Document n9BJ66XYd0NmDBY6LJ1v3dmZG

I FROM E. B. PARKER ROCKDALE WORKS tA&* TO MANAGERS DEPARTMENT HEADS ROCKDALE WORKS 1977 December 12 RE: OSHA INDUSTRIAL HYGIENE INSPECTION - ROCKDALE WORKS Attached are copies of the citations received thus fas as a result of the industrial hygiene inspection made by Mr. Carl Halgren, OSHA industrial hygienist, between November 3 and November 18. We have fifteen working days in which to meet informally with OSHA and resolve any questions, or in which to contest any of the citations. The list was received on 1977-12-09, so our clock will run out between December 30 and January 4, depending on how the Christmas and New Years holidays are counted. I will confirm the exact date. I intend to request an informal conference about December 20 to discuss such things as the nature of the violations on Citation 1 (serious or non-serious) and the abatement times where it is obvious that compliance cannot be achieved in the period specified. We will be conferring locally with those whose input is necessary to develop abatement plans and schedules. Pittsburgh assistance will obviously be required in some areas. I will be coordinating our efforts locally. Please direct any. comments Copy to: J. R. Archibald - Pittsburgh F. P. Bergeron - Rockdale K. Jacqueline Bernat - Pittsburgh T. B. Bonney - Pittsburgh Dr. B. D. Dinman - Pittsburgh R. C. McCormack - Pittsburgh V. W. Rieke - Pittsburgh S. I. Roth - Pittsburgh R. W. Wrenn - Pittsburgh l-ZL ALCOA ARD 015252 *`490 <*CV U S. DEPARTMENT i)f LABOR OCCUPATIONAL (Art TV AMO HEALTH ADMINISTRATION CITATION and NOTIFICATION OF PENALTY Austin Area Office Suite 310, American Bank Tower 221 West Sixth Street Austin, TX 78701 t meaaci aau Hu<niII wov t r- r*. 1 X *12 3 4 12/8/77 ' MEN MiA j* reel 06 0330 i 1 r 2 [t^PtOWOWIQHalfrUlTATlMWO INSPECTION OATE: SERIOUS I1 11/03-21/77 INSPECTION SITE. FM Road 1786 T0. Aluminum Company of America P. 0. Box 472 Rockdale, Texas 76S67 Attn: W. J, Drake, Plant Manager cc: W. B. Renner, President Rockdale, Texas THE LAW REOUIRES thl cost of thn Citation be potted wnmedtetety m a promtnanl piece et or near me location of the tnm lauonlti cited below. Tha Citation mutt remain potted unfit the vtoietiont cited betow Have bean corrected, or lor 3 working day* Uadudinf weekend* and Federal hot*deytl whichewer longer. Tht citauon detcnbei noiauon* o< th Occupational Safety and H**lth Act of 1970. The penalty(wt) Iritad below are bated on theta woUtiona. Vow mutt cooeci the vaoKtiont referred to m uua citation by the datot tcuad be<ow and pay the penai(t prdpotad. urtteu vwUtm I$ working days (adwd*n9 weekends and Federal holiday*] horn your reewpt ! that citation and penal tv you mad a nonce el coniett to tha U.S. 0apartment oI Labor Area O'kf at the aodren moan eoove. (Sat tha ancioaad booklet mhch outline* your re*ponub4tiic* and court** ot acuon and mould ba read in contuncnon Htfi tfio form.I _ ITEM NUMOCN STAMOAft Q REGULATION OR SECTION Of THE ACT VIOLATED: DESCRIPTION 1 DATE ay WHICH VIOLATION MUST SECORRECTEO KNAlTItS ARC 0U wirrn* is OATS OF RECEIPT OF THIS N0TIF1CATU UNLESS CONTESTED ISandnH ImUmI Th*t Sectran A1 Ba detached PENALTY THE VIOLATIONS 0ESCRIBE0 IN THIS CITATION ARE ALLEGED TO HAVE OCCURRED ON OR ABOUT THE DAY THE INSPECTION WAS MADE UNLESS OTHERWISE INDICATED WITHIN THE DESCRIPTION GIVEN BELOW: l 29 CFR 1910.23(a)(3)(ii): Where operating conditions necessitate the feeding of material into any hatchway or chute opening, protection was not provided to prevent a person from falling through the opening: Imediate ; $240.00 In the cathode mix room a 59 inch by 38 inch opening existed above the hot mix machine, through which methyl naphthalene, coke, and pitch were added 2 29 CFR 1910.134(d)(2)(H): Only a high-temperature alarm was used on oil lubricated compressors and the air from the compressor was not frequently tested for carbon monoxide to