Holcim US IncMining Incidents in 2019

PRODUCTION TECHS WERE REINSTALLING DOOR ON FM1 2ND COMPARTMENT WHEN THE LIFTING CHAIN BROKE. WHEN THE LIFTING CHAIN BROKE IT STRUCK AN EMPLOYEE IN THE LEFT HAND CAUSING LACERATION TO THE PINKY AND RING FINGER. THE EMPLOYEE WAS WEARING GLOVES AT THE TIME OF THE INCIDENT. THE EMPLOYEE WAS TAKEN TO THE HOSPITAL FOR MEDICAL CARE.

A scaffold was being dismantled in the clinker cooler at the kiln discharge (riser duct). A piece of buildup from the kiln nose fell and struck EE in the back of EE's hard hat. EE climbed down the scaffold and laid on the ground beside the scaffold refusing treatment until the EMT's arrived. EMS took EE to the hospital, and diagnosed with a slight concussion and released.

Independent Contractor Driver accessed flatbed trailer while away from tarping station. Driver lost footing and fell to the ground from top of bags on flatbed cement trailer.

Maint employees were removing a large cracked bearing from the dryer crusher shaft. As the outer race was moving outward, it released suddenly, and rotated. Due to its damage, the ee's hand was caught between the race and shaft, which resulted in a fractured left ring/pinky finger.

Employee reports EE was driving 10 mph across railroad tracks and didn't realize it was dug out and as the truck went over the tracks, the truck suddenly stopped, seatbelt didn't lock up, causing EE's head to hit the rear view mirror and EE's back to lock up.

The employee was attempting to loosen a valve when the pipe wrench employee was using slipped, causing employee to fall and hit shoulder. Employee was working from the ground and not an elevated platform.

Employee sliding a dam ring out the de-energized Coal Mill. EE twisted, bent over, and manually slid the heavy metal part resulting in a back strain. Same employee had non-work-related back surgery in Nov. 2018. Occupational doctor placed employee off work due to pain, limited mobility, and complexity of issue. Employee to see neurologist and complete diagnostic testing.

While walking along the boom catwalk at the wharf employee tripped and attempted to catch themselves with left hand on the handrail.

Employee was using the Shear machine to trim metal when the right index finger was pinched.

EE was leaving work for the day and as they pushed the building door closed, felt pain in their right shoulder. Tried otc and self-care until 12/18/2019 when was seen by dr and given prescription meds.

Employee was shoveling beside and under a ramp. EE pushed the shovel under the ramp and mashed EE's right thumb between the side of the ramp and the shovel. This ""strike"" broke the employees right thumb. As a result of the break EE cannot use EE's right thumb for a short period.

Maintenance EE installing lagging on a head pulley. EE lying between belts on left side. EE stated that when they went to crawl out, they noticed pain in the right shoulder between the top of the shoulder and neck. As of Dec 9, 2019, the EE was still experiencing pain, went to dr, EE arm/shoulder was put in a sling, and was given prescription meds.

Employee operating drill motor with EE's right hand when EE's left hand came into contact with the rotating roll pin. The rotating roll pin twisted into the employee's glove and resulted in a laceration in the webbing between EE's left thumb and left index finger.  Employee received stitches, and returned to work on modified duty.

EE was assigned to clean and wash out the inside of the coal mill and slipped while in the mill and fell to EE's left. When falling EE reached EE's left arm out to EE's side to catch self and upon impact EE's left hand and thumb bent backwards when bracing self from the fall.

While removing buckets from the stacker reclaimer with torches and hand tools a bucket fell off and landed on EE's foot. Bucket landed just above the steel toe of EE's right boot.

Employee was at the north coal feeder. EE was shoveling coal from around the base of the feeder. While twisting the shovel to dump it they felt a pain in the right bicep.

EE was adjusting a limit switch on stacker. As EE adjusted, EE pushed on lever and opposite side of lever impacted EE's right hand. Resulted in a cut and bruising of the middle finger of the right hand. Employee was diagnosed with fracture and cut put together with glue, meds given.

Employee had finished cleaning the hot gas generator fan 353-FN1. While closing the door to the fan, they felt a discomfort in their back, due possibly to ""moving the wrong way"". EE reported to mgmt on 9/19/19 and nurse prescribed home care, EE went to doc on own on 9/20 and given injection.

EE was building guard using grinder. Guard was clamped to table but EE was using left index finger to help stabilize. Grinder hit protrusion, caught EE's glove between disc and grinder guard. This caused the wheel to cut the employee's glove, pull EE's index finger towards the wheel and cut EE's finger. Reqd 6 stitches to close.

