Workers Burned in Oxygenated Air

Two men working for a municipality subcontractor died of burns received while installing a valve in a concrete sewage channel. The victims both had confined space safety training and were using a pneumatic hammer to chip the concrete channel wall.

The first man’s clothing abruptly caught fire. The second man jumped into the channel to help the first, but his clothing also caught fire. Co-workers shouted at them to “stop, drop and roll,? but the men suffered burns to 80 percent of their bodies. The men were transported to a burn center, where they died of their injuries.

The channel carried waste sewage, injected with 60 percent oxygen to aid in treatment. Excess oxygen was being released into the air, and the workers’ clothes became saturated. It appears the pneumatic hammer struck a spark from the concrete wall, which set the two men on fire. Because of the oxygen-rich atmosphere and clothing, the fire was extremely hot and fast.

There was no confined space entry program or rescue plan at the sewage plant, and no atmosphere test was conducted.

The host employer did not tell the contractor’s work crew what to expect in the channel nor what hazards might be present. Contractor’s employees should be briefed as new workers are briefed to raise their awareness of danger.

Source: California Fatality Assessment and Control Evaluation (FACE) Program, Case Report 94CA00202

Explosion Kills Floor Finishers

The goal was gleaming, refinished wood floors. Instead, the result was fire and death.

A company hired several men to sand and refinish a stairway and wood floors on the third floor of a three-family home.

The men were applying flammable lacquer floor sealer when it ignited. The explosion caused a fireball that shot through two stairways down to the first floor and engulfed the entire third floor. People in adjoining units grabbed phones and within minutes emergency medical services and firefighters arrived. One 35-year-old man was pronounced dead at the scene. Three other workers were rushed to hospital, where a second man, also 35, died of his burns the next day.

There were 52 fatalities among workers in the floor business during the decade, 1992-2002 (Bureau of Labor Statistics). In Massachusetts, three workers died in a 10-month period in fires caused when flammable lacquer floor sealer ignited.

Indoors, less flammable floor finishing products – with flashpoints greater than 100 degrees Fahrenheit – should have been used. Pilot lights and other ignition sources should have been out while this work was taking place. Windows and doors should have been open to ensure ventilation. The workers should have received training, communicated with the employer about the dangerous chemicals they were working with, and followed manufacturer’s safety precautions. A safety checklist should have been provided to them before they started work.

Source: Massachusetts Fatality Assessment and Control Evaluation (FACE) Program, Case Report 04MA032

Safety Talk

Fire Safety is Everyone’s Responsibility

Fire safety is an extremely important part of any workplace safety program. It’s everyone’s responsibility to help prevent fires.

Here are some fire-safe tips:

• Practice good worksite housekeeping habits. Do not let trash and waste material accumulate. Empty trash bins regularly. Oily rags must be stored and disposed of in covered metal containers, according to company policy.
• Do not store materials or allow clutter to accumulate around exits and stairways. Fire doors should be kept closed as directed. Fire exits should always remain free and accessible.
• A common cause of workplace fires is machinery or equipment which becomes overheated. Be sure to follow operating guidelines to prevent overloading. Follow manufacturer’s instructions in using and maintaining equipment.
• Electrical malfunctions are also a major contributor to fires in the workplace. Electrical equipment should be checked regularly for signs of trouble such as damaged cords or worn insulation. Never overload circuits, and never force circuit breakers to remain in the “on” position. Only qualified and authorized personnel should carry out electrical repairs and maintenance, but everyone is responsible for being alert to the signs of electrical malfunction.
• It is important to understand the fire hazards of the materials with which you work. They may be combustible, flammable, explosive or reactive. Read the labels and know where to locate the Material Safety Data Sheet for further information. Carefully follow any instructions when you are using any materials which might pose hazards.
• Be sure to observe any smoking restrictions. Smoke only in designated areas. Smoking in unauthorized areas such as storage rooms has resulted in serious fires. Do not empty ashtrays until smoking materials are cold.
• Observe company security policies and be alert to any suspicious persons or activities. Many workplace fires are set by arsonists; do your part to prevent these incidents.

Know what to do in case of a fire. Make sure your safety training includes this information:

• What is your responsibility in case of fire ? to report the fire, fight it or evacuate the building?
• Where is the fire alarm located?
• Where are the fire extinguishers located? Do you know how to use them, and on what kinds of fires?
• Do you know how to use other fire emergency equipment such as fire blankets, hoses and sprinklers?
• What safety procedures should you carry out in case of a fire? Are you responsible for shutting down equipment or operations before you leave?
• Do you know where you and your co-workers are supposed to meet for a head count after evacuating the plant?