insure that it met the requirements of the specification for grade 0 breathing air as described in Compressed Gas Association Commodity Specification G-7.1-1966: 1/3/78 $240.00 The Ingersol-Rand compressors, serial numbers JH5869, JH4706, JH4440 , 4760, located in building No. 37G 3 29 CFR 1910.178(p)(1): Powered Industrial trucks with defects or In any way unsafe had not been withdrawn from service until restored to safe operating conditions: 12/27/77 i $300.0C Industrial truck #33-164 operated in the vicinity of furnace #12 was operated with an unapproved and broken overhead support brace 4 29 CFR 1910.242(b): Compressed air used for cleaning purposes was not reduced to less than 30 p.s.i.: 12/27/77 : $300.0< Plant air at 100 psig 20 psig was used to clean pot #51 in Room 132 during pot patching operations - AREA OIRECTOR HERBERT M. KURTZ 12/8/77 =~orrrA5PAGE NOTICE TO EMPLOYEES -- The law gives an employee Of hu representative the opportunity to object to any abatement date set lor a violation i! he be'ieves the date to be unreasonable. The contest must be mailed to me U S Department of Laoor Area Office at the address shown above within IS working days (excluding weekend! and Fedcial holidays) of the receipt by the employer of this citation and penalty. EMPLOYER DISCRIMINATION UNLAWFUL - The law pro TOTAL PEN hibits discrimination by an employer against an employee for FOR THCITATIO filing a complaint or for exercising any rights under this Act. Mt* cN#cLo* t An employee who believes that he has been discriminated Chew Pww against may hie a complaint no later than 30 days after the "ol_os> discrimination with the U.S. Department of Labor Area Office . IWimi* OS** . on R*IWII< at the address shown above. EMPLOYER RESPONSIBILITIES AND COURSES OF ACTION - The enclosed booklet outlines employer responsibilities and courses of action and should be read m conjunction with this notification. CITATION AND NOTIFICATION OF PENALTY OSHA 7 REV. S/76 u s. department of labor OCCUPATIONAL SAMTV ANO HCALTH AOAHNISTRATION CITATION and NOTIFICATION OF PENALTY Austin Area Office Suite 310, American Bank Tower 221 West Sixth Street Austin, TX 78701 tSSaUKl BATE ow biwdi 12/8/77 1174711 044 attiae aria .reel ___ Q______ 0330 1 2 "'2 .TTPfcOe VIOLATEON ttM|iOTATIOa INSFCCT10N OATt: SERIOUS I1 11/03-21/77 INSPECTION SITE: FM Road 1786 to: Aluminum Company of America P. 0. Box 4 72 Rockdale, Texas 76567 Attn: W. J. Drake, Plant Manager cc: W. B. Renner, President Rockdale, Texas THE LAN REQUIRES mat a easy ol Pin Outsort N potted vnimMitiv <* a proms* mai place i or Mar ttu location of the v*otoiion(s) atod beAow. Tho CsUtson mitt wniin posted urttsi ftu moUtsOM cstad bo* io* how* boon corrocud. or tor 3 working day* Usefcadmf moiiaH and Podoraf holi days! whehrw rs longer. This citation aaicron -Pnnni oi in* Occuoaiional Salary and Haalrh Act of 1970. Tha panaityfiaa) Hatad Mow ara bawd on Plata woianom. You mu( correct iM mout'OM 'emred 10 in this citation by (ha dam listed betow and pay ine pmUtai propoaod. unless within 1S worksite days IndudiAf Nftktnci ano Paoarat *o*davil tsom your ractspi of this cstaiton and penalty you mad a noro of contest to IN Ui. Papartment of Labor Area Odea at ma auorasi mown eoove. (Sea tha anctoud booklet whch outlines your rasponaibdiuea and courses of actson and dtoutd be read m conjunction drM Pits lormJ s ITEM NUMBER STANDARD. REGULATION OR SECTION OP THE ACT VIOLATED: DESCRIPTION OATE BY WHICH VIOLATION MUST BECORRECTED . tl/U TILS ARE 0UE WTMIR IS ATS OF RECEIPT Of THIS OT1FICATIO 01 LESS CONTESTED (SNaadaaad ipaMatl Rafaro Pottwa PENALTY The conditions described in the alleged violations of this citation exposed employees to a serious .hazard which could reasonably be expected to cause death or serious physical injury. ARD 015254 ` AREA DIRECTOR HERBERT M. KURTZ 12/8/77 $1080.OC NOTICE TO EMPLOYEES -- The law gives an employee