Fairborn Cement Plant Metal/Non-Metal

An employee was riding the elevator down from the 10th floor and the elevator stopped at the 2nd floor. The outer door would open but the inner door would not. The elevator company was notified, and the employee was eventually able to pry the inner door open and successfully get out.

An employee was traveling on our preheat tower elevator when it stopped between floor 1 and 2. The elevator contractor was called, however the elevator came down to the ground level prior to them arriving. The elevator stopped due to a gate switch failing.

Employee was stepping down off a roll around step ladder when EE came down on a bent step causing EE's knee to twist. Employee had knee surgery on 5/31/2024. EE returned to work on EE's next scheduled shift.

Employee was pushing a wheelbarrow when EE heard a pop in their left knee, EE then felt pain and discomfort in left knee. EE was diagnosed with a sprain of left knee.

Employee was stepping up on a platform to access a clinker feeder when their right knee popped causing their leg to give out and they fell back. Employee was diagnosed with a sprain of unspecified site of right knee.

Employee was driving an articulated haul truck when EE hit something causing a pop in EE's right leg. EE looked for what EE hit the rest of EE's shift and never could find anything. The following day EE had back pain and was given restrictions by the doctor.

At approx. 6:20 PM the control room operator got an alarm that the coal belt shut down. The operator sent the utilitymen to investigate what the cause was. At approx. 6:30 PM the utilitymen determined a fire was in the #2 coal feeder. The fire department was called and clay was put on the feeder and the fire was smothered around 1:30 AM.

Employee was cleaning a conveyor belt tunnel below the rock crusher with a skid steer loader when EE hit the top left of the windshield on a partial support beam. The impact caused EE to hit head however EE was unable to say whether their head hit the windshield or the head rest. The employee was written off work for 3 days with concussion-like symptoms.

Employee was using stake-on pliers to cut back the jacket on wires to install new lighting in a newly built office in the repair shop. They felt an odd pull in right elbow. The following day they wanted to see the doctor. On 7/21/22 employee was approved to receive physical therapy.

The employee was using a HAO switch in an electrical room when the bucket for a different piece of equipment arc'd. A flash of light and smoke came from the arc'd bucket. The employee was having dry eye symptoms and was prescribed antibiotic eye drops for precautionary purposes.

Contractor ridding to top of cement silos in elevator & base of cart came to a stop approx. 6 inches from top platform which prevented doors from opening. Contractor instructed to use foot pedal to bring cart down to ground level. Cart base went 5-6 inches below platform again preventing doors from being opened. Ice on rack and switches caused this occurrence.

An employee was traveling in the preheater elevator when it came to an abrupt stop between floors 1 and 2 at 4:45 PM. A technician for the elevator company was able to come out and release the employee at 7:06 PM. There was material that got into the 3rd-floor locking device that caused the sensor to believe the door was open which caused the elevator to stop moving.

Employee parked front end loader and was getting down off the ladder. When EE took the last step, the ground was dug down further than EE was expecting and EE fell on right shoulder. Employee bruised their shoulder and worked light duty the next shift.

An employee used their legs, extending them fully, to push an air-seal valve into place and EE strained the right groin.

3 employees got on the preheater elevator on the 2nd floor to travel to the 1st floor. The elevator suddenly stopped between the 1st and 2nd floor at 5:02 AM. The elevator technician was able to get the elevator back to the 2nd floor and release the employees at 7:27 AM. A safety governor switch tripped which caused the emergency stop to engage.

Went to toss a stick & felt a sharp pain from shoulder to elbow.

The employee was removing an abnormally heavy dust collector bag and cage with the use of a crowbar through the cage when the cage and bag slid on the crowbar causing the cage to pinch the employee's left hand which caused a laceration that required 4 stitches.

The employee was lifting hoist chains above EE's shoulders to hook to a forklift when EE felt pain in EE's right shoulder. The employee was using first-aid measures until the pain continued and then was prescribed physical therapy sessions which were started on 10/15/2020.

An employee was walking along the bulk tanker truck scale while a truck was on it and was being loaded while carrying a tall cardboard box. EE's box got pinned between the truck and a wall causing EE to forcefully push it through which caused EE to trip off the scale and strike face with the box. Employee went back to work but ended up having Septoplasty surgery on 12/5/19.

