OSHA Inspection: ARMOROCK, LLC

Issued

Jun 30, 2022

Abate by

Jul 27, 2022

Penalty

Initial $13,052 · Current $6,280 Reduced

General-duty citation text

29 CFR  1910.28(b)(1)(i):Except as provided elsewhere in this section 29 CFR 1910.28, the employer did not ensure that each employee on a walking-working surface with an unprotected side or edge that is 4 feet (1.2 m) or more above a lower level is protected from falling by one or more of the systems described in 29 CFR 1910.28(b)(1)(i):  (a) On or about March 2, 2022, and times prior thereto; employees on Tanksafe feed tank #1 in the continuous casting unit #1, employee(s) working on the  feed tank walking working area were exposed to a fall hazard to the ground below.  (b) On or about March 2, 2022, and times prior thereto; employees on Tanksafe feed tank #2 in the continuous casting unit #2, employee(s) working on the feed tank walking working area were exposed to a fall hazard to the ground below.  (c) On or about March 2, 2022, and times prior thereto; employees on Tanksafe feed tank #3 in the continuous casting unit #1, employee(s) working on the feed tank walking working area were exposed to a fall hazard to the ground below.

Issued

Jun 30, 2022

Abate by

Jul 27, 2022

Penalty

Initial $9,324 · Current $6,280 Reduced

General-duty citation text

29 CFR  1910.106(h)(4)(iv)(a):Equipment was not designed and arranged to prevent the unintentional escape of liquids and vapors and to minimize the quantity escaping in the event of accidental release:  On or about January 13, 2022, and times prior thereto; employees in the continuous casting process areas #1 and #2 were exposed to fire and explosion hazards associated with the Interplastic concrete polymer resin:  (a) Tanksafe feed tank 1-  1.5 inch uncapped pipe opening on containment drain (N5); (b) Tanksafe feed tank 1- 2 inch uncapped pipe opening  on level connector and ball valve (N7); (c)Tanksafe feed tank 2-  1.5 inch uncapped pipe opening on containment drain (N5); (d) Tanksafe feed tank 2- 2 inch uncapped pipe opening on level connector and ball valve (N7).

Issued

Jun 30, 2022

Abate by

Jul 27, 2022

Penalty

Initial $9,324 · Current $6,280 Reduced

General-duty citation text

29 CFR  1910.106(h)(6)(ii)(d):Processing plants shall be protected by an approved automatic sprinkler system or equivalent extinguishing system:   (a) On or about January 6, 2022, in the main production area of the continuous casting process areas 1,2,3  employees are exposed to fire and explosion hazards associated with the Interplastic polymer concrete resin.

Issued

Jun 30, 2022

Abate by

Jul 27, 2022

Penalty

Initial $9,324 · Current $6,280 Reduced

General-duty citation text

29 CFR 1910.106(h)(7)(i)(b): Category 1 or 2 flammable liquids, or Category 3 flammable liquids with a flashpoint below 100 �F (37.8 �C), were dispensed into containers without the nozzle and container being electrically interconnected:  (a) On or about January 6, 2022, in the main production area of the continuous casting process unit  1, employees dispensed  a category 2 flammable liquids, acetone 55-gallon drums, into a plastic bucket and the nozzle and container were not electrically interconnected exposing employees to explosion and fire hazards;  (b) On or about January 6, 2022, in the main production area of the continuous casting process unit  2, employees dispensed a category 2 flammable liquids, acetone 55-gallon drums, into a plastic bucket and the nozzle and container were not electrically interconnected exposing employees to explosion and fire hazards.

Issued

Jun 30, 2022

Abate by

Jul 27, 2022

Penalty

Initial $9,324 · Current $6,280 Reduced

General-duty citation text

29 CFR  1910.119(c)(1): Employers shall develop a written plan of action regarding the implementation of the employee participation required by this paragraph.    (a) On or about January 13, 2021, and at times prior thereto, this violation occurred in the main production areas of the continuous casting process area #3 where employees were exposed to fire and explosion hazards when the employer did not ensure that a written plan of action regarding implementation of the employee participation was developed in the event of a release of the Interplastic polymer concrete resin.