or his representative theooportumry to object io any abatement date set ior a violation if he believes the dale to be unreasonable. The contest must be mailed to the U S. Department of Labor Area Office at the address shown above within 15 working days (excluding weekends and Fedeiai holidays) of the receipt by the employer of thss citation and penalty. EMPLOYER DISCRIMINATION UNLAWFUL - The lew pro TOTAL PENA . hibits discrimination by an employer against an employee for FOR THIS CITATION filing a comoJamt or for exercising any rights under this Act. MakvcMckor* An employee who believes (hat he has been discriminated Ofirr Piyiov against may file a complaint no later than 30 days after the : "oolosh. discrimination with the U.S. Department of Labor Area Office IndKili OSHA on Rtmiui at the address shown above. EMPLOYER RESPONSIBILITIES ANO COURSES OF ACTION - The enclosed booklet outlines employer responsibilities and courses of action and should be read m conjunction with this notification. CITATION ANO NOTIFICATION OF PENALTY OSHA 7 REV. s/re U-S. DEPARTMENT .IF LABOR OCCUPATIONAL SAFETY ANO HEALTH ADMINISTRATION CITATION and NOTIFICATION OF PENALTY Austin Area Office Suite 310, American Bank Tower 221 West Sixth Street Austin, TX 78701 BlVABCt OAfl i OSMAawmlft 12/3/77 * ituca 06 H7471 044 a i< mi 0330 I 1 o' 3 INSPECTION OATE: OTHER 2 11/03-21/77 INSFECTION SITE: FM Road 1786 T0. Aluminum Company of America P. 0. Box 472 * Rockdale, TX 76567 Attn: W. J. 0f3k6, Plant Mdna96r Rockdale, Texas THE LAW REQUIRES txai cody at ihn Citation b potted vnmedmeiy <n a oromi mtn piece at or near 9>* location of lit# woletionfi) cited below. The Citation mwu rMi potted until the *o!etont cited be tow hWe been corrected. Of 3 working cc: W. 8. Renner, President ad*a*rt) whenever longer. * fntn km- Thu ettauon detcnOn vtouiwnt of the Ocewoational Safety end Health Act of 1970. The penaftyfiet) fitted below ere baaed on these note(tom. You mutt correct the vtoieuont referred to m ttut citation by the dates Ifcted below end pay the penettm proposed, uniesa withet IS working days leuludmi weekends and Federal holiday?) from your receipt of ttws citation and penalty you mad a notce of contact to the U S. Oepartmom of Labor Area OI1< at the addresa shown above. ISea the enclosed booklet when outlines your repionarbditdi end courses of action and dsouSd bo read m conmnetion with this tormJ ITCM NUMBER STANOARO. REGULATION OR SECTION OF THE ACT VIOLATED: DESCRIPTION DATE SY WHICH VIOLATION MUST IE CORRECTEO PEN AITIES ARE OUE WITHIN IS OATS OF RECEIPT Of THIS N0TIFICAT10I UNI ESS CORTESTEO (Sm indnH (Mkltll Thai Section Ma te OttacM Before Poetiog PENALTY THE VIOLATIONS DESCRIBED IN THIS CITATION ARE ALLEGED TO HAVE OCCURRED ON OR A80UT THE DAY THE INSPECTION WAS MADE UNLESS OTHERWISE INDICATED WITHIN THE DESCRIPTION GIVEN BELOW: 1 29 CFR 1910.95(b)(1): Employees were subjected to sound levels exceeding those listed in Table G-16 of subpart G of 29 CFR part 1910 and feasible administrative or engineering controls were not utilized to reduce sound levels: 12/8/77 $165.00 An.employee operating the stub press In the roddlng room STEP 1: A written detailed plan of abatement leading to the complete abatement of this Item shall be submitted to the area director. Such a plan shall: a) employ the use of qualified engineering personnel; b) include detailed engineering studies and their results; c) outline the ordering of equipment and materials and completion of the design phase; and d) outline dates for the anticipated implementation of the plan. 1/09/78 STEP 2: Abatement shall be completed by the implementation of feasible engineering controls and/or administrative controls and its effectiveness at achieving compliance verified. 90-day progress letters are requested during the abatement period. 