OSHA Inspection: STONER, INC.

Issued

May 8, 2025

Penalty

Initial $6,620 · Current $6,620

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 from struck by hazards.  a. The Mixing Area - On or about November 12, 2024, the pallet rack systems which are used to store pallets with barrels of materials, ISO totes and various other stored products, was not marked or placarded to identify the weight capacity of the rack system and support grates.  b. The Mixing Area - On or about November 12, 2024, the pallet rack systems which are used to store pallets with barrels of materials, ISO totes and various other stored products, was not anchored to the floor to prevent movement and collapse in the event of contact with MHE or other equipment.  Corrected During Inspection

Issued

May 8, 2025

Abate by

May 23, 2025

Penalty

Initial $4,965 · Current $4,965

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. Flammable Liquids Atmospheric Tank Farm - On or about November 12, 2024, employees accessing the tank farm by use of the ladder and platform system to get over the diking system were exposed to a fall hazard of greater than 4 feet without fall protection on the ladderway front and back face.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

May 8, 2025

Abate by

May 22, 2025

Penalty

Initial $6,620 · Current $6,620

General-duty citation text

29 CFR 1910.37(a)(3): Exit route(s) were not kept free and unobstructed:  a. 2nd Floor Mixing Room Door - On or about November 12, 2024, the Dry Film Tanks 3 door was blocked by medium and large size batch mix tanks. This exit door would be the primary door if the employee was standing at the batching station, and a fire broke out where they dispense the flammable liquids. The obstructed door exposed employees to smoke inhalation, fire and thermal hazards.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

May 8, 2025

Abate by

May 22, 2025

Penalty

Initial $6,620 · Current $6,620

General-duty citation text

29 CFR 1910.37(a)(4): Safeguard(s) designed to protect employees during an emergency (e.g., sprinkler systems, alarm systems, fire doors, exit lighting), were not in proper working order at all times:  a. 2nd floor Shipping Door - On or about November 12, 2024, the emergency lighting over the door was not in proper working order, and did not illuminate upon test of the battery backup. Emergency safeguards that fail to function in the event of power outage or other event can result in employees being exposed to smoke inhalation, fire, or thermal hazards.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

May 8, 2025

Abate by

May 22, 2025

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.37(b)(6): Each exit sign was not illuminated to a surface value of at least five foot-candles (54 lux) by a reliable light source and be distinctive in color:   a. The Mixing Room Door - On or about November 12, 2024, the emergency exit sign was not illuminated under normal conditions to provide lighting raising concerns of effectiveness in an emergency. Failure to ensure emergency exit signs are adequately illuminated to provide 54 lux of reliable light in the event of power outage or other emergency such as fire where smoke clouds the area the need for effective illumination can result in employees being exposed to smoke inhalation, fire, or thermal hazards.  b. 1st Floor Shipping - On or about November 12, 2024, the emergency exit sign was not illuminated under normal conditions to provide lighting raising concerns of effectiveness in an emergency. Failure to ensure emergency exit signs are adequately illuminated to provide 54 lux of reliable light in the event of power outage or other emergency such as fire where smoke clouds the area the need for effective illumination can result in employees being exposed to smoke inhalation, fire, or thermal hazards.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

May 8, 2025

Abate by

May 28, 2025

Penalty

Initial $8,276 · Current $8,276

General-duty citation text

29 CFR 1910.119(d)(3)(i)(A): Process safety information pertaining to the equipment in the process did not include materials of construction:   a. PSI - On or about November 12, 2024, the materials of construction lacked the specifics related to the schedule 80 carbon steel process piping, the employer did not identify  the piping circuits by size, they did not include minimum wall thickness values and the wall thickness of design, rating of junctions, elbows and the type and calculated stresses on the system. Failure to compile and maintain PSI on materials of construction can result in release of highly flammable gas under pressure, causing fire or explosion hazards.     Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

May 8, 2025

Abate by

Jun 26, 2025

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.119(d)(3)(i)(F): Information pertaining to the equipment in the process did not include design codes and standards that were employed.   a. PSI - On or about November 12, 2024, the employer failed to include the edition of the design codes and standards which were employed for their process piping in their process safety information. Failure to define the edition they employ could result in improper inspection methods which can lead to release of flammable gas exposing employees to fire and/or explosion hazards.   Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