An employee was closing a bulk tanker hatch with a pole from the ground when EE slipped and fell. The employee twisted EE's right leg in the fall ultimately causing a fracture in EE's right fibula.

Two process utility men were riding down in the preheater elevator to the first floor when it came to a complete stop between 2nd and 3rd floor. A technician for the elevator company arrived and was able to get the employees out at 10:50 AM. The 9th-floor door to the elevator shaft had a mechanical bind that engaged safety interlocks to hard stop the elevator.

An employee was working in the mill with the mill completely open in the annual shut down and was exposed to carbon monoxide. Two days later the employee sought treatment for a cough and chest pain.

An employee was walking along a catwalk and tripped approaching a step and made contact with their face on a handrail. The employee has facial abrasions and an open fracture of the maxillary sinus.

An upset employee punched a steel door on the 5th floor of the preheater tower resulting in a boxer fracture in the right hand.

The employee was observing trainee from a 10" high platform. When the employee stepped off the platform employee came down on right foot and it rolled causing popping noises and immediately swelled up.

An employee stuck their left arm into inspection port on a hopper chute to unplug. An air knife gate above the inspection port shut on the hand when the dust collector cycled and when the cycle was complete the air knife gate opened and released the employee's hand.

An employee was looking up towards the raw mill when the employee took a step back and tripped over a forklift attachment. The employee tried to reach out with left arm to stabilize self and tripped further until falling to the ground. The employee reported left shoulder pain the following day.

The employee was unplugging the raw mill triple gate and when EE was able to remove the large rock that created the plug, fine rocks and material flushed out through the port and made its way into the employee's right eye causing a corneal abrasion.

2 employees were riding preheat tower elevator from 1st to 2nd floor when they came to a complete halt. Murphy Elevator was notified to send technicians. Communication was maintained through radio and phone for the 2 hours the employees were in the elevator.

An employee was walking down a set of stairs when their left knee buckled and gave out, causing the left knee to twist. The stairway was clear and employee was holding the handrail. Employee reported the injury on 3/13/18.

An employee was traveling from the 1st floor to the 2nd floor in an elevator when it stopped 6-8' up. The elevator lowered itself to the first floor and it suddenly dropped 6-8". The outer door was unable to open until the employee manually released the mechanics allowing it to open.

Mine employee was injured while securing an impact plate on a feeder chute. The plate was secured in place by the employee using a pry bar. The pry bar slipped allowing the plate to shift coming into contact with the employee's left index finger causing a laceration that required four sutures.

Three employees were traveling in an elevator from the 2nd floor to the 1st floor of the preheat tower. The elevator traveled approximately 2ft and stopped due to a safety interlock fault code. The employees were removed from the elevator after approximately 45 minutes. There were no injuries.

Employee suffered a laceration on left wrist while cutting a plastic tie with a knife. The employee was cutting towards their body when the knife after cutting the tie struck the employee's wrist requiring medical treatment.

Employee was struck on their head by a tool as they were reaching for their hard hat which they had knocked off during their work activity. A laceration was received to their scalp requiring three sutures. The employee returned to work the same shift.

An electrical storm passed through the area causing the plant to drop power, it was found later that this event created potential to cause a coal dust ignition in the plant's coal mill. Damages were contained internally to the coal mill system. It was found that the damper plate in the outlet piping was damaged.

Employee had some cement dust get into left boot causing a cement burn to the outside of left ankle. Medical treatment was given and placed on restricted duty. The employee reported the incident to supervisor on 9/17/2016.

Employee was stuck on the 4th floor of the Pre-Heater Elevator from 1:18 am until 1:37 am. The elevator was reset which allowed it to function allowing employee to exit. An elevator repair service was brought out to trouble shoot for the cause of the stoppage and make repairs.

Employee had hand caught between a rock and the side of a hopper causing a laceration to EE's right index finger which required sutures.

Employee experienced pain in his right knee while walking to his locker 5 minutes prior to the end of his shift. Diagnosis was a sprained Knee MCL.