Everyone has a responsibility for preventing fire. It is up to you to report any unsafe situation, and to correct it if you are qualified and authorized to do so.

Heat Illness Not Handled

The symptoms of heat-related illness would have been obvious to anyone trained to spot them. Unfortunately, even though a heavily perspiring California cantaloupe picker told his field foreman that he had a headache and requested pain medication, the worker did not receive medical treatment.

Instead, he continued laboring for another hour before boarding a bus with his crew. The Hispanic worker’s symptoms accelerated during the drive to another picking field. He became short of breath, anxious and nauseated. Finally, paramedics were called, but the picker was critically ill with a body temperature of 105. 6 F (41 C) upon arrival at hospital. He died of kidney failure and pneumonia 36 hours after medical help was first summoned.

Cantaloupe picking is one of the most strenuous jobs in agriculture. Had the crew been given regular rest breaks in shade and provided with ample water, this tragic death almost certainly could have been prevented. Had someone certified in first aid been part of the field work team, the worker’s early symptoms might have been recognized and medical help summoned. Unfortunately the crew also had no cell phone or radio, so no call for help could be made.

Source: National Agriculture Safety Database (NASD) California, Case Report 191-002-01

Death by Strangulation

A cattle farmer died from strangulation that resulted when his loose clothing caught in the rotating shaft of a conveyor belt.

The fatality occurred while the 53-year-old victim was in the feed shed adding cracked corn to ground corn that was then taken by conveyor belt to the outside feed bunk and a herd of 182 beef cattle.

The conveyors and controls in the shed were set up in a way that required the farmer to crouch down and crawl under the feed bunk conveyor several times during each feeding cycle. It was while ducking under the three-foot-high conveyor that the collar of his coat became caught in the exposed rotating shaft. The rotating shaft was one of many unguarded and dangerous pieces of equipment at the farm.

This victim was one of two (in 12 days) who died when his clothing became entangled in exposed rotating silage conveyor pulley shaft ends. The two nearly identical incidents illustrate why farmers and other lone workers must take extra precautions to ensure their safety including wearing appropriate clothing and keeping a two-way radio or cell phone within arm’s reach. Clothing and accessories that could become tangled in equipment, including frayed or loose-fitting clothing, dangling drawstrings or jewelry should never be worn.

Source: Iowa Fatality Assessment and Control Evaluation (FACE) Program, Case Report: 04IA060

Worker Killed Clearing Rock Crusher

The 45-year-old worker was operating the crusher for a construction company, which subcontracted to the US government to produce gravel for forest roads.

The crusher itself was a cylinder inside which big hammers rotated at 2400 rpm, battering the rock to pieces. A loader placed rocks on a vibrating screen, which fed the crusher. Although it was possible to shut it down from a distance, it was important that someone watch the machine closely in order to notice jams. If a jam built up, it would mean hours with the machine shut down while workers dug out compacted debris.

Despite this, there was no protected observation platform, and workers had the habit of standing on the crusher housing almost directly above the hopper opening. This was where the victim was standing when a large rock apparently jammed on its way in.

The victim turned off the vibrating feeder screen, but not the crusher, and tried to pry the rock out with a five-foot pry bar. The pry bar caught one of the rotating hammers and was flung back with tremendous force. A co-worker noticed the victim lying on a platform at the base of the machine. The victim was bleeding heavily from a wound in his neck. The bleeding couldn’t be stopped, and the victim died.

Do you take care around machines? No one should ever be standing guard over moving machinery without having both protection and a kill switch. The jam-clearing procedure required that the crusher be turned off. Attempting to avoid the delay cost this worker his life. Follow the instructions and perform the steps correctly and in order.

Source: Oregon Fatality Assessment and Control Evaluation (FACE) Program, Case Report 03OR040

Counterweights Crush Worker

An elevator operator died when the elevator’s counterweights came crashing down on his head and chest. The victim, a 49-year-old Hispanic man, had been working at the site for three months and was responsible for operating the site’s exterior construction elevator, moving workers and materials between floors. On the day of the fatality the victim noticed the lift was not returning to a level position on the ground floor. He asked a co-worker to bring him tools and entered the mechanism area where he began making repairs.

While the victim was making adjustments to the elevator, a group of workers arrived and asked to be transported to their floor. The victim asked a laborer to take the workers up and it was then as the elevator ascended that the counterweights descended and slammed down on the victim. The laborer discovered the victim almost immediately and called paramedics, but it was too late. The victim died as a result of major trauma to his head and chest.