12/8/77 2A 29 CFR 1910.1000(c): Employees were exposed to nuisance dust in excess of the 8-hour time weighted average limits listed for nuisance dust in Table Z-3 of subpart Z of 29 CFR part 1910: 6/8/78 $300.00 A front-end loader operator in the vicinity of the bath crusher was over-exposed to the respirable fraction of nuisance dust ' 2B 29 CFR 1910.1000(e): Feasible administrative or engineering controls were not determined and implemented to reduce employee exposures to nuisance dust: A front-end loader operator in the vicinity of the bath crusher was over-exposed to the respirable fraction of nuisance dust 6/8/78 ARD 015255 _____________ --1 /, rn AAA OIAECTOR 1/ . . ^ .N ~ * /' Herbert m. kurtz 0 12/8/77 ''njN last PAGE NOTICE TO EMPLOYEES - The law gives an employee or his representative the opportunity to object to any abatement date set for a violation if he believes the date to be unreasonable, The contest must be mailed to the U-S. Depaitment of Labor Area Office at the address shown above within IS working days (excluding weekends and Federal holidays) of the receipt by the employer of this citation and penalty. EMPLOYER DISCRIMINATION UNLAWFUL - The law pro hibits discrimination by an employer against an employee for filing a complaint or for exercising any rights under this Act. An employee who believes that he has been discriminated against may hie a complaint no later than 30 days after the discrimination with the U.S. Department of Labor Area Office at the address shown above. TOTAL PENA FOR THIS CITATION kltkeriwcfc o M O'** PovHMv "OOtOSM. Indicate OStiA on RfmtitAK EMPLOYER RESPONSIBILITIES ANO COURSES OF ACTION - The rnclotcd booklet oullinei employer rnpontiUilitiet nd ' courses of action and should be read m conjunction with this notification. : CITATION ANO NOTIFICATION OF PENALTY OSHA 2 AfV. V76 US. DEPARTMENT 3F LABOR OCCUPATIONAL SAFETY AMO HEALTH ADMINISTRATION CITATION nd NOTIFICATION OF PENALTY Austin Area Office Suite 3)0, American Bank Tower 221 West Sixth St. Austin, TX 787C1 amici ears < oema atmilft 12/8/77 itcie* )6 H7471 . 044 ~AM* 1* AGI 0334 2 *'3 PTVPB OP.VlOUmOHMWtLIIXTIDBRO INSPECTION OATC: OTHER 11/03-21/77 INFECTION LITE: FM Road 1786 TO: AAlluummiinnuumm cCoommppaannyy oorf AAmmeerriiccaa P. 0. Box 472 Rockdale. TX 76567 Attn: W. J. Drake, Plant Manager Rockdale, TX nre law reouires .h. copy o4 tht Oution bt potted immediately tn a prom*imm place at or noar pie location p< th# v*olattenUI citod Mow. Tho Citation mutt remain posted until the woUtiont ated be low Mm been corrected, or for 3 working cc: W. B. Renner, President dart leadwdmg weekend* and Federal holi day*) whichomc longer- The citation e**eo*i v*o<i*on of in# Occwpauond SaUty and Health Act of 1970. The penalty!***) lifted below are bated on thee violation*. Yog mutt correci the v'ouuon* *e<t*ed tom tnn citation by me date* listed Mow and pay the penal!* proposed. unleu wiihm IS working day* (excluding wcend* and Fertef* hd*dayti from your receipt Of th* ciution and penalty you mai a note* of contact to the U.S. Department of Labor Area Oll< at th aoni mown aooe. ISee die enctoaed booklet which outline* your reeponobditiea did courvet ol action and dioutd be read mconiwnction wim tfm form.) PENALTIES ARE OUE T/1THIN IS DAYS OF RECEIPT OF THIS NOTIFICAT: UNLESS CONTESTEC (Sat ladial Beakfttti TMS ITEM ffltklflCW STANOARD. REGULATION OR SECTION OF THE ACT VIOLATEO: DESCRIPTION DATE BY WHICH VIOLATION MUST Bt CORRECTED STEP 1: Effective respiratory protection shall be provided and used by employees as an interim protective measure. 12/27/77 STEP 2: A written detailed plan of abatement leading to the complete abatement of this item shall be submitted to the area director. Such a plan shall: a) employ the use of qualified engineering personnel; b) include detailed engineering studies and their results; c)outl1ne the ordering of equipment and materials and completion of the design phase; and d) outline dates for the anticipated implementation of the plan. 1/09/78 STEP 3: Abatement shall be completed by implementation of feasible engineering.and/or administrative controls and Its effectiveness at achieving compliance verified. 