinding mandrel.

Issued

Jul 25, 2018

Abate by

Aug 22, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.212(a)(2): Guard(s) on machine(s) were not affixed to the machine or secured elsewhere when attachment to the machine was not possible:    Guards on machines were easily defeatable and/or removable because they were not securely affixed as required.    (a) Steel plant, Pro-rib roll forming machine lines 1 and 2; Guards were not securely affixed to the flying shear section.    (b) Steel plant, Pro-snap roll forming machine; Guards were not securely affixed to the tooling section.    (c) Extrusion plant, Extrusion lines 2; Guards were not securely affixed to the sides of the embossing machine section.    (d) Laminate countertops plant, Production lines 1 and 2; Guards were not securely affixed to the Quad saw section.

Issued

Jul 25, 2018

Abate by

Aug 22, 2018

Penalty

Initial $0 · Current $0

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) Extrusion plant, Extrusion line 2; Point of operation guarding was not provided on the in-feed side of embossers.

Issued

Jul 25, 2018

Abate by

Aug 3, 2018

Penalty

Initial $6,097 · Current $5,000 Reduced

General-duty citation text

29 CFR 1910.215(a)(4): Work rest(s) on grinding machinery were not adjusted closely to the wheel with a maximum opening of one eighth inch:    (a) Truss plant, maintenance area; The work rest on a pedestal grinder was not adjusted to within one-eighth of an inch of the stone wheel.

Issued

Jul 25, 2018

Abate by

Aug 3, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.215(b)(9): The distance between the abrasive wheel periphery(s) and the adjustable tongue or the end of the safety guard peripheral member at the top exceeded one fourth inch:     (a) Truss plant, maintenance area; The gap between the guard and stone grinding wheel a pedestal mounted bench grinder was greater than one-fourth of an inch.

Issued

Jul 25, 2018

Abate by

Sep 13, 2018

Penalty

Initial $12,195 · Current $10,000 Reduced

General-duty citation text

29 CFR 1910.1200(h)(2)(ii): The employer did not provide information to the employees on operations in their work area where hazardous chemicals were present:    (a) Concrete Plant; The employer did not provide information and training to address the hazards of employees exposure to silica during tumbling operations, and maintenance activities including, but not limited to, cleaning the hoppers, side scrapers, and mixer arms, as well as changing the tumbler lining.     (b) Countertops Plant; The employer did not provide information and training to address the hazards of employees exposure to silica while working in the quartz area.

Issued

Jul 25, 2018

Abate by

Aug 22, 2018

Penalty

Initial $30,487 · Current $12,934 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i)(A): Authorized employee(s) did not receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control:    (a) Truss plant, UltraDeck tabletop area; Authorized level lockout training was not provided for each employee that performed setup/adjustment operations on the multi-spindle (Desoutter) drill press.    (b) Laminate countertops plant, Lines 1 and 2; Authorized level lockout training was not provided for each employee that performed cleaning operations on the quad saws.    Menard, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.147(c)(7)(i)(A), which was contained in OSHA inspection number 1075847, citation number 1, item number 2b and was affirmed as a final order on December 29, 2015, with respect to a workplace located at 5231 Kane Road, Eau Claire, WI.

Issued

Jul 25, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(g)(1)(iv)(A): Flexible cords and/or cables were used as a substitute for the fixed wiring of a structure:  (a) Truss plant, maintenance area; A portable relocatable power tap (power strip) mounted to the wall was being used to provide electrical power to equipment in place of permanent wiring.