EE was in the discharge of cement mill #4 removing buildup from discharge screen. While exiting the mill, EE's right foot was held in place at the door opening while EE stepped out onto the ladder with left leg. EE was ok at the time, reported just in case. Still had discomfort and on 9/13/2019 was issued physical therapy and restricted duty for sprain.

Employee was throwing a rope up 1 level to lift up a bucket of tools. As the employee threw the rope, EE slipped and fell. EE got up and brushed self off, a bit embarrassed. The next day when EE came to work EE complained of shoulder pain. X rays were taken, no issues reported by doctor. EE recently went to see a physical therapist.

Employee stepped onto a concrete pylon and felt pull in right foot.

Employee was cleaning under the packaging rainbow line and felt discomfort in EE's lower back after picking up a partially filled cement bag. Same day self-care measures & OTC medication used; however, discomfort continued so EE was seen by occupational clinic on April 25 and placed on restricted duty.

EE reported that they were replacing a side liner at work. It was tight area. EE was twisting and turning and felt a pull to the middle back.

EE was walking down the east side staircase from the second floor of the pug mill to the ground floor when at the second to last step EE felt EE's right leg give out and EE fell. EE noted pain in the area of EE's right knee and could not bend it.

While clearing a choke above the impactor, the material flushed pulling the bar that the employee was using downward rapidly causing a strain in the employees, elbow, shoulder and neck.

The vehicle employee was a passenger in got stuck on an icy patch on relatively flat ground. Employee got out to push the vehicle out and while pushing felt a ""pop"" in the right calf. Their calf was in pain and unable to bear their full weight. Medical diagnosis was ""strained calf muscle"".

EE hit their head on a pipe line for compressed air on the second floor of the packhouse by the inside lane conveyor belt which jerked EE's head back causing EE's neck to pop. At this time EE felt minor discomfort in neck but continued to work next shift without issue (3/10).

Employee experienced low back while doing normal job duties this morning. Employee denies a specific injury which caused the back pain stating ""I was just lifting tires like I always do at my job"". Employee reports the pain started in the center of the low back and progressively got worse.

A small piece of scale/debris fell inside the bottom stage cyclone and struck the employee on the backside of EE's hardhat resulting in a laceration on the back of EE's head. Nine staples were required to close the wound.

Employee was lifting hinged bearing cap on the belt winder. The cap sprang back quickly, smashing the employee's right middle finger. The right middle finger sustained a small laceration and fractured bone.

While a Production Utility Operator was lancing at the finish mill, EE stopped what EE was doing to talk to another employee and lifted the face shield. When EE lifted the shield there was cement on the brim of the shield and some dust got into EE's eye. EE was wearing all appropriate PPE, safety glasses, face shield etc.

Employee entered the Packaging Rainbow doorway and felt a pop in the right knee. EE stated they did not feel any pain at the time. They continued walking about 50-feet and stopped at a desk to get something to drink. When leaving the desk they turned and felt a pop again and experienced pain in the right knee.

An electrical Employee received a cut / laceration to left knee while reinstalling a cover on a guard.

An iron worker was performing welding tasks when during the work shift received arc flash burns to the eyes. It was determined that the light from the sun was behind the welder and entering EE's welding shield that caused the automatic lens to malfunction.

Cleaning air conditioners and changing filters in the MCC area. As employee was pulling air hose to unit, coil in the hose caught. When the air hose caught, they tripped, fell, and injured left shoulder.

The employee was engaged in vacuuming cement dust when they felt a sharp pain in right eye, followed by a burning sensation. The employee's eye was flushed and they returned to work. That evening, the employee went to a medical facility. The employee was diagnosed with a corneal abrasion, treated and released with a prescription for eye drops.

Technician was working on the vac truck crew and was picking up material in the raw grind. Employee was holding the handle on the suction nozzle and pinched pinky finger between the handle of the nozzle and a cross member of the stair structure at the discharge of the mill due to the nozzle suddenly surging forward due to vacuum suction.

Process operator was repairing a leaking cement line gasket, when dust got underneath safety glasses and into left eye. Employee immediately reported the injury to supervisor. Irrigated the eye for 30 mins. Believed they removed all dust. Next morning employee woke up with an irritated eye. Went to physician who prescribed medication for possible eye infection.

On 9/9/19 employee was assigned to perform annual lube of a pan conveyor. Technician reached down to pick up a 5 gallon bucket of grease and felt 3 pops in back. The incident became reportable on 10/10/19 due to medical treatment.

Employees were working to unplug the gas conditioning tower. Employee got dust in EE's eyes, diagnosed with scratched right cornea, given eye drops.

Employee was tasked with cleaning out return roller guard of built up material on Mill #1 feed conveyor. While employee was reinstalling the guard they tore left bicep muscle.

