Holcim US IncMining Incidents in 2006

Employee was using cutting torch to install safety hand rails. Hot material fell in tire pile and ignited tires. Hot work permit was in place.

Build-up of fine clinker had accumulated in the clinker cooler. The clinker cooler baghouse was by-passed due to concern for overheating the baghouse cloth bags. The discharge gases heated up the insulation under the roof decking to the point that the insulation caught fire and smoldered. Fire was extinguished with no injuries and no major equipment damage.

Kiln stopped due to disruption in raw material feed, coal mill stopped. smoldering palverized coal made its way to the baghouse. Potential ignition source was tramp metal in coal mill, CO2 inerting was effective until CO2 level in storage tank became too low to start mill system. High O2 atmosphere in baghouse due to mill off-line & lack of CO2 led to need to stop smolder w/water.

Employee working in calciner unit operating a cordless circular saw to build wooden forms in preparation for guniting. As he was making a miter cut on 3/4"" piece of plywood @ 2""x8"" long, the saw blade came in contact with left index finger cutting the tip off.

Installing #9 Rebar when foot slipped down into the formwork and rebar at the end.

Speed of truck, inexperience of driver, wet haul road, and possible inattentiveness of driver - causing him to lose control of his 100 ton truck and slide into oncoming 65 ton truck (t-boning it). Both drivers were wearing seatbelts.

EE was making a connection of scuba bottles to filter rack preparing for advie job to inspect ship hull. He connected the hose from these bottles into down steamed of the filter rack, by passing the high to low pressure regulator. When system was pressurized a pneumatic explosion occurred. Striking him in the face with debris

Employee was moving welding unit and twisted back causing strain.

Employee was helping change out division head in finish mill when weld on plate broke, causing it fall on employee.

While installing overload device for dust collector, injured drilled into back panel with drill bit-causing electrical flash. Injured was thrown to floor with burning shirt. burns: face, both arms, hands

Employee and 2 coworkers were pulling and pushing steel plate. Employee's right hand was between the wall and plate. The 2 coworkers pushed the steel plate which placed employee's right index and middle fingers between the wall and plate, crushing his fingers. Tips of fingers cut, bones fractured, but no amputation of bone.

Employee was holding 5"" pipe used to guide jackhammer bit onto bolt as employees were jacking raw mill liner bolts out of mill. Jackhammer bit came out of pipe and down on employee's right little finger, causing laceration and fracture.

Working on scaffold platform, tripped on a piece of plyboard protruding on the deck of the scaffold and struck scaffolding injuring left shoulder. He was diagnosed with cervical strain, L. shoulder strain and right eye conrtusion. Employee reached maximum medical improvement with a 6% upper extremity impairment for loss of motion.

While installing #9 Rebar and feeding into structure, the rebar hit a ""C"" channel as he was pushing downward. The bar hit his wrist and his wrist twisted back and toward the right.

Employee, while working on automated bagging machine, complained of sore lower back. On Dr visit 21 Nov 06, he was diagnosed with sprained lower lumbar muscle(s) and placed him on modified duty.

Employee strained his left shoulder 11/01/06 when he shoved a piece of metal into the metal shear. Injury didn't become reportable until a partial tear of the rotator cuff was discovered and he underwent surgery on 3/2/07 and was placed on restricted duty.

Employee was inspecting kilns when he stepped on a foreign material. He lost his balance and fell which probably led to the employee using his right arm to brace his fall. The employee suffered a dislocation of right shoulder which was set back into place.

Employee was driving a mini skid steer into the mill building & down a hallway. There was low conduit across pathway & he struck his head when going under. He felt his neck jam & his spine pop at the joints all the way down. He was taken to CCOM the next day & is on light duty for 2 weeks or until released by the doctor.

Employee and two maintenance mechanics were replacing flights and return rollers on pan feeder. The bolts securing one of the flights had been removed. Employee was pushing on flight with left hand. The flight dislodged and as it fell, it struck employee's left hand causing a fracture to middle finger and back of hand (3rd metacarpal).

Ee states he was walking down a flight of stairs carrying his tool box. Ee turned the corner left to access another flight of stairs when his right knee popped causing ee to fall down. Pain is to inner side of right knee. Knee was immobilized with knee brace until follow up visit.

While EE was lifting bags of sugar in the finish mill, the EE twisted his back.

While transferring materials, employee came into contact with residual fluids (acetic acid/toluene) left in transfer line. Employee showered and was taken to doctor for evaluation. The employee was treated for 2nd degree burns to his left forearm, stomach and left leg. The employee was released to return to work the next shift.

EE was handling buckets of CKD dust and dropped one on the floor. The lid popped off and dust got in her eyes. EE may have handled too many buckets at one time causing her to drop one.

Employee was stepping off crane and foot slipped on wet outrigger pad and twisted his knee.

