Holcim US IncMining Incidents in 2005

A loose connection on a transformer caused a power failure to the plant air compressor which caused exhaust valves to close on the Pyro main baghouse which allowed hot gases to reach the dryer feed belts and started a fire. The Mobile Fire Dept was called and they put the fire out in less than an hour. Valves will be installed to prevent future like incidents

On June 22, employees reported hearing a loud thunder-like noise. An immediate investigation was initiated to determine the source of the unexplained noise. Personnel discovered that 3 gaskets were blown out on the oxygen enrichment channel. Deformation on the pipe and flanges was observed. There were no employees working in the area, no injuries sustained.

Employee was attempting to remove plugged material from dust feed line with a 8' -10' steel rod when the rod came into contact with a rotating agitator in the bottom of the mixing tank. This resulted in the employee's glove becoming entangled with the rod and causing the injury.

Employee handing 15# brick to brick mason and felt strain to left groin area.

EE was installing a head (door) located on the east end of the mill. EE bent over to lift the head and felt a sharp pain in his lower back. EE sustained unknown injuries to his lower back. Started losing time as of 10/7/05.

THE EMPLOYEE BELIEVES HIS CONDITION STARTED ON THE PREVIOUS FRIDAY AFTERNOON BUT SAYS HE EXPERIENCED NO PAIN OVER THE WEEKEND BUT WHILE SHOVELING DRY MATERIAL HE BEGAN TO EXPERIENCE PAIN IN HIS CHEST AND ALSO BECAME SHORT OF BREATH AND DIZZY

The EE was reaching his left hand into an air slide to clean it when he came in contact with a lump crusher. EE sustained several puncture wounds to his lift hand and some tissue damage.

THE CONVEYOR WAS NOT DEENERGIZED. EE WAS SWEEPING UNDER CONVEYOR AND GOT CAUGHT/ENTANGLED IN RETURN IDLER.

Key Temp employee contractor was en route to the cement silos to change silos. When exiting the clinker silos on the north end, he slipped on granular clinker. This caused him to lose footing and apparently twist ankle. Two days later by x-ray a doctor found a broken bone in foot.

Demolition of Ball Mill by means of torch cutting. Torch cutter burns left leg when he ignites pant leg with burning slag that was inadvertently directed towards his leg due to awkward cutting angle and rebounding slag. Second degree burn from bottom of knee to just above ankle approxiamtely 3-4 inches in width. Burn was superficial (no deep tissue damamge) but very painful.

EE was assisting in the recovery of used conveyor belting. While inspecting belting as it was being wenched across the ground the tangled belting untwisted and impacted EE knocking him to the ground. Injury resulted in fracture to left wrist and left leg below knee.

EMPLOYEE WAS CARRYING BOX UNDERNEATH SCAFFOLDING.

EE wa pulling and straightening kiln chain through the rotary kiln in preparation for the chain to be re-hung. EE was working in a bent over position for a majority of the time period.

Employee was cleaning the waste dust scales using an air hose. When he turned the air on, the hose popped off and the coupler struck him in the face. Xray at time was negative for fracture, but ee later required surgery for deviated nasal septum. Underwent OP surgery on 2/1/06.

HAD A STARVE ON CKD FEEDER ON FINISH MILL #4. EMPLOYEE WENT DOWN TO BEAT ON CONE OF SILO TO GET MATERIAL TO FLOW. AS HE BEAT ON THE SILO CONE A 4"" PIPE CAP CAME OFF THE ACCESS PORT ON THE SIDE OF THE CONE. THE CKD CONE CAME OUT AND GOT IN EE'S LEFT EYE.

Had Stiffness and pain in neck on the left side, numbness in arm after picking up ladder and moving it from one location to another. Carring ladder on shoulder. Employee put on restricted duty. 10 lb limit on lifting and no crawling or climbing.