Issued

Jun 30, 2022

Abate by

Jul 27, 2022

Penalty

Initial $9,324 · Current $6,280 Reduced

General-duty citation text

29 CFR  1910.119(d)(3)(i)(B):The employer did not develop piping and instrument diagrams for the equipment that was part of the process:   (a) On or about January 14, 2022, and at times prior thereto, information concerning the technology of the process did not include a block flow diagram or simplified process flow diagram in the event of an Interplastic polymer concrete resin release.

Issued

Jun 30, 2022

Abate by

Nov 14, 2022

Penalty

Initial $9,324 · Current $6,280 Reduced

General-duty citation text

29 CFR 1910.119(e)(1):  The employer did not perform an initial process hazard analysis (hazard evaluation) on processes covered by this standard. The process hazard analysis was not appropriate to the complexity of the process and did not identify, evaluate, and control the hazards involved in the process. Employers shall determine and document the priority order for conducing process hazard analyses based on a rationale which includes such considerations as extent of the process hazards, number of potentially affected employees, age of the process, and operating history of the process:   (a) On or about January 13, 2022, and at times prior thereto, the employer did not conduct a process hazard analysis for the evaluation and control of the hazards involved in the continuous casting process unit #3, exposing employees to inhalation, fire, and explosion hazards associated with  Interplastic polymer concrete resin

Issued

Jun 30, 2022

Abate by

Nov 14, 2022

Penalty

Initial $9,324 · Current $6,280 Reduced

General-duty citation text

29 CFR  1910.119(f)(1)(i)(D):The employer did not develop and implement written operating procedures that provide clear instructions for emergency shutdown, including the conditions under which emergency shutdown is required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner.  (a) On or about January 13, 2022, and times prior thereto; the employer did not ensure that written operating procedures provided clear instructions for emergency shutdown procedures for the Interplastic polymer concrete resin used in the continuing casting process area #3 were developed and implemented, exposing employees to inhalation, fire, and explosion hazards.

Issued

Jun 30, 2022

Abate by

Jul 27, 2022

Penalty

Initial $9,324 · Current $6,280 Reduced

General-duty citation text

29 CFR  1910.119(i)(1): The employer did not perform a pre-startup safety review for new facilities.  (a) On or about January 13, 2022, and at times thereafter, in the continuous casting process area #3, the employer did not ensure that a pre-startup safety review was completed with regard to potential releases of Interplastic polymer concrete resin that were used in a batch manufacturing process.

Issued

Jun 30, 2022

Abate by

Jul 27, 2022

Penalty

Initial $9,324 · Current $6,280 Reduced

General-duty citation text

29 CFR 1910.119(n):   The employer did not establish and implement an emergency action plan for the entire plant in accordance with the provisions of 29 CFR 1910.38:   Or in the alternative:    29 CFR 1910.38(a): The employer did not have an emergency action plan whenever an OSHA standard in this part requires one:  On or about January 13, 2022, and at times thereafter, the employer did not to establish and implement an emergency action plan to ensure that each employee working at the facility was protected from emergencies involving Interplastic polymer concrete resin. The emergency action plan must include, but is not limited to the following:  (a) Procedures for reporting a fire or other emergency.  (b) Procedures for emergency evacuation, including type of evacuation and exit route assignments.  (c) Procedures to be followed by employees who remain to operate critical plant operations before they evacuate.  (d) Procedures to account for all employees after evacuation.  (e) Procedures to be followed by employees performing rescue or medical duties.  (f) The name or job title of every employee who may be contacted by employees who need more information about the plan or an explanation of their duties under the plan.  (g) Employee alarm system with a distinctive signal for each purpose.   (h) Employee training.  (i) Review of emergency action plan with each employee covered by the plan.

Issued

Jun 30, 2022

Abate by

Jul 27, 2022

Penalty

Initial $9,324 · Current $6,290 Reduced

General-duty citation text

29 CFR  1910.304(g)(5): The path to ground from circuits, equipment, and enclosures was not permanent, continuous, and effective:  (a) On or about March 2, 2022, and times prior thereto; the Tanksafe feed tank #3 did not have an adequate grounding wire and rod.  Employees were exposed to fire and explosion hazards associated with the Interplastic polymer concrete resin.