Workers should not perform tasks they are not authorized or trained to do. In this case, two workers performed duties outside their job description: the laborer who used the elevator to transport the worker and the victim, who attempted repairs he was not qualified to do. An elevator technician qualified to make repairs would have known the importance of lockout procedures.

Source: California Fatality Assessment and Control Evaluation (FACE) Program, Case Report 05CA009

Operator Killed While Repairing Running Machine

A 61-year-old woodworker was killed as he was trying to replace a glue tray in a glue-press machine while it was still operating. The glue tray had been removed to repair a drip. The woodworker took the repaired tray, and with a new co-worker attempted to reattach it. At the same time, he instructed another employee to continue processing a product that was already in the press machine. When the victim could not see where to reattach the tray, he stuck his head inside of the machine, between the frame and the closed top lid of the press. Suddenly, the top lid lifted at the end of a programmed automatic cycle, crushing the man’s head against the frame. He was pronounced dead at the hospital.

Employees need to completely lock and tag out equipment before performing any maintenance. Along with this, companies must develop and implement a comprehensive lockout/tagout program. All pinchpoints and moving parts need to be fully guarded. Employers should routinely conduct hazard surveys and follow up with corrective action. Work procedures should be reviewed and changed if needed to prevent future incidents. Finally, only qualified personnel should have performed the work.

Source: Oregon Fatality Assessment and Control Evaluation (FACE) Program, Case Report 05OR005

Mechanic Killed Inspecting Stacker

On May 5, 2005, a 55-year-old maintenance mechanic was killed while inspecting a lifting machine at a masonry production plant. The recently repaired building materials moving platform, sometimes called a “stacker,” had run normally for four days. The mechanic had been warned not to inspect the moving parts beneath the machine without telling the operator and to use the machine’s lockout system.

An hour into the shift, an operator put the machine into idle to hand load materials. During this time the mechanic opened the gate beneath and inspected the chain mechanism without telling the operator. The operator finished his chore and put the machine into motion and the traveling bar slid and pinned the mechanic’s head against a support bar.

A short time later, a supervisor saw the chain gate open and found the man. An emergency team and the police were called. The mechanic died of blunt force head injuries.

All employees and management should follow and strictly maintain a program of safe operating practices around large machinery. Pinchpoints and large moving parts should be enclosed and danger signs should be visible at these locations. An interlock device should have been in place to shut the machine down when the maintenance gate was opened. An alarm should have activated whenever the machine started to move, not just at start-up.

Source: Oregon Fatality Assessment and Control Evaluation (FACE) Program, Case Report: 05OR008

Eliminate Doubt, Lock It Out!

Always follow your company’s lockout and tagout procedures. Just shutting off the power is not enough. You must isolate all forms of energy for the machinery or equipment. Energy can come from many different sources. It can be electrical, mechanical, hydraulic or pneumatic. It can even be stored energy such as a spring under tension.

These steps may be part of your company’s lockout procedures:

• Prepare for the shutdown by identifying the potential hazards and the type of energy used by the machine. Locate all of the switches, valves and other devices which need to be isolated.
• Tell affected employees about the lockout, and why you have to do it.
• You must wear the appropriate PPE (Personal Protective Equipment) required for the task. Ask your supervisor if you are not sure.
• Turn off the equipment or machinery following the proper procedures.
• “Tag” these turn-off points, especially if they cannot be monitored from where the work is being done.
• Isolate all energy sources, including any secondary power supplies. “Tag” these isolation points, particularly if they cannot be monitored from the worksite.
• Apply approved lockout and tagout devices. Fill out the tags completely and correctly. Each person working on the repairs should apply his own lock.
• Remove stored energy. This may include releasing the tension on springs, blocking or blanking pipe lines, releasing hydraulic and pneumatic systems, bleeding lines and opening valves.
• Verify the isolation of the equipment after making sure all personnel are clear of the danger area. Ensure the main energy disconnect cannot be moved to the “on” position. Then operate all controls on the equipment to make sure the equipment cannot start.
• Place all controls, switches and valves back in the “off” position.

Now that the equipment is locked out, you can begin to do your authorized repairs, adjustments or cleaning. When you have completed your work, you will need to remove the lockout and tagout by following certain procedures. If more than one person has installed a lock and tag on the machinery, the last person working will likely be responsible for ensuring the correct startup procedures are followed. This may include the following:

• Make sure all employees are safely clear of the equipment.
• Remove your tools.
• Replace machine guards.
• Remove your lockout device.
• Never remove another person’s lock.

A lockout and tagout should be used whenever an unexpected start-up or release of stored energy could injure you or your co-workers. Don’t leave anything to chance. Follow your company’s procedures, and lock it out for safety.