Process operator was moving wheelbarrow from underneath raw mill tail wheel. While lifting and pulling the wheelbarrow caught on frame of conveyor suddenly stopping causing muscle strain.

EE was working to remove small pieces of metal blocking the feed chute & needed to kneel in a tight area several times to work on the blockage. EE was stiff after working and kneeling in the tight area. As the night went on there was an increase in pain & he had difficulty walking. He was taken to the hospital for evaluation. He is restricted sedentary work for 1 week.

EE was working to put coal mill back together after outage. EE states that he was working while lying on his back, performing several twists and turns and performing several unnatural movements. ee does not remember any one particular instance when he felt a strain, rather the end of the day and over night developed lower back stiffeness. it is assumed that the extended unnatural

Mechanic was using a 1"" impact wrench with a 2 3/8"" socket. The safety pin that held socket on was a welding rod, which was hanging out of socket. The mechanic's hand (which was in glove) was slashed and cut by the rod while socket was in motion. 12 stitches were required to seal wound on right hand.

While unplugging air lines, injured got ash in both eyes after pulling coupling off.

Employee was outside of transfer house walking to the motor control center when he slipped on a patch of ice on the ground (inclement weather) and fell, striking his upper back and head. Employee received osteopathic manipulative treatment on 12/11/06.

Employee was changing grates on underside of cement clinker cooler drive. Dust in air probably entered eyes after employee removed his goggles. Prescription eye drops prescribed due to conjunctivitis on 11/21/06.

While attempting to tighten a bolt on the cyclone tipping valves, his wrench slipped and his arm came in contact with a sharp edge on the guard.

Employee was in physical/chemical laboratory. He removed a procelain funnel from the drying oven with tongs. The funnel slipped out of the tongs. Employee grabbed for it with right hand as it hit the counter & broke, causing laceration to right palm that required sutures.

The Injured Worker was operating a rock crusher & had some dust fly into his eye. The IW flushed his eye out then used a kleenex to wipe his eye. He reported it to his supervisor around 11:40. Around 3:00 his eye began experiencing a burning sensation. The company then drove him into the eye doctor's office. The IW was wearing safety glasses at the time of the accident.

Ee was using screwdriver to break cap off of 55 gal drum of oil. He removed his gloves and began to pry cap. Screw driver slipped and cut fingers on right and left hands. He was treated in er and released without restrictions.

EE was making his routine rounds around the kiln when he felt something in his left eye. EE was wearing safety glasses so the object must have been blown in by the wind. A small speck was seen on his eye so, being it was night shift, he was sent to the hospital to have particle removed. The attending physician flushed out the eye and suggested he get some occular fluid.

On 10/3 EE was walking on walkway between finish mills when he slipped on oil causing a strain to lower back (unreported). On 10/9 he was setting mill basket on top of #2 Raw Mill. Basket shifted when he began walking on it causing him to re-strain lower back. He requested medical treatment 10/9 and is continuing follow up treatments with chiropractor.

While running jitter bug machine, injured felt pain in left arm. * 5 lb limit w/left hand *Splint given

While the EE was lifting a hydraulic cylinder, his right index and middle fingers were ""pinched"" in the object. As a result, the EE was diagnosed with a right index finger fracture.

Employee was swinging sledgehammer at feed end building of cement plant to break up built-up, hardened cement when the hammerhead hit the roof overhead & on rebound pinched his right little finger between hammer handle & his steel-toed boot. Caused laceration and fracture of finger.

While working in #1 Finish Seperator, injured felt dust go into left eye. Saw Dr. prescription given.

Employee was in storeroom using pocket knife to cut cardboard to place over dust compressor. He was cutting toward self when his right elbow struck an object, causing hand w/knife to redirect and stab his left forearm. Wound required 2 sutures to close.

Employee was stretching out welding cable when he raised up and struck his head (wearing hard hat) on the damper control arm of the cooler exhaust fan. This caused sprain to his cervical spine. Injury became reportable 8/28/06 when he received an osteopathic manipulative adjustment.

Employee was putting chain in a bucket elevator and was attempting to straighten the chain when folded links straightened and forced his finger into a friction wheel. This caused fracture to the fingertip of his right 3rd finger.

While taking grizzly bar out, of #12 silo, injured got dust in left eye.

Employee was using hand-held electric grinder inside duct work at the glass baghouse and was grinding the surface of the damper housing when the grinder slipped out of his sweaty hands and cut his right index finger. Laceration of knuckle required 2 sutures.

Employee was machining grates in machine shop. He was attempting to remove the shim stock from under the material when the sharp edge of the shim cut through his glove and into his right thumb. This caused laceration requiring sutures.

Employee was cutting off a tie wrap on a bag with a knifte. He cut his left thumb.

Employee was riding in manlift basket ascending to bottom of cement mill #2 in order to hook a cable onto the mill, when he caught his right ring finger between the manlift basket and the mill. This caused a laceration of the finger that required 5 sutures to close.