EMPLOYEE WAS USING A #8 HAMMER & SLUGGING WRENCH TO REMOVE A BOLT FROM THE RETAINING CAP OF A GEAR BEARING. WHILE ATTEMPTING TO STRIKE THE SLUGGING WRENCH, THE EE HIT A NEARBY GEAR WHICH CAUSED THE HAMMER TO DEFLECT INTO HIS HAND.

EE was climbing stairs while lifting a motor and gear rducer when he twisted his rt knee.

Employee was walking down the inclined coal/iron ore welt walkway, he slipped on some loose material injuring his right knee. 9-27-05 employee was sent to doctor to be checked and doctor placed him on restricted duty - no stairs or prolonged standing.

EE was pulling with a 48"" pipe wrench trying to turn #2 clinker cooler breaker that had locked up with material when he strained his lower back. EE did not request medical attention until 9/27/05. Given prescription and placed on restricted duty. Re-check in one week.

Miner was filling a bottle of ammonia in lab. He pressed down on the bottle stopper and the bottle broke, causing a laceration to his right middle finger on his right hand that required sutures.

EMPLOYEE WAS GETTING OFF OF THE #3 PIER AT THE #2 KILN. WHILE PUSHING WITH HIS ARMS, HE STRAINED HIS RT. SHOULDER & HIS RT. WRIST. EE DID NOT REQUEST MEDICAL ATTN. UNTIL 09/26/05. HE WAS GIVEN A PRESCRIPTION & PLACED ON RESTRICTED DUTY. RE-CHECK IN ONE WEEK.

CUTTING THE SUB CONNECTOR OFF OF A PIECE OF DRILL STEM WITH OXY/ACETALINE TORCH. SUB CONNECTOR HAD MALE THREAD AT EACH END & DRILL STEM HAS AN INNER JACKET FOR DRILL OIL. APPEARS THAT SOME OF THE OIL HAD RESERVOIRED IN UPPER END OF THE MALE THREADS. AS EE CUT, THE TORCH HEATED & PRESURIZED THE DRILL OIL, CAUSING IT TO FLASH/EXPLODE. 1ST & 2ND DEGREE BURNS TO FACE & NECK.

EE WAS PULLING JAMMED TIRE FROM WHOLE TIRE SYSTEM BELT WHEN HE FELT A SHARP PAIN IN HIS RIGHT FOREARM AND ELBOW. HE HAS BEEN PLACED ON RESTRICTED DUTY.

EMPLOYEE BENT AT WAIST TO PICK UP A PIECE OF CRIBBING FOR CRANE OPERATION. EMPLOYEE HAD MUSCLE PAIN AND SORENESS IN LOWER BACK AS A RESULT OF LIFT PROCEDURE.

WALKING THROUGH RAW MILL MAIN BAG HOUSE AND WALKED INTO A LOW BEAM STRIKING THE FRONT OF HARD HAT, JARRING NECK. SENT TO CCOM FOR REVIEW AND WAS PUT ON RESTRICTIONS

Employee was in manlift basket alongside the rotary cement kiln, assisting as his supervisor drilled holes in a crack in the kiln shell. Hot dust coming out of the crack got into employee's right eye. This caused an anterior corneal burn.

EE was at raw mill location on 2nd shift maintenance pulling and adjusting an air nozzle, when he felt a pull in his lower back, resulting in a strain.

EE was assisting another EE move a pallet, using a prybar. The prybar slipped off the pallet, smashing his right thumb between the prybar and a beam. Specific injury is unknown.

While EE was lifting cement bags and placing them on a pallet, he injured his back. This resulted in an unknown injury to his back.

While lifting water spray pipe off forklift, injured felt pain in lower back. Restriction; cold packs intermittently.

Employee was performing corrective maintenance at the east agitator of the slurry basin. He picked up a 20-ton hydraulic cylinder (weighing 25-30 pounds) to move it, twisted and strained his back while setting it back down. Was put on restricted duty and given an injection.

Employee was lifting a 10' section of 8"" pipe when he suffered a back strain. The injury resulted in the employee being assigned restricted duty activities.