Passenger was entrapped in Pre-heater Tower elevator due to governor safety being tripped. Person was extracted with no injury at 8:00 PM that evening.

Passengers in the preheater tower elevator could not open the inner door to exit the elevator on the second floor. The contact switch on the first floor door prevented the inner door on the car from opening.

The door switch on the 5th floor of the passenger elevator failed. Two employees where in the elevator at the time and the car stopped 18"above the 4th floor landing. The outer doors would not open, MSHA was notified at 1:00am of the situation and Murphy Elevator Company was called. The employees where removed from the elevator at 2:30am. No injuries resulted from this event.

While driving a golf cart to retrieve a sample. The cart hit a yellow guard pole by the kiln walkway support beam. The cart came to a complete stop and his chest hit the steering wheel of the cart.

Employee was waiting at the time clock to punch out at the end of his shift. He noticed he had left the south warehouse lights on and went to turn them off. Employee did not put his PPE back on and took a shortcut under the frame work of a walkway instead of walking around and struck his head on a beam. It required two staples to close the wound.

The rolls where adjusted to far out and the chute had become plugged. There was no external or internal damage. To correct the problem the rolls where adjusted and the chute will be monitored to insure the chute does not plug after the rolls are adjusted.

Employee was removing a strut pin from a Cat 773B Haul truck. He used a sledge hammer to strike a pin driver and the pin driver chipped on the end. The chip hit his left forehead. He was taken to the hospital and the chip was removed and received stitches,

While removeing a wheelbarrow for the tower elevator employee lifted and turned at the same time. He strained his lower back.

Employee was assisting in installing ball mill head liners and the liner shifted. His left hand index finger was caught and resulted in the pad of his finger being ripped open.

While re-stacking 94lb type 1 cement bags employee felt of pop in his left shoulder. Employee has not missed any days and can perform his job duty's with lifting restrictions.

Employee was leaning out of position to remove a sprocket. Stretching and felt something pull in his right shoulder blade area of his back. Was not reported to the company until 06/10/2013 at 3:30pm. Employee was placed on light duty until further notice.

Employee was bitten by a bug on the face and the area began to swell. He was taken to the doctor and given a shot of cortisone.

At the end of the work day the employ said he felt some pain in abdomen, like gas. He went home and pain got worse. When he came in next day he repoted it. He was later diagnosed with a hernia. He has no idea when, were, or how the injury occured.

Lifting 4 wheel cart weighing under 35lbs over a 15" wall in doorway with another employee. when lowering cart to the ground he was extended out over the small wall and hurt lower back.

Employee A hit the end of a chisel with the hammer and a small piece of the chisel fractured off upon impact. The small piece hit Employee A in the left arm. The wound quickly stopped bleeding and he was taken to Urgent care. At this point it was not reportable. The employee had a follow up and fragment was removed and wound stitched.

Employee was cutting a thick rubber hose with a pocket knife. The knife caught a metal stiffener on the inside of the hose. The locking mechanism faulted and the blade came back and cut his finger. The employee went to the doctor and received 5 stitches. He returned to work with the doctor giving him restrictions based on his pain tolerance.

Employee was installing a new burner pipe. While positioning the support arm, he placed his right middle finger in bolt hole to check alignment, when the pipe shifted and lacerated his finger

A fire lasting more than 30 minutes occurred in a lateral flexible rubber pipe when a power failure occurred and the coal mill exhauster fan could not be restarted.

Employee was welding anchors in the cooler and some hot material broke free above him striking him in the head and and neck.

Employee was descending the pre-heater stairs and prior to reaching the ground level, felt a pull and pop in his calf.

The employee was laying next to a large motor to obtain a bolt measurement to ensure he had the appropriate socket and was required to scrape off some build up cement dust. After scraping off the dust, he sat up and felt some dust in his left eye. He received some small eye scratches.

Employee was using an air lance to blow cold cement down an air slide. Air slide was not blocked but had cold dust laying on the air slide cloth. A puff back occurred and cement dust went over the top of the employee's safety glasses.

Injured EE had degreaser sprayed into his eye by another employee, due to lack of communication.