Employee was using a multitool screwdriver to adjust the door stop on an office door and was reaching overhead tightening screws at the top of the door when he suffered back spasms. He received osteopathic adjustment and muscle relaxers.

Employee was standing by as other employee used jackhammer to unplug the clinker breaker, when a hot piece of cement clinker flew up and struck him in the mouth. This caused a contusion and 2 degree burns to his right upper and lower lip.

While walking on road, injured slipped in oil spill on road way. *8/3/06--Meds given and scheduled to begin therapy.

Employee's left index finger was pinched between a box-end wrench and an air chucker hook while he was working with other employee to remove nuts from bearing springs of a gear reducer. This caused laceration requiring sutures.

EE was removing tramp metal from division screen with electric grinder, when a small piece of metal ricocheted back and struck the EE in the neck, below his face shield. EE had metal removed, did not miss any workdays, however, received 4 stitches.

Employee was holding a shaft to prevent it from turning while another employee was securing a locking collar on a bearing using a pin punch to tighten the collar. As the collar was struck a piece of the collar sheared off and embedded in the employee's left arm which required one stitch.

While taking samples, injured go finger stuck in the sampling port, causing laceration to left ring finger.

Employee was in process of installing an oil cooler on the cement plant coal mill. He smashed his left middle finger between the oil cooler and a pallet while sliding the cooler on a pallet under the coal mill. This fractured the tip of his finger.

EE was hitting the neck of the finish mill with a sledge hammer (because of a neck choke up) trying to unstop the neck. Cement falling from above got into his left eye. He was wearing safety glases at the time.

EE was getting down from an elevated (2.5'- 3.0') platform when he landed on an area of unlevel surfaces. This caused his right knee to buckle. A more detailed description is included in the attached report. While the ee did not miss time or have restrictions, the knee was placed in a splint. Interpretations of Part 50 make thisreportable.

While replacing J-Casting, injured felt a pull in the lower side of his back.

While checking water level on scraper radiator, injured slipped and fell to the ground landing on elbow and right shoulder.

Employees were preparing for new electrical installation and were removing electrical conduit at plant silos. Employee was pulling on conduit and when it came free, he smashed his left middle finger against a screw conveyor housing. This resulted in a tuft fracture which required splinting.

The cement raw mill was being manually turned by a crane. A bolt holding the choker cable broke, causing a jolt to the mill and releasing a large cloud of dust and debris. As employee standing by watching the process (wearing safety glasses) looked up, foreign body entered his left eye. Eye doctor removed metallic FB on 3/27/06 and prescribed drops.

This injury occured while doing overhead lifting over a period of four days.

Employee states while performing maintenance he sustained cement dust in his left eye causing irriation. EE received prescription from examining physician with follow-up visit to ophthalmologist.

Employee struck right elbow on bracket securing ladder to handrail inside cement plant raw mill. He was jackhammering inside the shut down mill at the time. He did not seek treatment until 5/3/06 at which time he was diagnosed with olecranon bursitis with a chip fracture of elbow.

Working on Iteca Vacuum arm and while lowering plunger 2nd finger of the left hand got caught. Employee sought medical treatment at the emergency room. Stitches were needed. No work restrictions - stitches to be removed in 7 to 10 days.

Employee was using utility knife to cut rubber cement mill liner when the knife slipped and he cut his right leg above the knee. Laceration required sutures.

EE strained his upper back while lowering twin compressor air filters to a co-worker.

While walking on concrete by Maintenance Shop, the injured employee slipped on snow surface, falling on right shoulder & right side of back (fractured 3 ribs).

Employee was disconnecting a temporary electrical connection and was using a box blade knife to cut the electrical tape. The razor went through the tape, glove and cut about a one inch cut in left index finger, requiring five stitches.

Employee was working in kiln and got some grit in his left eye.

At the start of employee's shift on 2/6/06 he reported that he woke up with irritated right eye. He had been grinding the day before and assumed he had gotten a foreign body in his eye. He was sent to doctor who flushed eye out but saw nothing. A prescription was given. The next day he still felt something in eye and went to an eye doctor who removed particle from under eyelid.

Employee was changing out dust collector bags. The pipe wrench was used to loosen the holding bars. It slipped under pressure and mashed his left ring finger. Stitches were required.

Another employee was blowing out a cement silo aeration line on other side of silo when air backtracked and pushed open a valve near injured, blowing cement dust into his right ear and right eye. Ear and eye were flushed and prescription eye drops were administered.

Employee twisted right knee while emptying 5 gallon buckets of cement dust into loader bucket at feed end of kiln and again while going down steps at slurry basin on 1/4/06. Saw ortho specialist on 3/28/06 and was given steroid injections.

EE complained that over a period of time he has experienced an increase in pain and numbness in both of his hands and arms. Surgery has been performed on the left arm and once healed, surgery will be performed on the right arm.