Bulldozer Kills Operator Standing on Track

A 33-year-old man, with eight years of experience, was crushed by his own bulldozer when he fell between the treads and the deck. The worker was giving a ride to a co-worker who needed to retrieve an all-terrain vehicle at the top of a hill. After the operator let the co-worker off, he saw that the other man had left behind a jacket. He stopped the bulldozer on a relatively level area of the hill, lowered the blade of the machine, and placed the bulldozer’s engine in idle, but did not set the parking brake. As he stood on the track to hand the other man his jacket, the machine moved backward. The bulldozer operator lost his balance, and fell feet first between the track and the deck. The machine continued to roll backwards another 8-10 feet (about three meters), and the operator was pulled below the bulldozer to his death. A follow-up examination found that the operator’s blood-alcohol content was 0. 08, above the legal limit for driving.

Heavy equipment operators should not operate equipment when drunk, even if the level of intoxication seems slight. Secondly, operators must become familiar with recommended safety procedures, such as applying the parking brake whenever they stop the machine. Finally, government safety regulations prohibit passengers on heavy equipment unless a proper seat has been installed for them to ride upon.

Source: Oregon Fatality Assessment and Control Evaluation (FACE) Program, Case Report 04OR023

Bulldozer Slides Over Worker

A 52-year-old ranch hand died when he was run over by a bulldozer on a cattle ranch in Oregon.

The victim was an experienced logger, with most of his work history in the logging industry. He usually set his own chokers behind the bulldozer, and operated the bulldozer to pull logs to the landing.

With the engine running, gear in neutral and parking brake set, the ranch hand had exited the cab and was busy setting chokers to logs behind the bulldozer, which abruptly slid backward and over him. The bulldozer did not slip into gear, but the tracks rested on woody debris, which may have contributed to the slide. The victim was pinned under the bulldozer, and was pronounced dead at the scene.

The sheriff’s department inspected the bulldozer and determined the brakes were in working condition. Cause of death was multiple blunt trauma.

Recommendations:

• Before exiting, the bulldozer operator must lower the front blade to the ground.
• Never rely solely on the brakes to prevent movement; bulldozer tracks may be unstable.
• Develop a site-specific safety plan.

Source: Oregon Fatality Assessment and Control Evaluation (FACE) Program, Case Report 04OR023.

Forklift Safety

As a forklift operator, it’s important to realize the majority of the safety responsibility rests on your shoulders – you are in the driver’s seat.

Despite its low speed capability, a forklift can still dump its load on a worker, roll, tip over or crush a worker against a wall causing injuries that can be fatal. That’s what you have to consider every time you get behind the wheel. It’s also why only trained and authorized personnel should drive a forklift.

As a trained operator, you complete the following checklist at the beginning of every shift:

• Condition of tires and wheels
• Condition of forks, carriage, upright and chains
• Hydraulic levels
• Horn, brakes, lights
• Checked for leaks
• Speed control and brakes

Now it’s time to pick up your first load. You know where you are going, what you are carrying and how much it weighs. You’ve also determined that the load weighs less than the weight-carrying capacity of your forklift.

Okay, you’ve secured your seatbelt and now you’re ready to roll. You watch for pedestrians and vehicles, aware that others may not be paying attention.

Remember these tips:

• Carry the load as far back as possible to minimize the possibility of tipping.
• Always tilt the load toward the truck.
• Carry the load as low to the ground as possible while still clearing any obstructions.
• Avoid loose loads above the backrest.
• Always look in the direction you are moving in.
• Don’t rely on mirrors.
• Make sure that the area behind you is clear before backing up and turning.
• Know your job-site: depth of loading dock, clearances, blind spots and obstacles.
• Know the Ramp Rules – go up and down ramps forward. But if you are carrying a load, back down a ramp.

Keeping speed with the rules of the “road” and the condition of your vehicle will help you keep yourself and your co-workers safe. Many warehouse complexes have established traffic routes. Forklift operators should follow these routes at all times and heed all warning signs.

Swing Stage Motor Failure Proves Deadly

Having a swing stage scaffold motor fail can be a pain, but if a worker is left stranded in a hazardous area, he or she can die. That type of situation occurred in a boiler at Suncor Energy in Fort McMurray, AB.

Two workers were cleaning the inside of a Trans-Alta operated boiler when a motor on a swing stage scaffold failed. The inside of the boiler was very hot, and the workers were stranded in place for over three hours while rescuers tried to get them out. One man was taken to hospital suffering from heat stress. He did not survive. His co-worker was treated and released from hospital.