May 8, 2025

Abate by

Jun 26, 2025

Penalty

Initial $11,585 · Current $11,585

General-duty citation text

29 CFR 1910.119(d)(3)(iii): For existing equipment designed and constructed in accordance with codes, standards, or practices no longer in general use, the employer did not determine and document that the equipment in the process was designed, maintained, inspected, tested, and operating in a safe manner.    a. Tank Farm PSI - On or about November 12, 2024, the employer did not have or maintain the U1 or U1A for the 152A pressure vessel to document that the equipment was designed, maintained, inspected, tested and operated within safe operating limits for the equipment such as temperature, relief and head pressure and volume. Failure to document and maintain process safety information for process equipment such as the 152A pressure vessel can result in failure to develop effective maintenance and operating procedures that can lead to equipment failure, the release of flammable gas resulting in fire or explosions.  Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

May 8, 2025

Abate by

Jun 26, 2025

Penalty

Initial $8,276 · Current $8,276

General-duty citation text

29 CFR 1910.119(e)(3)(v): The process hazard analysis did not address facility siting.  a. Tank Farm Piping Circuits PHA - On or about November 12, 2024, the employer failed to ensure the PHA addressed the hazards of flame impingement and fire protection of piping systems which are minimally spaced within the PHA facility siting, the piping circuits transporting flammable liquids alongside the pipes transporting aerosol propellent. Failure to address the proximal effects of conveying flammable liquids alongside propellent gases can result in fire and explosion hazards.  Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

May 8, 2025

Abate by

Jun 26, 2025

Penalty

Initial $11,585 · Current $11,585

General-duty citation text

29 CFR 1910.119(e)(5): The employer did not establish a system to promptly address the PHA team's findings and recommendations.   a. PHA - On or about November 12, 2024, the employer did not take action to resolve PHA recommendation 1.E.2, and is an ongoing violation "Determine if the Gas House building can be modified to meet the "damage-limiting" construction design which is best available technology (see NFPA 30B & 68). If so make the necessary modifications. If not, consider installing an alternative option such as deflagration suppression system." Failure to resolve PHA findings specific to building design and construction to meet RAGAGEP or implement deflagration suppression can result in the release of flammable gas resulting in fire or explosions.  b. PHA - On or about November 12, 2024, the employer did not resolve PHA recommendation 1.B.1, 2.B.1, 1.20 and is an ongoing violation, "After completion of the PPE assessment, develop procedures or signage to ensure that only personnel with necessary PPE are allowed within an appropriate distance of the propellant storage area when unloading a truck or the cylinder fill station. (See NFPA 30B & 497)." Failure to resolve PHA findings specific to PPE required for personnel working in areas where deflagration hazards exist can result in exposure to flash fire hazards.   c. PHA - On or about November 12, 2024, the employer did not take action to resolve PHA recommendation 1.1.2 and is an ongoing violation, "Conduct Corken compressor MI inspections and tests per current MI schedule." Failure to resolve PHA findings related to Mechanical Integrity can result in the release of a flammable propellent gas that can result in fire or explosion.  Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

May 8, 2025

Abate by

Jun 12, 2025

Penalty

Initial $11,585 · Current $11,585

General-duty citation text

29 CFR 1910.119(f)(4): The employer did not develop and implement safe work practices to provide for the control of hazards during operations such as lockout/tagout; confined space entry; opening process equipment or piping; and control over entrance into a facility by maintenance, contractor, laboratory, or other support personnel:  a. Gas house - On or about November 12, 2024, the aerosol process did not have procedures or policies to prevent unauthorized entry of visitors, contractors, lab personnel and other support staff or the public from entering into the gas house or process area. Failure to secure and ensure that access to the gas house is limited to trained personnel can result in the release of flammable gas resulting in fire or explosion.   b. Gas House - On or about November 12, 2024, the employer had not implemented the use of lockout tagout when performing servicing and maintenance of pumps, compressors and gas injection equipment. Failure to develop and implement lockout tagout to process equipment can result in release of flammable gas causing a fire or explosion hazard.  Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

May 8, 2025

Abate by

May 28, 2025

Penalty

Initial $0 · Current $0

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. Aerosol Line - On or about November 12, 2024, prior to allowing employees to engage in servicing and maintenance the employer did not implement and utilize an energy control procedures to prevent unexpected energization, startup or release of stored energy from machines, equipment and gas transmission equipment, employees were exposed to caught in, struck by, fire and explosion hazards.    Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

May 8, 2025

Abate by

May 28, 2025

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(6)(i): The employer did not conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirement of this standard were being followed:   a. Aerosol Line - On or about November 12, 2024, periodic inspections were not performed at least annually to ensure that lockout tagout procedures and policies were being followed, the production employees engaged in servicing and maintenance of equipment did so without the oversite of periodic inspections which had resulted in the program not being used throughout the facility. Employees were exposed to caught in, struck by, fire and explosion hazards related to uncontrolled energy.   Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