Employee was moving a 12' jackhammer bar during a downtime. As the employee was moving the bar, the tail end of the bar struck dryer crusher, which caused the employee's left wrist to be bent sideways sharply. Treated with OTC meds until not getting better. Brace and prescription meds given 8/27/2019.

While re-bricking the kiln our employee was getting a sledge hammer to help drive shims to complete the job. When EE was returning EE slipped and dropped the hammer on EE's finger causing a cut. EE received stitches to the right middle finger and was released from care.

On 7/22/2019 an employee reported that the previous week, EE had gone home and broke out in a rash after cleaning in an area with clinker dust. EE said that due to the nature of the rash EE had sought care at the ER during EE's days off.

Employee was using a gunning machine to complete work on the nose required for restart of the kiln. The hose plugged at the discharge end and caused back pressure which created a failure in the hose causing the line to rupture at the pump. The failure in the hose blew monolithic at the employee and resulted in EE's PPE being blown from EE's face and material to enter EE's eye.

A Maintenance employee was driving a bearing off of a shaft, a piece of metal hit the employee in the left wrist and broke skin. Employee had gloves and long sleeves on but the piece hit in a small gap between glove and shirt.

Employee was installing an SNCR well into Kiln 22 from a 60' manlift under the roof of the kiln. The Employee had hands under both sides of the flange on the well and while lowering it they pinched the right ring finger between the flange and the manlift basket railing causing a laceration to their knuckle.

Pump Operator was standing on the deck cleaning the mixer while the engine was running. The grate that had been opened to gain access to the mixer was propped up beyond 90 degrees. Due to the vibration of the unit, the grate fell and struck the operator in the hard hat and ear, cutting them above the ear.

Technician was changing bags in baghouse. After removing approximately 20 bags the technician reached down to pull out another bag when the technician felt pain in right shoulder. The bag became stuck on the way out causing the strain. The incident became reportable on 6/14/19 due to assigned physical therapy.

Employee was removing a drain plug from a hydraulic reservoir using a 1/2 Snap On breaker bar. The plug was in tight and EE gave it a little extra truck and felt a pop in EE's upper shoulder. EE was taken to a Work Med clinic where they prescribed Celebrex (allergic to ibuprofen) and then put EE on light duty.

Employees raising an aerial lift to clean & did not see a conduit bank. Lighting insufficient but were using hard hat lights. Employee struck hard hat on conduit bank causing employee to strike chin on the left side causing a laceration. Employee was transported to hospital & received stitches for the laceration. Employee released to go back to work same day with no restrictions.

Employee was assisting another employee with a tower plug. Employee was unaware that kiln dust had accumulated on face shield. The dust fell into employee's right eye.

While working on the stone box floor of the primary crusher on the lube system an EE and IE had the power go out without notice at 07:45. As they were leaving the lighting was very dim as only the emergency lights were on and IE tripped over a pad eye on the floor welded to a steel plate and fell on IE's left shoulder and the left side of IE's face.

While clearing a chunk of shale, employee struck left thumb against a chute bracket while lancing.

Employee walking on silo roof fell, at the same level, to their knees fracturing left patella. While walking employee leaned down to pick up plastic debris. Did not notice it was wired to heavier object. As they grabbed it and continued walking the wire tightened, lost their balance, fell forward onto knees.

Employee ""Tweaked"" Back while attempting to remove inner pipe from outer cooling jacket on inlet analyzer probe. This incident was initially a first aid but do to the employee seeing a physical therapist on 3/15/2019 it has been moved to a Medical incident.

Lab EE slipped/fell in muddy area between the baghouse and MCC. The EE fell and landed on left side. At the time of the incident, EE said they had no injury from fall. Later the EE developed left shoulder pain and was given prescription meds and physical therapy on 1/18/19.

Employee hearing tests confirmed an STS at yearly audiometric test.

Employee hearing tests confirmed an STS at yearly audiometric test.

Employee hearing tests confirmed an STS at yearly audiometric test.

River Belt Conveyor system (8A + 8B) caught fire. The fire was due to a malfunction in the tail pulley bearing on 8B which caused excessive heat and tracking issues with the conveyor belt. A fireman, from the Ravena Fire department was transported to Saint Peter's Hospital where fireman was treated for over exhaustion and dehydration.

Employee was diagnosed with Carpal Tunnel on both wrists.

Death at mine site - natural causes- not mining related, suspected heart attack. Employee was eating lunch in the contractor parking lot. When another employee went to pick employee up it looked like employee fell asleep. Employee opened the door of the injured employee. Injured employee was unresponsive. CPR was started and 911 called.

Employee found collapsed and having health trouble (possible seizure) in the Main Office downstairs hallway. This incident is a result of a pre-existing health condition that is not work-related, and non-compliance with prescription medication.