Alberta’s Human Resources and Employment branch investigated the fatality. It has ordered TransAlta to address hazards that can occur during boiler cleaning operations. TransAlta was also ordered to ensure that workers are properly trained. It also must develop and implement emergency response and rescue plans and certify that equipment is in safe operating condition. ?

Do you work in confined spaces? The oilpatch is full of them, and they are dangerous to life and health. To avoid exposing yourself to unnecessary hazards in confined spaces:

• Always have an exit strategy and a rescue plan: If the air turned poisonous in an instant, how would you get out? More importantly, how would someone else get you out?
• Never enter any confined space unless you have the training to do it safely.
• Think about what you’re going into: A confined space might be the size of a house, or too small to stand up in.
• Confined spaces are often hot. Carry water if possible, make sure to take regular breaks, and get out if you start feeling ill.

Source: Alberta Human Resources and Employment, Workplace Incident Fatalities, January 1, 2006 to November 8, 2006

Shingler Falls Off Roof

While shingling a house, a 46-year-old roofer fell more than 20 feet (six meters) to his death. He had been shingling a steep roof section, working in cold weather with a chilling wind. The roofer was not wearing any of the fall protection equipment required for tasks 10 or more feet (three meters) above the ground.

The victim took lunch around 12:30 p.m., and started work again, shingling a small section of the corner of the roof. At about 1:30 p.m. he was discovered lying in the snow. The nail gun he was using was on the roof, suggesting the point where he fell.

Though the slope of the roof was approximately 3 in 5, witnesses confirmed that no fall protection was being used, although toe boards had been affixed to the roof. It was also uncommonly cold for roofing on the day of the incident. The temperature was 24 degrees with winds of 20 mph.

OSHA inspectors made these recommendations:

• Ensure that appropriate fall protection is available and used.
• Consider installing fall protection attach points into a home during construction.
• Stress importance of always following prescribed procedures.

Source: Nebraska Fatality Assessment and Control Evaluation (FACE) Program, Case Report 95NE010

A mobile home assembly worker was electrocuted while installing a roof on a mobile home.

The worker died after he touched the exterior of the home. It was electrified due to a short in the wiring of another mobile home on the assembly line. Four workers were installing the metal roof in their workstation. In the station next door, a home had a hot-to-ground short because an exterior nail pierced the wiring in the wall.

Electrical power (120 volts) is connected to mobile homes on the assembly line in order to use interior lights and electrical outlets during assembly. In this case, there was no ground wire. The short energized the metal frame, which was connected to the other homes by a chain. It was a very humid day, and the man was sweating, possibly contributing to the accident.

Investigators made two recommendations to prevent this sort of tragedy:

• Electrical and non-electrical metal parts in a mobile home must be grounded. After the accident, the firm designated one individual to complete this connection.
• Prior to connecting power to mobile homes, the wiring should be subjected to appropriate testing between live parts and the mobile home ground. This should be done after all exterior screws and nails are in place.

Respiratory Hazards Are Difficult To Detect

Your five senses are of little use in alerting you to respiratory hazards. You usually can’t see, feel or hear them, and they often have no smell or taste. You have to rely on your brain instead and what it has learned in safety training to protect you.

Respiratory hazards are conditions in the air that can cause you harm. Included are substances that can damage the respiratory system consisting of the nose, mouth, throat and lungs. Others are harmful substances which enter the body through the lungs, causing internal damage, poisoning or chronic illnesses. A major respiratory hazard is lack of oxygen which can cause immediate death.

Smoke, fumes, dusts, mists, gases and vapors are some of the substances which may injure you directly. Gases and vapors can also displace life-giving oxygen in the air.

Many corrosive gases signal their presence by irritating the nose, throat and eyes, resulting in coughing or watery eyes. But many other harmful airborne substances don’t give you a clue, such as carbon monoxide which has no color, smell or taste. In the case of deadly hydrogen sulphide, the rotten egg odor quickly disappears because of a reaction called “olfactory fatigue” in which the sense of smell becomes overwhelmed and fails to detect the odor. This can give a person a false sense of safety when in fact respiratory paralysis is quick to follow. Organic solvents cause headaches, dizziness, disorientation and possible lung damage and death.

These hazards often occur in confined spaces, where lack of ventilation allows harmful substances to accumulate and where the normal mix of breathing air is absent.

The only way to identify these hazards is by measuring the atmosphere periodically and thoroughly. Regardless of how often you measure the atmosphere, air quality in a confined space must be determined immediately prior to entry. The situation may be different in different areas or levels of the confined space and can change in an instant.

