OSHA Inspection: KEWAUNEE FABRICATIONS, L.L.C.

Issued

Dec 5, 2022

Penalty

Initial $14,502 · Current $14,502

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 they were exposed to crushed-by and struck-by hazards from fabricated parts falling from below-the-hook magnets.  At an establishment located at 520 North Main Street in Kewaunee, Wisconsin, in the Initial Processing Department:  (a) On or about June 7, 2022, an employee using an Eriez XPL-15/9 Close Proximity Operated Lifting Magnet (Identifier: 5512K) was exposed to crushed-by and struck-by hazards created by a 1,254-lb counterweight falling from the permanent magnet after it failed to hold the load. The magnet had metal build-up and pitting on the contact surface and was not removed from service prior to use.  (b) On or about June 23, 2022, to July 6, 2022, an employee utilizing a Power-Grip Close Proximity Operated Battery-Powered Magnet (S/N: 111895, rated load capacity 2,500 lbs) was knowingly exposed to potentially being struck and crushed by falling metal parts when the magnet was placed back in service after it failed a breakaway force test on or about June 23, 2022. The electromagnet failed to lift the minimum calculated breakaway force of 5,000 lbs.  (c) On or about June 23, 2022, to July 6, 2022, an employee utilizing an O.S. Walker Close Proximity Operated Battery-Powered Magnet (S/N: 2558, rated load capacity 5,500 lbs) was knowingly exposed to potentially being struck and crushed by falling metal parts when the magnet was placed back in service after it failed a breakaway force test on or about June 23, 2022. The electromagnet failed to lift the minimum calculated breakaway force of 11,000 lbs.  (d) On or about June 23, 2022, to July 6, 2022, an employee utilizing an O.S. Walker Close Proximity Operated Battery-Powered Magnet (Model WBM-25PB, rated load capacity 5,500 lbs) was knowingly exposed to potentially being struck and crushed by falling metal parts when the magnet was placed back in service after it failed a breakaway force test on or about June 23, 2022. The electromagnet failed to lift the minimum calculated breakaway force of 11,000 lbs.

Issued

Dec 5, 2022

Abate by

Jan 26, 2023

Penalty

Initial $10,360 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.178(o)(1): Only stable or safely arranged loads shall be handled. Caution shall be exercised when handling off-center loads which cannot be centered.  On or about July 21, 2022, at an establishment located at 520 North Main Street in Kewaunee, Wisconsin; the employer did not ensure only safely arranged loads were handled when employees utilized in-house fabricated wagons and paint carts or "Picture Frames" to move fabricated parts and raw materials in the storage yard and throughout the facility. The wagons were prone to slipping off the forks during handling, when braking, and during wet weather.

Issued

Dec 5, 2022

Abate by

Jan 26, 2023

Penalty

Initial $0 · Current $7,000

General-duty citation text

29 CFR 1910.178(o)(2): Only loads within the rated capacity of the truck shall be handled.  On or about June 30, 2022, to July 21, 2022, at an establishment located at 520 North Main Street in Kewaunee, Wisconsin; employees were handling loads that weighed in excess of 8,000 lbs. with forklifts that had a rated capacity of 6,050 lbs. Employees utilized wagons to transport fabricated parts throughout the storage yard and the facility during the fabrication and finishing processes.

Issued

Dec 5, 2022

Abate by

Jan 26, 2023

Penalty

Initial $10,360 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.178(l)(3)(ii)(B): Powered industrial truck operators shall receive initial training in workplace-related topics; Composition of loads to be carried and load stability.   a) On or about July 14, 2022, at an establishment located at 520 North Main Street in Kewaunee, Wisconsin; employees were exposed to struck-by and crushed-by hazards created by employees operating forklifts that had not received training regarding the load composition and load stability of the in-house fabricated wagons or trailers. Wagons or trailers were utilized to move raw materials and fabricated parts in the storage yard and throughout the plant.  b) On or about July 21, 2022, at an establishment located at 520 North Main Street in Kewaunee, Wisconsin; employees were exposed to struck-by and crushed-by hazards created by employees operating forklifts that had not received training regarding the load composition and load stability of the in-house fabricated paint carts or "Picture Frames". Paint carts or "Picture Frames" were utilized to move painted parts in the storage yard and painting areas.

Issued

Dec 5, 2022

Penalty

Initial $10,360 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.184(i)(9): Removal from service. Synthetic web slings shall be immediately removed from service if any of the following conditions are present: (i) Acid or caustic burns; (ii) Melting or charring of any part of the sling surface; (iii) Snags, punctures, tears or cuts; (iv) Broken or worn stitches; or (v) Distortion of fittings:  a) On or about July 13, 2022, at a facility located at 520 North Main Street in Kewaunee, Wisconsin; employees were exposed to potential struck-by and crushed-by hazards created by a synthetic web sling that was not removed from service immediately when the sling was used to lift fabricated parts onto the 250-ton Farquhar hydraulic press and became degraded in the center of the sling, showing red indicator threads where it had abraded.  b) On or about July 21, 2022, at a facility located at 520 North Main Street in Kewaunee, Wisconsin; employees were exposed to potential struck-by and crushed-by hazards created by an 8-foot synthetic web sling that was not removed from service immediately after it showed signs of wear, threading damage, and cuts to the sling threads. The 8-foot nylon Safeway Sling (STK NO. EE2-902P) was showing red indicator threads near the center of the sling where it had been partially cut.