WHILE WORKING ""SHOVELING MATERIAL ONTO CONVEYOR BELT"" THE LABORER LOST HIS FOOTING ON SOME LOOSE MATERIAL & FELL FORWARD. HE TRIED TO BREAK HIS FALL BY EXTENDING HIS ARM & THEREFORE CAUSING A SPRAIN/STRAIN TO HIS RT. WRIST & ELBOW.

While jackhammering injured noticed ache and pain with numbness and some swelling in both wrists. Prednisone, wrist splint, no jackhammering/guzzler, lift, carry, push/pull (light duty).

WHILE LIGHTING A TORCH, EE BURNED HIS FACE AND NECK FROM FLASHBACK FROM TORCH. EE ALSO BURNED HIS WRISTS AND SINGED BROWS AND HAIR. MEDICATION; RESTRICTIONS: PUSH/PULL, LIFT, CARRY; AVOID PROLONGED EXPOSURE TO DUSTY ENVIRONMENT.

EE was working on level 6 of tower at the watertank. Plastic wrap around tank needed to be replaced so that the water lines would not freeze. EE was removing plastic when the support structure 4x8 plywood on 2x4s around outside came loose and hit EE in the right knee. EE is on light duty.

While the EEwas entering the sweeper truck, she felt a pain in her knee. As a result EE sustained a sprain to her rt knee

Employee was on shift and experiencing lower back pain throughout the day. Upon examination it was determined that his hip has been out causing extreme pain to lower left side of back. He is on modified duty at this time.

LIFTING CHAIN IN CEMENT KILN AND STRAINED HIS SHOULDER.

WHILE REMOVING SHEET METAL FROM PALLET, EE GOT FINGER CAUGHT BETWEEN TWO SHEETS, WHEN ONE SHEET WENT ONE WAS AND ANOTHER WENT THE OTHER WAY

EE was getting a sample on the dome reclaim belt when some blew in his right eye. Prescription medicaiton

EE was underneath 50 ton haul truck changing transmission filters. Upon exiting he complained of pain in right knee. EE did not requested medical attention until 12/9/05 and return to work with no lost time. Coninued with dr follow-ups. Dr has no requested physical therapy treatments beginning 1/4/06.

Employee was working on kiln floor installing a monorail. There was welding in the area and clinker dust on the burner pipe. Employee was not sure when or what got into his left eye. Employee reported eye irritation 7:00 a.m. next morning. A small piece of material was removed from eye; EE's eye felt better. Next day still some irritation; sent to doctor. Eye drops prescribed.

Employee was holding bolt/socket & extension being tightened by other employee using impactor when the socket slipped off the bolt, causing the extension to spin around and strike him in the mouth. This broke the crown on tooth #7 and knocked tooth #8 out of its socket.

Employee was removing sections of guides from cement mill discharge bucket elevator. In the process, the employee struck the grating above him with one of the beams, causing cement dust to dislodge and fall into his face. Dust subsequently got into his left eye and caused irritation. He was given prescription medication for the eye.

Employee was hooking up portable air compressor while he was lifting the tung of the air compressor it rolled back causing his right pinky finger to be caught between tung of trailer and i beam it had been selling on. Employee injury was laceration requiring stitches and fracture. Both to 5th digit of right pinky finger tip.

EE WAS REPLACING BUCKETS ON THE CLINKER ELEVATOR WHEN HE KNOCKED BUCKET LOOSE FROM CHAIN, LODGING BUCKET BETWEEN WALL AND ANOTHER BUCKET. WHEN EE TRIED TO DISLODGE & REMOVE IT, BUCKET DROPPED AND SMASHED HIS FINGERS BETWEEN BUCKETS REQUIRING SUTURES.

EE was driving a shaft through a platico value with a hammer, when he struck his middle finger with the hammer.

Employee's eyes started hurting after work 9/13/05. He had been welding on a coal mill ladder & had also been on fire watch while other employee welded. While on vacation 9/14/05, Dr. diagnosed mild keratitis & hx of foreign body right eye. Possibly saw coworker strike arc with welding hood up. Unsure where he got FB. Report delayed due to lack of paperwork from doctor.