90-day progress letters are requested during the abatement period. 6/8/78 2C 29 CFR 1910.154(a)(2): The employer did not establish and maintain a respiratory protection program which Included the requirements outlined in paragraph (b) of this section: 12/27/77 A front end-loader operator In the vicinity of the bath crusher was over-exposed to the respirable fraction of nuisance dust 20 29 CFR 1910.134(b)(1): Written standard operating procedures governing the selection and use of respirators were not established: 12/27/77 A front end loader operator transporting bath material in the vicinity of the bath crusher 2E 29 CFR 1910.134(b)(3): The users of respirators were not instructed and trained in the proper use of respirators and their limitations: 12/27/77 Training on the uses and limitations of respirators was not given a front-end loader operator in the bath crushing area * AREA DIRECTOR HERBERT M KURTZ 12/8/77 "ON LAST PAGE NOTICE TO EMPLOYEES -- The law gives an employe* or his representative the opportunity to obiect to any abatement date set tor a violation if he believes the date to be unreasonable. EMPLOYER DISCRIMINATION UNLAWFUL - The law pro hibits discrimination by an employer against an employee tor filing a complaint or for exercising any rights under this Act. TOTAL PENAL FOR THIS CITATI0.N The contest must be mailed to the U S. Department ol Labor Area Office at the address shown above within IS working days (excluding weekends and Federal holidays) of the receipt by the employer of this citation and penalty. An employee who believes that he has been discriminated Of dm* Pw*W r against may file a comolaint no later than 30 days after the : ~ool osha discrimination with the U.S. Department of Labor Area Office . Ind'iAi# OSHA * . MHWi at the address shown above. EMPLOYER RESPONSIBILITIES ANO COURSES OF ACTION - The enclosed booklet outlines employer responsibilities and courses of action and should be read m conjunction with this notification. CITATION ANO NOTIFICATION Of PENALTY OSHA 2 RCV V76 nrU.S. department labor OCCUPATIONAL SAFETY AMO HEALTH AOMINItTRATION CITATION and NOTIFICATION OF PENALTY Austin Area Office Suite 310, American Bank Tower 221 West Sixth Street Austin, Texas 78701 ttseaacf mti ISMAIWMI 12/8/77 1 at siM 06 H7471 . 044 * AMA , net 0330 1 3 ' 3 INSPECTION DATE: OTHER 11/03-21/77 INSPECTION SITE: FM Road 1786 TO: Anliuwmiinuuwm VCo^mapanny, UoIf Ammiicei rIiLcOa Rockdale, TX THE LAW PEOUIRES Out cost M Um P.0. Box 472 Gutiofl be posted vnmoaiaiy m a promt* Rockdale, TX milt plan at or new me location pa the woluioalri otod bdao. The Caution mutt remain poeted until the viofeuone atad be* Attn: W. J. Drake, Plant Mgr. low ten boon corrected, or for 3 working cc: W. B. Renner, President deys (excluding weekends and Federd Hoiidays) wheneverlonger. This citanon dncnDn notations oi ih Occupational Safety and Health Act of 1970. Tho penalty(fed bstad below are based on these viefetiora. You must correct tha violations referred to m this citetion by the datas Itstad below and pay the penalties propoead. tmfeu withm I & working days (excluding w*eends and Ftdwai hddnti horn your receipt of this citation and penalty you mad a notes of contest to the U.S. Department of Labor Area 0<fe at tha address mown above. (Sat tha enclosed booklet whh outlines your nponebliiw end courses of action and sboutd bo read in confunction with pus tormj "1 item number STANPARQ. REGULATION OH SECTION Of THE ACT VIOLATEO: i OATE BY WHICH VIOLATION MUST DESCRIPTION_____________________________ IECOHRECTEO PENALTIES ARE DUE mrma is OATS OF RECEIPT Of THIS NOTIflCATlOR UHL ESS C0ITESTE0 iMUMi"1' Tlue Section Mae Se Detached IsfertFeiiwf PENALTY 