Issued

Dec 5, 2022

Abate by

Jan 26, 2023

Penalty

Initial $10,360 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.212(a)(1): Types of guarding. One or more methods of machine guarding shall be 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. Examples of guarding methods are-barrier guards, two-hand tripping devices, electronic safety devices, etc.  On or about July 21, 2022, at an establishment located at 520 North Main Street in Kewaunee, Wisconsin; employees welding on ladder fixtures were exposed to crushing hazards associated with the vertical movement of the ladder fixtures used to rotate and lift fabricated ladders for welder employees. The ladder fixtures were operated using a pendant controller that was accessible to other employees working in the area and a second welder on the same fixture. The machines were not effectively guarded to prevent exposure to these hazards.

Issued

Dec 5, 2022

Penalty

Initial $10,360 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.219(f)(3): Sprockets and chains. All sprocket wheels and chains shall be enclosed unless they are more than seven (7) feet above the floor or platform. Where the drive extends over other machine or working areas, protection against falling shall be provided. This subparagraph does not apply to manually operated sprockets.  On or about July 1, 2022, at an establishment located at 520 North Main Street in Kewaunee, Wisconsin, in Bay 4; employees were exposed to ingoing nip points and caught in hazards created by a chain and sprocket on a Worthington welding positioner (S/N: 53414).  The chain and sprocket were not effectively guarded to prevent exposure to the hazards.

Issued

Dec 5, 2022

Penalty

Initial $10,360 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.303(g)(1): Space about electric equipment. Sufficient access and working space shall be provided and maintained about all electric equipment to permit ready and safe operation and maintenance of such equipment.   On or about July 13, 2022, at an establishment located at 520 North Main Street in Kewaunee, Wisconsin; an electrical disconnect located in Bay 4 South utilized for Jib Crane 10D and Jib Crane 9D was blocked with permanent storage racking immediately in front of the disconnect.

Issued

Dec 5, 2022

Penalty

Initial $10,360 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in cabinets, boxes, and fittings shall be effectively closed.  On or about July 13, 2022, at an establishment located at 520 North Main Street in Kewaunee, Wisconsin; an unused opening in a 480-volt disconnect located in Bay 4 was not effectively closed when the control handle was removed. An employee was painting a nearby electrical conduit pipe in a scissors lift and was exposed to electrical shock hazards.

Issued

Dec 5, 2022

Penalty

Initial $10,360 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.333(c)(2): "Work on energized equipment." Only qualified persons may work on electric circuit parts or equipment that have not been deenergized under the procedures of paragraph (b) of this section. Such persons shall be capable of working safely on energized circuits and shall be familiar with the proper use of special precautionary techniques, personal protective equipment, insulating and shielding materials, and insulated tools.  On or about July 5, 2022, at a facility located at 520 North Main Street in Kewaunee, Wisconsin, in Bay 12; the employer did not ensure that only qualified persons were working near an energized 480-volt Ingersol Cabinet #1 (panel KFI-CPNL-4531). The employee opened the panel to observe if the relays were tripped after the Bay 12 East Ingersol machine tooling jammed, and was not familiar with the proper use of special precautionary techniques and personal protective equipment, exposing the employee to 480-volt electrical hazards.

Issued

Dec 5, 2022

Abate by

Jan 26, 2023

Penalty

Initial $145,027 · Current $125,022 Reduced

General-duty citation text

29 CFR 1910.212(a)(3)(ii): The point of operation of machines whose operation exposes an employee to injury, shall be guarded. The guarding device shall be in conformity with any appropriate standards therefor, or, in the absence of applicable specific standards, shall be so designed and constructed as to prevent the operator from having any part of his body in the danger zone during the operating cycle.   On or about July 13, 2022, at an establishment located at 520 North Main Street in Kewaunee, Wisconsin, in Bay 9, Initial Processing Department; at the Farquhar 250-ton hydraulic press; employees assigned to operate the press for straightening steel and aluminum parts had their hands exposed to the lowering ram's pinch point and caught-under crushing hazards likely to result in amputation or other serious injuries. Operators were required to place their hands near the unguarded point-of-operation and its associated danger zone to hold wood blocks in position between the stationary aluminum parts on the bed and the ram lowering onto the block for the initial contact. The employer did not safeguard the point-of-operation to prevent operator's access during the hazardous vertical downstroke.  Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).