OSHA Inspection: KDC ONE NORTHERN LABS

Issued

Sep 10, 2021

Penalty

Initial $13,653 · Current $9,557 Reduced

Hazardous substances 0640

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 working in the facility where exposed to respiratory hazards related to the release of chlorine gas from the unintended reaction of sodium hypochlorite and sulfuric acid due to the design and maintenance of the waste water treatment system:  On or about March 28, 2021 at the KDC One Norther Labs DBA Northern Labs facility located at 5800 West Drive, Manitowoc, WI 54220; the employer did not prevent the waste water treatment system from reacting bleach (12.5% sodium hypochlorite) with sulfuric acid (50%) in the household products waste water treatment tank (W1). The reaction caused a release of chlorine gas throughout the facility which resulted in employees suffering symptoms of exposures to airborne chlorine gas and necessitated employees to evacuate the facility.

Issued

Sep 10, 2021

Abate by

Oct 20, 2021

Penalty

Initial $10,728 · Current $7,510 Reduced

Hazardous substances 0640

General-duty citation text

29 CFR 1910.120(q)(3)(iv):  Employees engaged in emergency response and exposed to hazardous substances presenting an inhalation hazard or potential inhalation hazard shall wear positive pressure self-contained breathing apparatus (SCBA) while engaged in emergency response, until such time that the individual in charge of the ICS determines through the use of air monitoring that a decreased level of respiratory protection will not result in hazardous exposures to employees.   On or about March 29, 2021 at a facility located at 5800 West Drive, Manitowoc, WI 54220; the employer did not provide respiratory protection and did not determine through use of air monitoring, that concentrations of chlorine gas would not result in hazardous exposure to employees. The employer, acting as the Incident Commander allowed third-shift employees, including but not limited to Compounder and Maintenance employees, to attempt to neutralize the chemical reaction in the W1 tank through dilution and to reduce airborne chlorine gas by ventilating the building.

Issued

Sep 10, 2021

Abate by

Oct 20, 2021

Penalty

Initial $0 · Current $0

Hazardous substances 0640

General-duty citation text

29 CFR  1910.134(d)(1)(iii):  The employer shall identify and evaluate the respiratory hazard(s) in the workplace; this evaluation shall include a reasonable estimate of employee exposures to respiratory hazard(s) and an identification of the contaminant's chemical state and physical form. Where the employer cannot identify or reasonably estimate the employee exposure, the employer shall consider the atmosphere to be IDLH.  On March 29, 2021 at a facility located at 5800 West Drive, Manitowoc, WI 54220; the employer did not identify or evaluate the respiratory hazards in the workplace presented by chlorine gas generated from a chemical reaction in the waste water treatment system. First shift employees were directed to work in the facility and in areas where chlorine gas was present and caused symptoms of exposure.