BYK USA LLC Plants & Pits Metal/Non-Metal

Plant Electrician was responding to a pump outage and was walking to the area when they took a step off step onto a concrete walkway and slipped. The employee fell backwards and fell against the corner of the fiberglass step, breaking one rib.

Operator was standing on third rung of 6' step ladder while attempting to open a steam valve with a pipe wrench. They were using one hand on wrench and holding onto an adjacent valve with other hand when valve broke loose and they fell backwards off ladder onto concrete floor. Bruised heel of left foot and lower back. X-rays did not show any fractures.

A water hose used to fill a small tank slipped out of a flange and was spraying water outside the tank. A Plant Operator climbed up a small step ladder to retrieve the hose when the Operator slipped from the 3rd rung. Operator's left knee landed on a metal floor drain cover, resulting in a fractured patella.

Operator was walking up a set of stairs when the sole of their boot detached from the boot. The loose sole caught the stair and Operator tripped and their knee hit the metal grating landing, cutting their knee. Operator received four stitches.

Production Operator was attempting to clean a rotary valve and failed to properly isolate and lockout the electrical disconnect. The Operator inserted EE's right hand into the running rotary valve, amputating the middle and distal phalanges on EE's index and middle fingers, and partially amputating the distal phalange on EE's thumb.

Maintenance Mechanic was replacing bearings in the mill. EE and co-worker completed task and returned to Maintenance Shop when employee started feeling light-headed, nauseous and experiencing blurred vision. Reported to an air conditioned area and attempted to cool down. Temps were over 100F. Task only took 35 minutes to complete.

Plant Operator was carrying an empty wooden pallet to place on a stack of empty pallets when they lost their grip. The load shifted and the Operator attempted to catch the pallet, dislocating their shoulder.

Employee was attempting to disconnect two unloading hoses, which were stuck. Employee forced hoses apart, and one end swung up and struck employee above upper lip, causing a very small cut. Employee suffered a small cut on inner lip when contacting teeth. The inner lip cut became infected several days later and required antibiotic treatment.

Plant Operator was cleaning up a clay and slurry spill, primarily shoveling the material, when Operator strained lower right back.

Employee was assisting in removal of sump pump. 1 bolt was not identified and removed from pump base. Crane lifted causing bolt to sheer. Employees thumb caught between pump and adjacent blind flange resulting in thumb fracture

Operator was changing belt on belt press, and had to pull on belt at an awkward angle to feed the belt thru the rollers, when EE suffered a sprained muscle in middle back.

Plant Operator was attempting to shovel material out of a weigh kettle, and pinched a nerve in lower left back when material broke loose and jerked back. On 7/8/19, physician prescribed light duty.

Mechanic exited EE's job cart and sprained EE's left ankle when stepping onto uneven surface. Employee released to full duties, but continued to experience symptoms. No other accidents after to aggravate the original sprain. Physician eventually requested an MRI and found some calcium deposits in ankle. Surgery was performed on 06/17/2019 to remove the deposits.

Shift Supervisor was walking outdoors on a paved roadway when left foot slipped on a thin layer of wet clay dust. The employee rolled ankle and fell onto backside. The employee was unable to stand and was transported to the hospital, where EE was diagnosed with a fractured ankle. Weather condition was very fine misty rain.

Operator was dismounting from a Komatsu WA200 front end loader, when a foot slipped off the bottom step, twisting the left ankle.

Plant Operator was walking up metal stairs when right foot slipped off a stair tread. EE leg dropped suddenly and knee hit the front edge of the stair, cutting right knee. Five stitched were needed to treat the wound.

A Plant Operator removed a rotary valve cover to inspect for clay buildup. The Operator failed to isolate and lockout power to the R.V. prior to removing the cover, per company rules. The Operator placed left hand in the chute to remove some clay, and ee middle and ring fingers came in contact with the R.V. blades, amputating the distal phelanges on both fingers.

Employee just finished servicing a piece of equipment and was walking down a small set of steps (3 steps) when their foot slipped, and they fell onto concrete floor on their backside. Employee extended both arms/hands beneath them to break the fall, spraining both wrists.

Driller's Helper was lifting a core barrel off a storage rack when they pulled a muscle in their lower back.

