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The employee was attempting to calibrate the TA duct damper with a manual handle. While operating the gate with the LCB, the damper was moved to a fully open position. The employee applied firm pressure to move the manual operation handle, the counterweight pulled down, and the handle began spinning rapidly in an uncontrollable manner with heavy force.
EE stated they were collecting quality control samples from the stage 6 sample port when they were splashed by hot material on their left hand, burning through the glove.
The mechanic was climbing out of a small man door after making repairs to the chute when the angle grinder they were using inadvertently turned on, cutting the employee's arm. The employee was taken to the hospital for treatment and returned to work today. Installing another door for safer access to the chute.
Employee was clearing the opening of a vertical discharge pipe for the Cement Kiln Dust (CKD). The discharge of previous ckd had prevented the flow of discharge and had created a back-up. Employee used a rake to remove blockage at which point the material quickly flowed from pipe causing ckd to go airborne dusting the employee. The employee inhaled the material.
The employee while repairing an excavator bucket, after finishing a welding EE proceeded to clean it with a metal wire brush attached to an air grinder, a piece of metal ricochet inside the employee welding helmet used as face shield and got in EE's left eye, welding helmet had a crack from where is presumed the foreign body may entered
Employee was notching skirting for bolts while kneeling and cutting toward self received a laceration requiring stitches.
While operating the loader, the operator was on the way to the stockpile to get a bucket of material, the teeth of the bucket dug into the ground causing the loader to stop suddenly, projecting the operator into the windshield, cracking the windshield and hurting the operator's forehead and neck.
High heat warning for Yavapai county last ten days. Employee had been fasting for 24 hours prior contributed to this event. Employee received two staple to close a wound on the head.
Employee was working in raw mill duct with vac tube. EE was on hands and knees and turned around inside the duct which caused retractable lifeline cable wrapped around ankle. When EE crawled forward caused EE to fall forward impacting one rib on left side from raised metal lip around door entry. Hairline fracture diagnosis.
The worker and a coworker were unloading an empty plastic tote from a pickup truck. Doing that, the worker felt a pull in left biceps. The worker got first aid and continued working thinking that was a simple contraction due to cold weather. The worker was still in discomfort and after an MRI scan, EE was diagnosed with a disruption of the distal bicep on 2/9/24, requiring surgery.
The employee suffered a grand mal seizure (employee has history of grand mal seizures) that caused EE to fall down a set of steel steps, hitting EE's head and requiring stitches.
Maintenance Mechanics (R) hand was caught between the flange of a level indicator pipe for a knife gate and the housing of the Raw Mill Roll Press during maintenance activities to repair the knife gate. The equipment was locked out but the gate was not blocked/secured to prevent movement.
The employee was pulling on an oil fill hose to wrap it up and hit elbow against a concrete block.
Employee was working on the burn deck, trying to close the burn pipe door on the kiln, when a gust of wind blew fiberglass insulation material into the employees right eye. The employee was taken to an ophthalmologist, given a prescription antibiotic and was told to be off-work for one day.
On April 3rd, 2023. Employee was working on the second floor of the preheat tower installing conduit and wiring for the new kiln gas analyzer. The wind picked up around mid-morning suspending a lot of fugitive dust and debris making it airborne. The employee's eyes became irritated from the airborne particles.
Medical determination that employee suffered occupational illness (asthma) from exposure to hazardous gases during work and subsequent rescue activities of another employee from the Plant's Coal Silo.
Employee was inside the coal silo, conducting clean-up duties with another employee, when they became unconscious due to elevated CO levels.
During the process of cleaning up after maintenance work on the Crusher, the employee hoisted a tool bucket over EE's shoulder and then attempted to lift the welder, in order to carry everything out of the Crusher area at one time. The employee felt the pain immediately in their ribcage area.
NO PARTICULAR EVENT OR INCIDENT AT WORK CAUSED EE'S KNEE TO START HURTING HOWEVER EE HAD BEEN DOING A FAIR AMOUNT OF KNEELING AND CROUCHING PERFORMING GROUND CHECK INSPECTIONS AND THE FOLLOWING DAY EE WOKE UP WITH PAINFUL SWOLLEN KNEE INFECTED (SEPTIC BURSITIS)
SEPARATING GEARBOX FROM MOUNTING TO MOTOR GEARBOX MOUNT. FORKLIFT WAS BEING USED TO SUPPORT DURING DISASSEMBLY, WHEN GEARBOX WAS UNBOLTED FROM MOUNT THE FRAME KICKED BACK STRIKING EMPLOYEE KNOCKING EMPLOYEE UP AGAINST FORKS ON THE FORKLIFT CAUSING BRUISING TO STOMACH
PERSONNEL ATTEMPTED TO USE SKID STEER TO MOVE COAL OVERSIZED TIPSTER INTO LOAD & HAUL POSITION. OPERATOR LOWERED THE BUCKET ONTO THE TIPSTER WITHOUT SEEING PARTNERS HAND IN A PINCH SQUEEZE BETWEEN THE TWO RESULTING IN A PARTIALLY CRUSHED RIGHT PINKY FINGER.