You must wear the correct respirator to protect against the particular hazard. Some respirators filter or purify the air. Others supply a separate source of air to breathe.

The respirator will be tested to make sure it fits you exactly so no contaminants can enter. A respirator that fits properly will be an effective seal against contaminants. Some conditions make an effective seal impossible or hard to attain – facial hair, missing dentures, eyeglasses, heavy makeup and others.

Proper maintenance of your respirator is vital to your safety and health. Inspect it for defects before each wearing and clean it to remove contamination after each use, following the manufacturer’s instructions.

Wearing the wrong respirator is as bad as wearing none at all. Be sure you are adequately trained and equipped to deal with respiratory hazards.

Safety Training: Once Is Not Enough

Being experienced in your work does not provide immunity from injuries. Nearly a quarter of acute injuries happen to experienced workers – as a result of human errors.

Statistics like this remind us of the need for continued safety training. Refresher courses, new training with new information and regular safety reviews are all necessary to keep you safe from workplace injury.

Near misses or minor incidents indicate something is wrong with the way you are working. Or perhaps it has simply been a long time since you covered the material. You may have forgotten some of it, or there may be new information or new methods to make it easier to understand.

How can you update your safety training?

• Ask for a review. Go to your supervisor, qualified co-workers and company’s safety department with specific questions you need to have answered.
• Use the company’s library of safety resources. Self-directed study workbooks and CDs, safety booklets and videos are some of the ways to learn and review the information. If you are not familiar with computers, start with an easy course while you learn to navigate.
• Use your breaks for safety reading and discuss it with your co-workers. Encourage your company to supply safety literature in the break rooms. Help set up a television and video player in the lunch room for safety presentations.
• Read again the information presented to you when you started your job. It will make much more sense the second time around. This could include your company’s safety policies and procedures, emergency instructions, operating manuals for equipment, Material Safety Data Sheets and labels for chemicals in your work area.
• Ask for cross-training in other jobs. You will look at hazards and safety procedures from a new perspective.
• Take the materials home to your family if you are allowed to. Make your safety training a household project. This will give your family members a better understanding of what you do, and they will encourage you to work safely.
• Ask for help with advanced training and education if you are interested. Your company might have a budget for sending you to safety conferences or technical courses. Even if no financial help is available, the department might be able to schedule your shifts to accommodate learning. Consider distance learning, in which you communicate by computer, television and mail.

You are never too experienced or qualified to learn more about your job. Start your refresher training today.

Driver Trapped in Pipe

Lester L. Woda, an orchard manager, drowned in Okanogan, WA, after becoming trapped in a reservoir pipe.

Woda had entered the 50-foot-long pipe to perform work. He had first tried to drain the pipe, but the flow of water coming in was described as being “like a waterfall”, making work impossible. Abandoning that approach, he took a scuba tank and entered the pipe again. The pipe was only 30 inches (66 cm) across, so he supported the tank above his head to allow himself to work below.

While he was working on the bottom, a butterfly valve closed on his foot, triggered by water pressure. Trapped at the bottom of the pipe, Woda tugged his safety rope, but workmates at the surface couldn’t free him. He ran out of air before rescuers arrived. Removing his body took 50 rescuers nine hours.

There were other options, less dangerous, that could have been employed here. Deliberately placing yourself in an unbreathable atmosphere, in an awkward position, and in a confined space is stacking three enormous risks on top of one another. Learn to recognize work hazards and avoid them.

Source: The Spokesman-Review, Spokane, Washington, July 19, 2006

Fourteen-Year-Old Laborer Crushed by Five-Ton Beam

A 14-year-old boy, employed as a laborer, was crushed by a five-ton beam that fell on him while he was working beneath a house that had been moved onto a vacant lot several months earlier. The house was being raised on temporary supports and cross beams until the new foundation could be built. The beams, one of which was placed under the house, were being used to lift the structure. Using an accepted industry technique, the workers were lifting the beam with an airbag. The worker was kneeling on the ground beside the beam when it suddenly rolled off the airbag, crushing him.

There were a number of recommendations made as a result of this accident. First is the requirement that a comprehensive health and safety plan be prepared, and that this plan should include a job hazard analysis. The analysis should be used for developing safe work procedures and for training employees. Another recommendation was that prior to any work being conducted, a site inspection should be performed to identify and correct any potential hazards in or near the worksite. Finally, a recommendation was made that parents be made aware of the work that their underage children will be required to perform, as children under 16 are not allowed to perform the types of jobs or work in the sort of environment described in this incident.