EE was using a one inch imact gun in the removal of finish mill liners in the 1st compartment of the mill. Some small balls came back into the first compartment. 7/8" diameter. As he was lifting the imact gun the EE slipped on the balls, striking his left knee.

Injured employee was shoveling clinker dust off of kiln pier #3 when a gust of wind blew dust into his right eye.

Injured employee had punched out and was doing to his car parked behind the maintenenace break room. After exiting the break room he walked into a ball hitch ont he back of a pick-up truck, he stumbled about 9 ft and struck his face on the procurement office air contitioner unit, ground mounted.

EE had placed his right index finger into the opening of a 3/4" air operated ball valve to check its position. He manually operated the cylonoide valve allowing air to change the ball valve position with his left hand. His left index finger was amputated just behind the fingernail.

Employee & co-worker had gone to the 7th floor of the preheater to close access door, to the gas inlet duct to stage III cyclone. The door hinges were stiff & hard to operate. They had to force the door closed. The door let loose pinching the EE's right ring finger.

EE reported that she returned from her bathroom break & attempted to re-enter the articulated truck. She reported that she doesn't remember every detail, but reported that she remembers climbing the ladder to re-enter the truck, & somehow lost her grip with hands & fell. The reported fall distance was approx 65-74.5". She reported that she fell & landed on buttocks & tailbone.

Two employees were removing clinker build-up between two storage bins. The material was shoveled onto 4" square opening grating and a 20 lb jack hammer was being used to force the material through the grating openings. The injured worker had picked up the jack hammer and stepped backwards, twisting his left ankle.

Employee using hand tool, small handheld grinder. He was grinding on part of a metal handrail. Grinding wheel got pinched/caught in between piping, then "popped" out of piping which then it knocked into the bottom of employees faceshield causing faceshield to partially flip up. The grinder hit employee on lip causing a slight laceration.

Putting a quegon bolt on f49a screw when grit blew into eye from the draft in the hopper. required prescription antibiotic eye drops.

Grinding on a hole in a shroud in the raw mill, he got dust or dirt in his right eye. Flushed eye with saline solution. Eye didn't improve in two days so he went to urgent care. Doctor applied prescription eye drops. Employee was wearing safety glasses and grinding shield.

EMPLOYEE DUCKED DOWN TO WALK UNDERNEATH A CATWALK & STOOD UP BEFORE HE WAS COMPLETELY CLEAR OF THE CATWALK. HARDHAT MADE CONTACT WITH CATWALK ABOVE, JAMMING HIS HEAD & NECK. FILLED OUT A FIRST AID REPORT. THE INJURY BECAME PROGRESSIVELY WORSE. EE WENT TO THE DR. ON 9/30/05. AFTER A FOLLOW UP VISIT, PHYSICAL THERAPY WAS PRESCRIBED.

CLEANING PREHEATER WITH 12' WATER BLASTER. EE WAS BENT OVER WITH HEAD COCKED TO ONE SIDE WHEN HOT MATERIAL STRUCK FACE SHIELD AND KNOCKED IT OFF, ALONG WITH HIS HARD HAT. HOT DUST ENTERED LEFT EYE. EE WAS TREATED AT URGENT CARE, WITH ADDITIONAL CARE BY OPTHAMOLOGIST.

DURING HEAVY RAIN, EE WAS ADJUSTING TRACKING ON L201 ELEVATOR. BECAUSE OF A CEMENT PILE ON ONE SIDE, EE TRIED TO REMOVE A GUARD FROM THE OPPOSITE SIDE. BECAUSE OF THE SLIPPERY CONDITIONS AND HAVING TO REACH OUT TOO FAR, EE SLIPPED AND LANDED ON HIS BACK. WENT TO DOCTOR ON 9/2/05. REQUIRES 6 FOLLOW UP VISITS.

EE AND ANOTHER EE WERE REMOVING A BENT SIGN POST. LOADED SING ON FORKS OF FORKLIGT. SIGN HAD A PIECE OF METAL WELDED TO THE BOTTOM END, CREATING A WEIGHT OFFSET. SIGN WAS NOT SECURED PROPERLY BEFORE LIFTING AND SWUNG UP STRIKING EE ON THE RIGHT EAR, REQUIRING 3 STITCHES

WHILE USING CUTTING TOCH HOT MATERIAL LENDED ON TABLE WHERE HE WAS RESTING HIS ARM THE STEADY THE TORCH. IT BURNED THRU HIS CLOTHING CAUSING 2ND DEGREE BURNS TO ELBOW. WENT TO URGENT CARE WHER E THEY CUT AWAY SKIN AND APPLIED OINTMENT AND BAANDAGES.