Employees were attempting to level the base of a scaffold. While trying to level the base, concrete clinker material of various sizes broke loose from the sides of the cyclone. A piece of the material struck the employee on the left pinky finger crushing it between the clinker and scaffold material. The employee underwent surgery where pins were placed in EE's finger.
After turning off the loaded bucket elevator the back stop failed and the bucket elevator overspeed backwards which overspeed the fluid coupling causing it to explode. Pieces from the fluid coupling struck EE in the back. The pieces broke EE's ribs and ruptured EE's spleen and bruises.
Clinker cooler baghouse compartment #2. Inspecting bags for damage. Entered top of #2 compartment, Removed #2 compartment hatch cover. Stacked the hatch cover on top of the adjacent hatch covers. Crossed the top of the stacked hatch covers stepping off landed on right leg, slightly off balance and harder than expected impact, injuring back.
Worker was cutting conveyor belt with box cutter style knife & pulled knife into calf of right leg causing a laceration
Secured cable by wrapping control rope around hand to aid in controlling whip once cable cut for West Kiln Feed bucket elevator. Although the cable was restrained it was not tied to the point of connection allowing a distance of approx. 8" to 10" drop. Pulled hands, hurting right hand.
Replacing air cannon from the firing head to lower down to scaffolding. While lowering air cannon weighed more than thought pulling a muscle straining right shoulder.
Employee was installing steel members with rigging without using proper procedures at new silo, causing a hook to slip and impact employee. Employee was taken to the hospital, X-ray determined a fractured jaw. Employee was not trained in proper rigging procedures.
opening door to A building, Door suddenly shut catching left index finger on the hinge
Gear box of shaker screen at crusher system, loosening bolts with torque wrench when middle left hand finger got between wrench and bolt pinching finger causing laceration.
Cutting a steel plate and on final cut it dropped towards the ground and contacted EE's knee.
WHILE PINNING AND PLATING THE BAUXITE WEIGH FEEDER, WAS SWINGING SLEDGE HAMMER AND IT GLANCED OFF AND DOWN SMASHING EMPLOYEE'S FINGER INTO THE LIP OF THE BAUXITE DOOR
Employee was welding in the cement cooler. A piece of refractory broke from the wall, fell about 15 ft. and struck the employee on the hard hat and neck. The employee suffered a closed head injury and neck sprain.
Employee was welding in the cement cooler. A piece of refractory broke from the wall, fell about 15 ft. and struck the employee on the hard hat, neck and shoulder. The employee suffered a broken scapula, neck sprain and contusions,
Working on Raw Mill Sampler pinch tip of left index finger causing laceration
Adjusting the forklift tines and the middle finger on right hand got pinched in between the tine and fright guard
Employee received 2 lacerations on the right hand from a hand tool while troubleshooting a motor sensor.
Shooting out coating in the Calciner Loop duct, Day was windy and dust got in Left eye.
Employee was removing a metal liner and caught right thumb between liner and mill shell. Employee was taken to clinic and diagnosed with a fractured thumb and received sutures.
The JTT miner had not noticed the pressure gauge of the kiln rig jack system had broken. The JTT miner over pressurized the jack causing it to break. This caused the brick to pinch the tip of the left middle finger between the brick and jack.
Manually closing T/A Damper with hand crank, crank started spinning on its own and hit right hand.
Filled 5 gal. buckets and carried them to the discharge of the lanes. From there filled a wheel barrel and carried that to the back end of the cooler. When picking up buckets of clinker felt pain in abdomen that increased.
Looking ahead did not notice a step in the concrete. Stepped off and felt a sharp pain in right foot
cement kiln, materials hit two employees
Cement Kiln, materials hit two employees
Pulling with pry bar, bar slipped and smashed finger
Code 06 Fire
Dust blew in eyes.
Changing door, door opened and hit employee on hard hat.
The men were already started on their task for the day, tools and equipment had been laid out to use, the weather changed from overcast to raining. Started to gather up the tools to move them to an inside area, EE was carrying a pony threader, tripped over a cord, fell and the pony threader landed on his finger causing a fracture.