May 8, 2025

Abate by

May 28, 2025

Penalty

Initial $0 · Current $0

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.  a. Aerosol Line - On or about November 12, 2024, the employer failed to train authorized employees on the company energy control program, and procedures necessary to identify hazardous energy, isolate the energy, and steps to follow when performing these tasks. Production employees assigned to perform equipment changeover, clearing jams, servicing and maintenance of equipment to include pumps, motors, robots and slitters, did so without training to the authorized level to recognize and understand the hazards of the energies they may encounter and means of controlling that energy. Employees were exposed to caught in, struck by, fire, and explosion hazards from uncontrolled energy sources to include but not limited to electrical, gas, pneumatic, hydraulic, and mechanical.  Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

May 8, 2025

Abate by

Jun 26, 2025

Penalty

Initial $11,585 · Current $11,585

General-duty citation text

29 CFR 1910.119(g)(1)(i): The employer did not train each employee before being involved in operating a newly assigned process in the operating procedures as specified in paragraph (f) of this section.   a. Aerosol Process - On or about November 12, 2024, employees assigned to the newly developed PSM covered process of aerosol injection were not trained on the operating procedures developed under paragraph (f). Failure to train employees on the process to include the hazards of the process, how to avoid deviation from developed procedures can result in the release of flammable gases leading to fire or explosion hazards.   Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

May 8, 2025

Abate by

May 28, 2025

Penalty

Initial $11,585 · Current $11,585

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not establish written procedures to maintain the on-going integrity of process equipment:  a. Outside the Gas House - On or about November 12, 2024, the employer failed to establish written procedures to maintain the on-going integrity of buried schedule 80 carbon steel pressure piping feeding into the gas house. Failure to develop procedures can result in release of highly flammable gas under pressure, exposing employees to fire or explosion hazards.    b. Outside the Gas House - On or about November 12, 2024,  the employer failed to establish written procedures to maintain the on-going integrity of the piping thickness minimums (tmin) for the ongoing integrity schedule 80 carbon steel above ground pressure piping feeding into the gas house in order to determine the remaining life and replacement of process piping circuits. Failure to develop procedures can result in release of highly flammable gas under pressure, exposing employees to fire or explosion hazards.      c. Tank Farm - On or about November 12, 2024,  the employer  failed to establish written procedures to maintain the on-going integrity of pressure vessels used to feed the process with propellant gases. Failure to develop procedures can result in release of highly flammable gas under pressure, exposing employees to fire or explosion hazards.      d. Gas House - On or about November 12, 2024,  the employer failed to establish written procedures to maintain the on-going integrity of propellent injection equipment for inspection, replacement and frequency of the DME injector gaskets. Failure to develop procedures can result in release of highly flammable gas under pressure, exposing employees to fire or explosion hazards.   Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

May 8, 2025

Abate by

Jun 26, 2025

Penalty

Initial $11,585 · Current $11,585

General-duty citation text

29 CFR 1910.119(n): The employer did not establish an emergency plan for the entire plant in accordance with the provisions of 29 CFR 1910.38:   a) Stoner, Inc. - On or about November 12, 2024, the employer did not develop, implement and maintain procedures for emergencies including, but not limited to, natural disasters , such as  ice storms, tornados, lightning strikes, earthquakes  and torrential rain storms.    b. Stone, Inc. - On or about November 12, 2024, the emergency action plan called for procedures for performing rescue or medical duties, and the action plan lacked emergency contact information in the event of an emergency.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

May 8, 2025

Abate by

Jun 26, 2025

Penalty

Initial $8,276 · Current $8,276

General-duty citation text

29 CFR 1910.119(o)(1): Employers did not verify that the procedures and practices developed under the standard were adequate:   a. Facility Wide Compliance Audit - On or about November 12, 2024, the employer did not perform a compliance audit on the covered process to verify and ensure that policies, practices, procedures and program elements complied with 1910.119. Failure to conduct a compliance audit resulted in the employer failing to identify missing PSI, address open PHA findings, ensure employees were trained on and utilizing the employer developed operating procedures, implementation of controls to limit access to process areas like the gas house, determine the appropriate RAGAGEP for mechanical integrity tests and inspections and document that the inspections are complying with those chosen RAGAGEP's. Failure to conduct a compliance audit leaving significant gaps in the employer's program exposes employees to fire, and explosion hazards due to potential failure of equipment, unsafe operation, and uncontrolled access to untrained personnel.  Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.