Plant Operator reached under a vendor-owned tank trailer that was being offloaded to pick up an empty paper bag that had fallen to the ground. After retrieving the bag, the Operator raised up and arm contacted a sharp edge on the trailer's fender, cutting the arm above the left elbow. Operator received five stitches to close the wound.

Two Maintenance mechanics were using an overhead crane to lower a mill down onto some metal cribbing for rebuild, when the lifting bolts failed and the mill fell approximately two feet to the Shop floor. The mill struck one of the mechanic's left forearm, resulting in swollen and bruised forearm.

Employee claims arterial damage in right hand from using index and middle fingers to extend a safety knife blade to cut open paper bags. Injury was first reported as occurring off the job when playing sports, but a work claim was later submitted on 5/31/16. Mine Operator disputes the injury is work-related and has requested an insurance investigation.

Operator was carrying a plastic shroud to wrap a finished 1000 lb big bag of product. The Operator stepped on the bottom edge of the shroud and fell face first to the same level. The operator put EE's hands out to break the fall and EE's right hand contacted the concrete floor, resulting in a laceration of the palm and a fracture of the 5th metacarpal bone.

An employee was dismantling a storage rack in the plant when he slipped and fell to the same level while attempting to pull one of the rack rails loose. The rack rail landed on the employee's hand. Employee was taken to local ER for evaluation and it was determined he suffered a bruise to the back of his left hand.

Employee used an overhead hoist to lower an Alfa Laval bowl onto a pallet to transfer it to the Maintenance Shop for repairs. After placing bowl on pallet, the employee attempted to position the bowl in the center of the pallet by manually pulling the bowl, when he felt a slight pain in the lower abdomen area. Employee was diagnosed with a lower abdomen strain/ possible hernia.

Operator was walking up steps on Southwest corner of the SPU plate press when his right foot slipped off first step, causing his right shoulder to strike the press frame. The physical contact with the frame of the press caused a deep bruise on the right arm below the shoulder.

Operator was performing regular job duties when back became very sore. A week ago operator had been cleaning press plates, heavy lifting, back became sore. Normal activity aggravated the strain.

Employee tripped over a shovel, falling on left side of face and right shoulder, resulting in contusions.

Operator was climbing downstairs and slipped. When he slipped he reached out with his left arm to catch his balance resulting in a strain to the shoulder muscle.

Employee was walking between plants, slipped on a wet surface and fell, injuring lower back. Was diagnosed as lower back strain.

Operator slipped on a mine residue onto the floor and sprained his right ankle.

Operator was cleaning spray bar. Removed hose clamp while hose was still under pressure causing the hose to break free and strike operator in the chest.

Employee was visually verifying tank level by standing on platform above tank turning head downwards. When employee raised head to normal position felt a pop in neck and was unable to turn head to side.

Employee was walking from lab to break room. Tripped on uneven surface. Face came in contact with guard rail. Busted lip and broken front tooth.

After performing routine maintenance and starting process, plant operator noticed slurry leak from MG pressure sensor fitting. Operator attempted to reseat sensor and tighten clamp when sensor blew off, spraying hot slurry on operator's hands, wrists, and face (cheeks).

Employee was carrying load of supplies down outside steps using hand rail as a base. At foot of stairs hand rail ended and employee fell forward from last two steps, landing on sidewalk.

Individual was placing lightweight plastic conical cleaners (approximately 2oz. each) in a sweco screen when he experienced severe back spasms. Activity required slight bending at waist to replace cleaners. Employee was transported to hospital by ambulance for evaluation. After evaluation, was placed on restricted duty.

Operator was cleaning mill screen when a small piece of clay entered eye. Eye flushed repeatedly but operator was not sure if object was removed. Employee taken to local emergency room for examination. Nothing was identified to be in his eye during emergency room examination and no injury resulted. Treating physician prescribed antibiotics. Employee did not fill prescription.

Upon restarting Flash Dryer circuit a dust explosion occurred around the dryer cage mill. Pressure wave activated blow-out panels on dust collector whizzer and shut down plant. Personnel activated evacuation alarms and all personnel evacuated to designated locations. No personnel were injured and the accident resulted in minimal damage to plant equipment. MSHA notified at 12:39am.

The employee was shoveling material at the Fluid Bed blend station and felt a pinch in his left shoulder while lifting a shovel of material (approximately 15 lbs.)to put into the hopper. He was diagnosed with a strained left shoulder and placed on restricted duty.