Source: Alaska Fatality Assessment and Control Evaluation (FACE) Program, Case Report 01AK027

Roger*, who sowed the seeds of his farming career at the age of 13, may have scoffed at the foretelling of his death on a small farm in Iowa 22 years later. But who could have known his fate around the rotating shaft of a posthole digger? All there is left to do is learn from his tragedy.

Roger’s Background
Roger began working on farms when he turned 13. The years passed until he bought and operated his own ranch, where he lived alone and worked on it nights, weekends and holidays. His days were filled working for a local farmer.

What Happened
In the fall of 2005, Roger set about building a fence with a posthole digger (auger) that he borrowed from his employer. Somehow he became entangled in the auger, which amputated his right arm. He died of multiple blunt force trauma and other injuries to his head, neck and extremities.

The Investigation
Roger’s fatality was not witnessed, but investigators surmised how the incident occurred. There was clothing, along with body tissue, wrapped around the upper portion of the auger, and the victim’s severed arm was found next to the posthole digger. Roger’s body was discovered about 30 feet (10 meters) from the tractor. Investigators found a broken handled shovel at the site, where dirt was spread away from where it would pile up around the hole. An operator working too close to the auger; clearing dirt, for example, could come in contact with moving machinery, investigators noted. It was also reported that no guard existed in the area where the auger connects to the gearbox output shaft. It wasn’t concluded that Roger was wearing loose clothing; his attire consisted of jeans, sweatshirt, flannel shirt and T-shirt. However, investigators said frayed or loose clothing would be more susceptible to being snagged by moving machinery parts.

Workers Take Heed
Employees should follow these recommendations to prevent similar deaths when working with tractor PTO (power take-off) devices and rotating augers:

• Tractor operators should disengage drive elements and shut off the tractor’s engine before leaving the operator’s station (cab or seat).
• Operators, and others, should stay clear when the posthole digger is in operation. Workers may be tempted to clear accumulated dirt away from the hole while the auger is running, but this is very dangerous and could result in entanglement.
• Posthole auger drive elements should be guarded with all shielding in place.
• Work areas should be clear of slip, trip and fall hazards.
• Loose clothing should not be worn around rotating equipment or machinery.

*The names aren’t real, but the incidents are. These accounts are based on actual fatality investigations.

The moral of this fatality is: Never work beneath a suspended load. That was the tragic lesson learned by longshore workers who watched in horror as a colleague was crushed by a 750-pound lug while working under a suspended turbogenerator.

How It Happened
A barge-mounted crane was being used to transfer a turbogenerator onto a railcar. The generator was suspended in the air six to 12 inches above the railcar. Each of four lugs was secured to the generator’s housing by four nut-and-bolt assemblies.

Crewmembers attempted to put support timbers on the railcar beneath the edges of the generator, but the nut-and-bolt assemblies were blocking placement of the timber. So the workers decided to remove the nuts securing the lugs to provide the necessary clearance for the timber.

A supervisor removed one nut-and-bolt assembly from the bottom of the lug. The foreman then removed the second nut at the bottom of the same lug. That’s when the lug fell and crushed him.

The Mistake
The first mistake was working beneath a suspended load. The second mistake the crew made: believing that when the bottom nuts were removed, each lug would be held in place by its nut-and-bolt assemblies.

None of the longshore workers was aware that the top assemblies were not secured to the turbogenerator.

What Workers Should Have Done
A hazard assessment should have been conducted prior to the lift. This would have revealed that the lugs were not secured to the generator housing by the two horizontal bolts of the lifting lugs. In addition, the workers should have discussed an alternate method of bracing the generator on the railcar. A preconstructed platform would have eliminated suspending the load above the railcar.

What OSHA Says
The Occupational Safety and Health Administration (OSHA ) says standards dictate that employees “stay clear of the area beneath overhead drafts or descending lifting gear.”

OSHA says a hazard assessment should have been conducted for the procedure of removing the nuts and lugs prior to performing the task. And a pre-lift safety meeting with all the employees would have identified the risks associated with the lift. Training in safe work practices (moving large equipment) would also have made a difference in the outcome, according to OSHA .

Trevor* was 24 years old when he died in an unguarded conveyor at an asphalt plant, where investigators concluded that several safety procedures could have prevented his death.

WHAT HAPPENED

Trevor was a trainee who, along with a co-worker, was instructed to assist in the recalibration of a conveyor by clearing it of any remaining asphalt and running aggregate through it. While the conveyor was operating, Trevor climbed onto a support beam (directly above an unguarded opening of the conveyor) to operate a handle controlling a gate in the conveyor chute.