Employee was assisting contractor pull a new 13,800 VAC Feeder when he pinched his left 5th finger (pinky) between the wire being pulled and the wire way. The fingernail was loose so employee was sent to orthopedic group where fingernail was removed, cleaned & stitched (5) back on. This was done so new nail would grow back straight.

While blowing cement off product from flat storage, injured got cement in both eyes. Eye drop ointment. Corneal abrasion.

The EE was cleaning a feed shelf when dust fell into his eyes.

The EE was attempting to connect a pump off hose. As he struck the hose with a metal pipe, the pipe struck his finger. The EE ststained a contusion to his left fifth finger.

While pushing coal car door shut, injured felt ""pop"" in right knee.

During kiln shutdown employee worked inside rotary cement kiln welding a patch in the shell and had to walk through clinker dust to get to his work area. The dust penetrated his work clothes and got on his skin, resulting in dry chemical burn to his left leg. He saw Dr. on 8/9/05 and was given cortizone injection.

EE was cutting & removing old screw conveyor housing sections at the elect. precipitator Bldg. When he attempted to drop a section of metal housing off grating to the ground, a piece of sharp metal on the screw caught his glove & pulled his left hand to a pinch point,cutting his hand at the base of his little finger.Sutures were required to close the cut.

Employee was operating K-D forklift during kiln shutdown to move pallets of kiln brick in and out of cement kiln. While backing out of the kiln, a wheel ran up onto a large piece of coating. The wheel then fell back down to the floor, jolting the employee and dislocating a rib. (EE did not see Dr. until 7/28/05 at which time he received osteopathic manipulation.)

While pressure washing dozer, injured felt splash go into eyes. Was wearing goggles, long gloves but because of temperature outside sweat dripped into eyes. Prescription medication given.

Employee was pulling a clinker sample from the manufacturing process when his dipper hit the conduit overhead causing cement dust to fall into both eyes. Employee was given prescription and released.

WHILE MOVING 3 & 4"" MILL BALLS DOWN SORTING TRAY, A BALL POPPED OUT AND SMASHED EMPLOYEES LEFT RING FINGER. EMPLOYEES HAND WAS ON SAFETY RAIL

EMLOYEE HAD COMPLETED HIS ASSIGNMENT FOR THE DAY & IT WAS CLOSE TO QUITTING TIME SO HE WENT TO THE WELDING SHOP WHERE THERE WAS SOME FABRICATION OF CRAWL GUARD BEING DONE. THE EMPLOYEE CUT HIS BACKSIDE OF RIGHT HAND WHEN IT STRUCK A PIECE OF ANGLE IRON THAT HAD A SAW CUT 45 DEG. END, CREATING A SHARP EDGE.

Employee pinched right ring finger between air lance ""T"" handle and doorway of cement plant clinker cooler while using air lance to break up a high pile of clinker inside the cooler. This resulted in a laceration that required sutures.

EE WAS CUTTING AND INSTALLING CHAINS INSIDE #1 KILN. CONTRACTORS WERE WELDING NEAR THE DISCHARGE END OF THE KILN, CAUSING FUMES & SMOKE TO MIGRATE INTO EE'S AREA. EE BECAME LIGHT-HEADED AND FELL 3 TO 4 FT. ONTO KILN SHELL FLOOR, LANDING ON CHAINS, BRUISING RIGHT LEG AND HAVING TROUBLE BREATHING.

GRINDING ACTIVITIES

WHILE WORKING ON #2 KILN TIRE, EE FELT SOME METAL FLAKES BLOW INTO HIS EYE. FOREIGN MATERIAL (STEEL) REMOVED FROM EYE.

No specific injury - recurrent tennis elbow - picking up 4lb. bowls. Injection, forearm splint, restriction-left 10lb. right hand.

While lifting 70# jackhammer, injured felt something pull in left shoulder. It was still hurting a few days later. Physical therapy.