WHILE CARRYING A BUCKET OF OIL HE SLIPPED ON STAIRS WHICH WERE WET FROM MELTED SNOW. HE TWISTED AS HE FELL AND HIT HIS RIGHT HIP. HE CONTINUED TO WORK. THE NEXT MORNING HE HAD A KNOT ON HIS HI P WHICH WAS DIAGNOSED AS A HERNIA. HE DID NOT MISS ANY WORK UNTIL SURGERY ON 2/17/04.

EE WAS REACHING FOR A RAW MILL PRODUCT BOTTLE AND KNOCKED A KILN FEED JAR ONTO THE CONCRETE FLOOR. THE LID CAME OFF RELEASING DUST INTO HIS EYES. HE RINSED HIS EYES AT THE EYEWASH STATION, A ND AFTER HIS SHIFT, HE WAS DRIVEN TO THE HOSPITAL. THEY FLUSHED HIS EYES AGAIN AND WAS GIVEN ANTIBIOTIC DROPS.

EMPLOYEES WERE INSTALLING DOOR ON FINISH MILL COMPARTMENT USING OVERHEAD CRANE AND 1/2 INCH CABLE WITH 3/4 TON CHAIN FALL TO PLACE DOOR. CABLE BROKE WHILE SEATING THE DOOR AND THE CABLE WHIPPE D AROUND STRIKING HIS RIGHT HAND.

THE INJ EE STUCK HIS RIGHT HAND THRU A 6" INSPECTION PORTAL LOCATED ABOVE A SLAT FEEDER TO DISLODGE BRIDGED OVER COAL. WHEN HE DISLODGED THE COAL A LARGE FLAT ROCK FELL WITH THE COAL & STRUCK HIS RIGHT INDEX FINGER. THE FINGER WAS CUT & 4 STITCHES WERE NECESSARY. THE TIP OF HIS RIGHT INDEX FINGER ALSO REC'D A HAIRLINE FRACTURE

EMPLOYEE WAS MEASURING THE HEIGHT OF THE HIGHWALL IN FIERSTEIN QUARRY FOR TEST DRILLING. THE WEIGHT ON THE END OF THE TAPE MEASURE GOT STUCK. THE EMPLOYEE WENT TO THE EDGE OF THE HIGHWALL TO F REE THE TAPE MEASURE. THE SURFACE WHERE HE WAS STANDING GAVE WAY AND HE FELL ABOUT 15'. THE EMPLOYEE WAS NOT WEARING FALL PROTECTION.

EE PULLING 20 LB KEROSENE HEATER ON WHEELS ACROSS ROAD (INSIDE PLANT) THROUGH MUD, SNOW & ICE. HE SLIPPED TWISTING HIS RIGHT SIDE CAUSING PAIN IN RIB AREA ON HIS RIGHT SIDE.

THE INJURED EMPLOYEE AND ANOTHER EE HAD JACKED A BROKEN BEARING FOR F166 DRAG BACK IN PLACE. THE OTHER EE HAD GONE TO GET A BLOCK OF WOOD TO HOLD THE BEARING IN PLACE. A PIECE OF METAL THAT TH EY HAD JACKED AGAINST CAME OUT AND STRUCK EE IN THE FACE.

THE INJURED EMPLOYEE WAS TRYING TO UNPLUG THE BLOW BY HOSES ON #2 PACKING MACHINE. HE BECAME FRUSTRATED AND KICKED THE PLUGGED HOSE FOR #3 SPOUT, WHEN HE PULLED HIS LEG BACK HIS RIGHT LEG HIT THE BOTTOM OF #3 SPOUT AND PUNCTURED IT NEXT TO HIS KNEECAP (LEFT SIDE OF KNEECAP).