2F 29 CFR 1910.134(b)(11): Approved or accepted respirators were not used when they were available: A front end loader operator working In the bath crusher area did not wear a respirator and was over exposed to the respirable fraction of nuisance dust 12/27/77 " AREA DIRECTOR HERBERT M. KURTZ & 12/8/77 S465.00 NOTICE TO EMPLOYEES - The law gives an employee or his representative the opportunity to object to any abatement date tel for a violation if he believes the date to be unreasonable. Th contest must be mailed to the U S Department of Labor Area Office at the address shown above within IS working days (excluding weekends and Federal holidays) of the receipt by the employer of this citation and penalty. EMPLOYER DISCRIMINATION UNLAWFUL - The law pro TOTAL PENAl hibits discrimination by an employer against an employee for FOR THIS CITATION tiling a complaint or for exercising any rights under this Act. WjkftfetkoiUo An employee who believes that he has been discriminated ; Oe** Pevxbfe 1 against may file a complaint no later than 30 days after the : -oot osma discrimination with the U.S. Department of Labor Area Office . lAdiCMtf OSHA i ; ot a*Rntuw< at the address shown above. EMPLOYER RESPONSIBILITIES ANO COURSES OF ACTION - The enclosed booklet outlines employer responsibilities and courses of action and should be read in conjunction with this notification. CITATION ANO NOTIFICATION OF PENALTY OSHA 2 REV. V7S FROM J. J. CONGLETON ROCKDALE WORKS -X&-* TO MANAGERS DEPARTMENT HEADS SUPERINTENDENTS 1977-11-22 RE: OSHA CLOSING CONFERENCE, 1977-11-21 MONDAY 10:00 A.M. - 12 NOON ROCKDALE WORKS Attached is a list of those people who attended and their respective function. Attached is an item by item list of apparent safety and health hazards, associated area of the plant, and proposed abatement dates. Items marked with an asterik have been identified as hazards and a citation will be forthcoming. Those items not marked means that samples were taken and possible citations may result de pending upon the findings from the analysis of those samples. This list of items resulted from Mr. Carl Halgren, Industrial Hygienist and Mr. Walt Cunningham, Safety Engineer from OSHA conducting an inspection of the Rockdale Works facility on: 1977-11-03 1977-11-04 1977-11-08 1977-11-09 1977-11-10 1977-11-11 1977-11-17 1977-11-18 Mr. Halgren and Mr. Cunningham conducted themselves in a very professional and competent manner throughout the inspection. Mr. Halgren's closing conference was also conducted equally professional. The Union and the Company maintained a businesslike approach throughout the inspec tion and closing conference. It is now a matter of applying ourselves (jointly) to final resolution of these items. A copy of the results of the sampling and the methods used in analyzing the samples will be requested in writing from OSHA. A follow-up report will accompany the citation upon its receipt. r' J. J. CONGLETON JJC:mj 2/1 Attachments For Distribution See Page Two I . I i--l A ARD 015258 Copies to: F. P. Bergeron, Rockdale R. W. Wrenn, Pittsburgh R. C. McCormack, " T. B. Bonney, " B. D. Dinman, " J. R. Archibald, " S. I. Roth, " MANAGERS DEPARTMENT HEADS SUPERINTENDENTS 1977-11-22 Page Two ARD 015259 Attachment I Name 1. J. J. Congleton 2. E. B. Parker 3. W. G. Henson 4. J. E. Crowder 5. Joe R. Hughes 6. Fred Mabry 7. Harry W. Brooks 8. E. J. Gaas 9. A. G. Clayton 10. J. L. Roddy 11. J. W. Havins 12. Evan R. Goltra, M.D. 13. W. D. Essary 14. C. L. Green 15. Farrel H. Sutton 16. H. P. Dick 17. Thomas Williams 18. Neal Ritchey 19. Nelson Mueller 20. Jack Drake OSHA Closing Conference 1977-11-21 10:00 a.m. - Monday - Rockdale Works Position Manager of Safety Environmental Superintendent Union Safety Company Chairman Potlining Safety Chairman Staff Representative USWA Staff Representative USWA Personnel Manager Potroom Safety Chairman Chief Chemist Electrode Superintendent Production Manager Medical Engineering Manager Environmental Manager Potroom Superintendent Ingot Safety Chairman Carbon Plant Chairman Potlining Service Superintendent Safety 5 Health Administrator Works Manager mj 2/1 ARD 015260 ttachment II Action to be taken and tem Brief DescriptionArea of PlantLength of Abatement Period .