Employee was shoveling clay up from under the dryer and hit his head on a pipe causing him to strain his neck

Employee was lifting 2 bags at a time in bent position - 1 bag began to fall and employee turned sharply to catch bag from falling which caused him to strain his back in the process.

Employee was changing out a heavy extruder plate - when he went to lift it he felt something pop in his lower back causing a strain

The operator was unplugging the bagger when it cleared material and started to pour out of bagger spout. When the operator started to put the tube back on the nozzle some material went into the operator's face. The operator was wearing PPE - a dust mask. The operator did not cut off the blower.

Employee was operating forklift when he turned the corner too sharp and his left foot got pinched between the forklift and Quadromill support beam. Left foot suffered a laceration on the side of the foot extending around the small toe.

The employee felt a pull in his lower back when he moved a bag saddle.

The employee was stepping off a top catwalk to close the gate behind him when his foot slipped off the railing, causing him to fall thru the handrail and hit the concrete floor.

Employee was replacing paddles on 400 HP Pug Mill Assembly. His co-worker was rotating the shaft. The employee's left hand was placed on the lip of the shaft housing & as the shaft rotated, the employee's left hand pinky finger got pinched b/w rotating leading edge of the spiral screw conveyor & shaft housing.

Employee became overheated when shoveling clay into a dumpter - was taken to ER and received an IV for dehydration - employee was released to return to work that evening

When employee was exiting the IT Specialist's cubicle, she tripped on the strap of a lunch bag that was on the floor and was able to regain her balance without falling. However, she did sustain a sprain to the other foot used to break her fall (right foot injured - sprained)

The employee was clocking out at the end of his shift when he stepped off the curb and injured his ankle.

This employee reported the injury on 11/29/08 but did not require medical attention until 01/06/09. His doctor prescribed physical therapy on 01/20/09. But physical therapy was not approved until 02/05/09 by the workers comp adjuster.

The employee experienced pain after lifting a 5 pound bucket. The employee was diagnosed with a lumbar sprain to his lower back. On 9/23/08, the doctor prescribed physical therapy which will commence on 9/26/08; as a result, this accident becomes a reportable effective 9/26/08.

Employee was transporting parts from plant to vendor; trailer had a flat on Hwy 90A. While the employee was under the trailer positioning the jack, he felt pain in right side of neck. Subsequent doctor visits led to prescribed physical therapy which began on 7/22/08.

The employee was assisting in setting the XRD cabinet on base of diffraction unit. His fingers got caught inbetween the top unit and the base unit as it was released and his fingertip was lacerated.

EE was cutting a 1/2" scal-tite with a ban saw. The blade went through the metal and cut his finger. (middle finger, left hand).

Employee was using electric chain hoist to lift 1-ton bag that had fallen over. He ran the chain through the straps and hooked it above the block causing hoist to lift unevenly. Employee stuck his hand between chain and block and was caught when the tension shifted.

EMPLOYEE WAS ENGAGED IN HIS REGULAR JOB STACKING 50 LB BAGS ON PALLET. HE PLACED A BAG ON PALLET, FELT A POP IN HIS BACK AND SOME PAIN. HE DID NOT THINK IT WAS ANYTHING TO WORRY ABOUT AND FINISHED HIS SHIFT. HE REPORTED THE INCIDENT ABOUT A HALF-HOUR AFTER IT OCCURRED BUT DID NOT DECIDE TO SEE A DOCTOR UNTIL MONDAY, DEC 12TH.

Employee was walking from the lab along a wet sidewalk. His feet slipped from under him, causing him to fall on his tailbone.

OPERATOR WAS TRANSPORTING PALLET OF MATERIAL. AFTER COMPLETING A 90 DEGREE TURN, HE ACCELERATED. FORKLIFT WHEELS WERE NOT COMPLETELY STRAIGHT CAUSING FORKLIFT TO SLIDE SIDEWAYS INTO EQUIPMENT WALKWAY. EMPLOYEE'S HAND SLIPPED FROM GEARSHIFT LEVER AND WAS PINNED BETWEEN WALKWAY STRUCTURE & FORKLIFT ROPS SUPPORT CAUSING A FRACTURE OF BONES.

EE WAS WORKING IN SPECIALTY PRODUCTS DEPT. WHEN A PIECE OF METAL FLEW INTO HIS EYE. HE WAS WEARING SAFETY GLASSES.