WHILE HAMMERING PIECE OF STEEL, INJURED GOT PIECE OF STEEL IN LEFT WRIST. *HE WAS ADVISED TO HAVE THIS PIECE OF STEEL OUT A A REGULAR PHYSICAL FROM HIS OWN DOCTOR. SURGERY ON THIS WAS 9/8/2005. STITCHES REMOVED 9/14/2005.

EE was changing a proximity switch and did not lock out the flapper arm. got his thumb in between arm and bin. It pulled the thumb nail off.

EE WAS IN THE PROCESS OF REMOVING THE CARRY DECK DROTT CRANE FROM THE KILN FLOOR. AS EE WENT TO DRIVE INTO THE FREIGHT ELEVATOR, IT WOULD NOT FIT. EE STARTED SLIDING THE PIECE OF PLATE AND PINCHED LEFT MIDDLE FINGER, CUTTING THROUGH GLOVE CAUSING A CONTUSION REQUIRING 5 STITCHES

The freight elevator was jammed.EE was trying to get the elevator door unjammed. When the elevator door finally came loose, it shut on his right hand.

A brick was dropped by a brick mason off the kiln rig template. While EE was setting a brick down for the mason to install. The brick was dropped about eighteen inches on to EE's left hand causing a hand contusion.

EE operating a table saw cutting wedges when his glove on left hand got caught by blade and pulled his hand into blade. he sustained laceration to 1st and 2nd digits of left hand. four sutures required to close laceration

EE WAS STRIPPING INSULATION OFF OF TECH CABLE WITH UTILITY KNIFE, AND CUT HAND. HAND WAS GLOVED AT TIME OF INCIDENT.

Employee slipped stepping back into empty oxyacetylene cart; it rolled out from under him causing a fall, striking his head on concrete. Fellow workers said he passed out causing fall, unsure.

EE was changing out acetylene bottle. Smashed his finger between bottle and wall. After ee went home at night finger started to bother him. He went to clinic and had finger nail drained.

EE WAS DRIVING A TRUCK WHEN PARTICLES FROM THE DETERIORATED HEAD LINER FELL INTO HIS EYES, CAUSING IRRITATION.

EMPLOYEE HAS HAD TOLERABLE BACK PAIN OVER THE YEARS FROM AN INJURY HE RECEIVED BACK IN 1998(?) ON ANOTHER WORK SITE (NOT MSHA). HIS BACK BEGUN TO INCREASE IN PAIN DURING THE COURSE OF WORK IN THE LAST FEW WEEKS. JUST THE WEAR AND TEAR OVER THE YEARS BROUGHT THE PAIN TO WHERE HE IS NOW SEEING A BACK SPECIALIST.

While lifting heater, injured felt a metal pedestal fall and land on top of his right foot.

EE WAS THREADING ELECTRICAL CONDUIT AND CUT FINGER. TWO STITCHES WERE REQUIRED. GLOVES WERE NOT WORN WHILE COMPLETING TASK.

While on break in Shipping Dept. breakroom, employee bent over to tie his shoelace, went to stand upright and the next thing he knew he was on the floor. He stuck his left elbow on the floor when he fell. Saw Dr. 7/29/05, X-ray negative, injection administered. (Compensability to be determined.)

EE WAS HAMMERING CONCRETE OFF STEEL BEAM WITH SMALL WELDING HAMMER. EE WAS STANDING, STRADDLING METAL PIECE, & SWINGING HAMMER WITH RT. HAND. HAMMER STRUCK EE'S LOWER INNER L. ANKLE. TAKEN TO DR. WHO FOUND NO BROKEN BONES. IMPACTED NERVE WITH SWELLING & BRUISING. NO LOST TIME BUT ON RESTR. DUTY UNTIL 3/7/05 RE-EVALUATION. 10/11/05: NO RESTR. DUTIES & RX - PAIN MED. ONLY.

Employee had felt knee pain for two weeks. He was servicing a quarry haul truck and took a step and felt extreme pain behind the knee. Cause of pain has not yet been diagnosed. Employee is on modified duty at this time.