The co-worker told Trevor to “get down from there,” but the young man continued to operate the handle. He lost his balance and fell feet first into the conveyor. The co-worker grabbed Trevor’s arm but could not prevent him from being dragged into a narrow aperature of the conveyor and being crushed.

WORKERS TAKE HEED

Employees should follow these recommendations to prevent similar deaths when working around conveyors and other machines:

• Don’t work with machinery that has exposed moving parts. Report lack of guarding to your supervisor.
• Make sure you know where all stop buttons are located so you can deactivate a machine quickly.
• Do not climb or stand on machinery. Use elevated work platforms to activate out-of-reach handles or switches.
• Ensure you have been trained to identify and control the hazards associated with your job, and ask that a job safety analysis be conducted before you begin a hazardous task.
• Regularly inspect machinery before each use. You might find a problem that could lead to a serious injury

* The names aren’t real, but the incidents are. These accounts are based on actual fatality investigations.

Deputy Sheriff Tony* was quite certain that the downed power line hanging only a few inches above the road was a ground wire that was safe to move by hand. He couldn’t have been more wrong.

In a flash of sparks, Tony was electrocuted and thrown over the bank by a jolt of electricity. He was later pronounced dead at the hospital.

WHAT HAPPENED
A car struck a utility pole at a curve on a US highway, resulting in the primary (hot) wire drooping to within inches of the roadway.

A state trooper arrested the motorist for drunk driving, secured the area and began directing traffic with the help of a civilian. The local utility company had been notified of the car crash and the downed wire. As the traffic load increased, the trooper called the local sheriff’s department for assistance. Tony arrived shortly after and began assisting the trooper.

During a discussion, Tony assured the trooper that the downed power line was only a ground wire because it was not wrapped with insulation. Therefore, it could be moved safely. Tony then grabbed the wire and carried it to the side of the road. Seconds later there was a flash. A witness stated that the deputy sheriff stepped off the road and onto a wet berm when the “line got him.” The electrical current sent Tony tumbling over the bank, and the line swung back to its previous position. Why the deputy was not electrocuted when he initially grasped the energized line is unknown. It is suspected that he may not have created a path to ground until the soles of his shoes were moistened by the wet berm.

WORKERS TAKE HEED
Employees should follow these recommendations to prevent similar deaths associated with downed power lines:

• Workers should not perform tasks until they have been properly trained (including simulation training) to identify and control the hazards involved.
• Workers assigned responsibility to coordinate activities at an incident site should follow established safety procedures. Tony had received two weeks of law enforcement training, including instruction in power line safety procedures. These procedures require that a utility company be called to de-energize downed power lines before they are moved or contacted.

* The names aren’t real, but the incidents are. These accounts are based on actual fatality investigations.

Stan* was hired as a hotel maintenance worker, whose duties included janitorial functions and minor repair. So how did he end up dead with electrical flash burns to 20 percent of his body?

Stan’s Background
Stan had previously worked as a welder and computer programmer before taking the maintenance job, which he held for three months before his death. According to the hotel manager, Stan’s past work experience qualified him to perform the duties he had been assigned, but his job description did not include changing fuses in an electrical panel.

What Happened
The garage area of the hotel had lost electrical power, and the hotel’s assistant general manager told Stan to “check out” the problem. The 39-year-old maintenance worker went to the electrical room and opened a panel to expose a burned out fuse. The victim then called the maintenance supervisor at home for guidance and was instructed not to touch the fuse. But despite the supervisor’s warning, Stan removed the 30 amperage fuse and proceeded to replace it with a blade-type fuse of different amperage. When he did this, an electrical flash occurred, burning Stan’s arms and face.

He Lived…and He Died
Although injured, Stan was able to exit the electrical room and call for help. He was still conscious when paramedics arrived and transported him to a local hospital for treatment. Stan was later transferred to a burn unit, where he complained of shortness of breath. After further tests, it was determined he had suffered an inhalation injury and was given respiratory aid. Stan’s condition worsened over time, and he died five days after the incident.

The Investigation
Investigators discovered that the power was not shut off before Stan began working on the fuse. In addition, there were no lockout/tagout procedures followed. Although the company had a standard electrical safety policy for changing fuses, Stan had not been trained in the procedure.

Workers Take Heed
Employees should follow these recommendations to prevent similar deaths when working around electricity:

• Workers should only perform tasks that are part of their well-defined duties. And they should not conduct hazardous work unless properly trained. It was clear that Stan was performing a task beyond his job description.
• Prior to working on any task involving electricity, the power should be shut off, and a lockout/tagout procedure should be implemented for safety.

*The names aren’t real, but the incidents are.These accounts are based on actual fatality investigations.