EMPLOYEE WAS RUNNING ACETATE GEL TESTS. HE TAPPED JAR ON THE COUNTER TO RELEASE AIR BUBBLES AND THE GEL FLEW INTO RIGHT EYE. EMPLOYEE REMOVED SAFETY GLASSES WHEN RUNNING TESTS BECAUSE THEY WERE UNCOMFORTABLE TO WEAR ALONG WITH RESPIRATOR.

EE WAS USING HAND HELD KNIFE & SHARPENING TOOL IMPROPERLY. HE WAS NOT KEEPING HIS EYES ON TASK, SLASHING KNIFE ACROSS THE BACK OF HIS HAND. CUT FOREFINGER & THUMB OF LEFT HAND NEEDING SUTURES.

WHILE PERFORMING TROUBLESHOOTING PROCEDURES ON FLUID BED DRYER, ORGANO DUST SUSPENDED IN FILTER SOCK, DISLODGED, CAUSING A DUST CLOUD OF PROPER CONCENTRATION TO SUSTAIN A FIRE. THE DUST CLOUD WAS IGNITED WHEN IT TRAVELED INTO THE COMBUSTION CHAMBER AND CAME IN CONTACT WITH SMOLDERING ORGANO CLAY THAT HAD BEEN HEATED BY COMBUSTION BURNER FLAME. A VALVE BETWEEN THE COMB.CHAMBER AND

WHILE PERFORMING TROUBLESHOOTING PROCEDURES ON FLUID BED DRYER, ORGANO DUST SUSPENDED IN THE FILTER SOCK, DISLODGED, CAUSING A DUST CLOUD OF PROPER CONCENTRATION TO SUSTAIN A FIRE. THE DUST CL OUD WAS IGNITED WHEN IT TRAVELED INTO THE COMBUSTION CHAMBER AND CAME IN CONTACT WITH SMOLDERING ORGANO CLAY THAT HAD BEEN HEATED BY COMBUTION BURNER FLAME. A VALVE BETWEEN THE COMBUSTION CHA

WHILE PERFORMING TROUBLESHOOTING PROCEDURES ON FLUID BED DRYER, ORGANO DUST SUSPENDED IN THE FILTER SOCK, DISLODGED, CAUSING A DUST CLOUD OF PROPER CONCENTRATION TO SUSTAIN FIRE. THE DUST CLOU D WAS IGNITED WHEN IT TRAVELED INTO THE COMBUSTION CHAMBER AND CAME IN CONTACT WITH SMOLDERING ORGANO CLAY THAT HAD BEEN HEATED BY COMBUSTION BURNER FLAME.A VALVE BETWEEN THE CHAMBER AND DRYE

WHILE PERFORMING TROUBLESHOOTING PROCEDURES ON FLUID BED DRYER, ORGANO DUST SUSPENDED IN THE FILTER SOCK, DISLODGED, CAUSING A DUST CLOUD OF PROPER CONCENTRATION TO SUSTAIN A FIRE. THE DUST CL OUD WAS IGNITED WHEN IT TRAVELED INTO THE COMBUSTION CHAMBER AND CAME IN CONTACT WITH SMOLDERING ORGANO CLAY THAT HAD BEEN HEATED BY COMBUSTION BURNER FLAME. A VALVE BETWEEN THE COMBUSTION CH

WHILE PERFORMING TROUBLESHOOTING PROCEDURES ON FLUID BED DRYER, ORGANO DUST SUSPENDE IN FILTER SOCK, DISLODGED, CAUSING A DUST CLOUD OF PROPER CONCENTRATION TO SUSTAIN A FIRE. THE DUST CLOUD W AS IGNITED WHEN IT TRAVELED INTO THE COMBUSTION CHAMBER AND CAME IN CONTACT WITH SMOLDERING ORGANO CLAY THAT HAD BEEN HEATED BY COMBUSTION BURNER FLAME. A VALVE BETWN. COMBUSTION CHAMBER& DRY

DARKNESS, LIGHTS IN AREA WERE NOT TURNED ON BY EE. EE WALKING BACKWARDS, NOT WATCHING WHERE GOING.

WASHING DOWN EVAPORATOR WITH HIGH PRESSURE HOSE WHEN AMINE CHEMICAL SPLASHED IN LEFT EYE.