* Chlorine respirators not available for emergency escape from area. Properzi Provide respirators - 15 days Opening to the top of mixer not guarded Potlining - Building 127 Guarded and abated - 1977-11-10 3.* Carbon Monoxide alarm not installed for plant air compressors that are used sometimes for breathing air. Total Plant 4.* No attempt to reduce air flow from plant air system (100 psi +15 psi) - being used to blow off pots and superstructures. Potrooms 5.* Pot Tenders eating their lunch in Potrooms (exposure to fluorides through ingestion) 6.* Not wearing approved asbestos respirator while handling asbestos and in addition question whether the provided 3M 8710 asbestos respirator is adequate protection. Potrooms Potlining (Cradle insulation) Install alarm - 30 days Use of approved blow off pipes insuring no more than 30 psi air flow - 15 days. Discontinue eating lunch or working in potrooms- 30 days. Provide proper respirator. (15 days) 83510 QBV Attachment II Item $ Brief Description_______________________ 7.* Electric fork truck No. 33-164 had non- approved modification to overhead guard (from four post ot three post overhead guard). 8. Samples taken from Coal Tar Pitch Volatiles Area of Plant Ingot Carbon Plant 1. Mixer 2. Press 3. Ring Furnace Action to be taken and Length of Abatement Period Install proper design overhead guard - 15 days. A. Provide proper respirator (15 days) B. Develop Plan of Abatement (30 days) C. Final Abatement (1 year) 9. Samples for respirable dust taken of (primarily of vehicle operators) 10. Samples Taken for Fluorides Butt crushing mill Ore Unloading Bath Crushing Skim Room A. Provide proper respirator (15 days) B. Develop Plan of Abatement (30 days). C. Final Abatement (6 months) Potrooms A. Provide proper respirators (15 days). B. Develop Plan of Abatement (30 days) C. Final Abatement (1 year) Attachment II Item $ Brief Description 11. Samples Taken for Asbestos 12. Violation of respirators standards 13. Excessive Noise 14. Excessive Noise mj 2/1 > 3 D o pi Area of Plant Potlining (Shim Pot Cradles) Total Plant Action to be taken and Length of Abatement Period A. Provide proper respirator (15 days) B. Develop Plan of Abatement (30 days) C. Final Abatement (1 year) Follow the Alcoa Engineering Standard 18.1.1 - 15 days. Rodding Room A. Develop abatement Plan (30 days) B. Final Abatement - 1 year. Ingot Furnace A. Develop Abatement Plan (30 Days) B. Final Abatement (1 year). J. K. MC CLAIN 1977 September 27 TO MR. H. W. COOPER MR. R. G. BARLUND MR. D. J. FISHER MR. D. G. APPLEGATE cc: MR. G.B. SCOTT __^MR. R. M. ROSE RE: SAFETY We have this year been vety successful in improving our safety record as measured by serious and disabling injury frequency. This has required a great deal of attention to detail to avoid the numerous injuries caused primarily by indi viduals hurting themselves by careless work habits. Let me ask this question, how much have we done to prevent accidents which could result in fatalities? What percentage of our effort has been directed toward insuring that no one in our organization is killed on the job? Now let me answer this question as ! see it. Our overall safety program has improved all aspects of safety but we have not directly set out to minimize our chances of killing someone. This is what I want to do now. Please discuss this within your departments and identify the hazards inherent in our operation whereby inattention-nr'pquipmpaLfailure there is a distinct possibility of a fatal accident. Then outline what should be done to further minimize the risk.