EMPLOYEE WAS CONSTRUCTING AND INSTALLING PLYWOOD FORMS FOR A CASTABLE REFRACTORY POUR ON THE NOSE OF THE KILN. WHILE BENT OVER AND TWISTING HE FELT THAT HE STRAINED HIS LOWER BACK.

THE DUMP TRUCK WAS BEING LOADED WITH SHOT ROCK &WHEN IT TURNED THE BUCKET OVER TO DUMP INTO THE TRUCK BED THE ROCK BOUNCED OFF THE CAB SHIELD & ROLLED OVER ONTO THE CAB OF THE TRUCK. AS THE RO CK FELL THE CAB ROOF BEGAN TO CAVE SLIGHTLY CAUSING THE DRIVER TO QUICKLY MOVE TO THE LEFT TO AVOID BEING HARMED, POSSIBLY AGGRAVATING A PREVIOUS INJURY (HE REPORTED NUMBNESS A FEW DAYS LATER

EE REPORTED INJURY AT 3:30 PM ON 6/19/01. HE CALLED WORK & SAID THAT HE MIGHT HAVE PULLED A MUSCLE OR SUFFERED A SMALL HERNIA FROM LIFTING THE ALKALI LOADING PLATFORM INTO THE RAISED POSITION. HE EXPLAINED THAT HE ONLY FELT A LITTLE PAIN IN THE GROIN AREA AT THE TIME. HE WOKE UP AT 2:30 PM AND WAS FEELING MUCH WORSE.

CO-WORKER WAS TRAVELING ON THE ROADWAY & SAW #15 TRUCK SITTING IN A WATER POCKET, ABOUT 15' IN THE WATER, WEST OF THE ROADWAY. ANOTHER CO-WORKER NOTICED THE TRUCK WAS STILL RUNNING. AS HE BAC KED UP HE SAW SOMEONE SLUMPED OVER ON THE FRONT SEAT. HE CHECKED FOR PULSE & THERE WAS NONE. CPR WAS STARTED. IT IS BELIEVED HE STOPPED & TRIED TO PUT TRUCK IN PARK. FATAL HEART ATTACK.

EE HAD BEEN PULLING BAGS ON #2 CEMENT PACKING MACHINE A BAG GOT TWISTED ON THE 2ND BELT CONVEYOR & CAUSED A JAM UP. WHEN THE EE LIFTED THE JAMMED BAGS TO CLEAR THE BELT CONVEYOR HE FELT A TUGGING INSIDE HIS LOWER ABDOMEN. ACCIDENT WASNOT REPORTED UNTIL 4/18/01 LOST TIME ON 4/20/01

THE INJURED EE AND THE WITNESS WERE REMOVING AN OBSTRUCTION INT HE DISCHARGE CHUTE FROM E126 ELEVATOR TO THE ALKALI TANK. THE END OF THE AIRLANCE THEY WERE USING WAS PLUGGED AND BROKE LOOSE, B LOWING ALKALI DUST OUT OF THE INSPECTION HOLE THEY WERE WORKING IN. THE DUST ENTERED THE INJURED EE LEFT EYE. BOTH EE WERE WEARING SAGETY GLASSES ONLY.

INJURED EMPLOYEE WAS LIFTING A 75 LB LINER PLATEINTO POSITION INSIDE THE PRIMARY CRUSHER. THE WITNESS USING A PINCH BAR TO ALIGN THE BOLT HOLES TO SECURE THE LINER. THE INJURED DID NOT REPORT THE ACCIDENT UNTIL 2/5/01 & MADE AN INITIAL DOCTOR VIST ON 2/6/01. THE COMPANY WAS UNAWARE OF ANY FURTHER VISITS UNTIL 2/21/01 WHICH MADE THIS INJURY REPORTABLE.

EE AND TWO OTHER WORKERS WERE TRYING TO POSITION A 2' X 4' X 1/2" STEEL PLATE INTO A POSITION SO THAT IT COULD BE INSTALLED WHILE DOING SO HE HEARD A POP IN HIS RIGHT SHOULDER. EE CONTINUED WO RKING UNTIL 6-12. INJURY BECAME REPORTABLE ON THAT DATE.