Document vVyDB4GoxEwvVnqjXoDn38RDb

n Nansen National loaa Control Sorvict Corporation Long Grove. Illinois 60049 * (312)540-2400 SAFeTY & Loss Contro1 Report Prepared for GAF CORPORATION Address 2400 Eiaogene Street City Mobile State AL 5ECURI ziKa6t By Tom Shetterly Date of Survey May 14,1980 ____ Original Title Senior Loss Control Consultant; Contract No.030579^^^^QMtionbcSe S52?0 X Follow Up , RC } No. of Employees 286 Location Manager: Mr. E. M. Trigg, Plant Manager FiLE l^lLl INTRODUCTION Today's visit to your Mobile, Alabama plant was'coordinated through Mr. Vernon Boddin, Jr., Assistant Plant Manager; and Mr. Curtis Robinson, Personnel Manager and Safety Coordinator. I also met with the Plant Manager, Mr. Trigg, to discuss the objectives of an effective loss control program, and the need to update and improve the present program, by applying recognized accident prevention principles. Objectives for this visit were: - Review the current loss control activities. - Inspect specific areas for employee hazards. - Attend and participate in a supervisor's safety meeting. ./ - * Set objectives for the next visit. The new recommendations developed during today's survey were reviewed with the Safety Coordinator, Mr. Robinson, and were also covered during the supervisor's safety meeting. GAF 11401 GAF CORPORATION Mobile, AL May 14, 1980 Page-2- Loss Control Program: The local management has not as yet received a copy of the March 3, 1980 safety survey report, so were not familiar with the comments and recommendations contained therein. fr** Management recognizes that they will have to assume full responsibility for safety and health, and consequently will need to restructure and upgrade the present activities in order to effectively control the number of accidents at this plant. , MV- This plant is one of a number of locations, singled out by the corporate headquarter management -heeding immediate implementation of a loss control program with emphasis on accident investigation, self-inspection and employee training. Revision of the present safety program is indicated by a thorough evaluation of the present activities and results. Inclusion of new elements to create more interest and maintain a good loss record is also indicated. A program that does not change with developments will not be fully effective, and a stagnant program will adversely effect the attitudes of the supervisors and the workers. See DISCUSSION section - Loss Control. Physical Hazards Inspection: Housekeeping was found greatly improved over the conditions noted during the last visit. (Special interest was given to the area involving the use of asbestos in the manufacture of a roofing mastic compound. See DISCUSSION section S' pl ecial hazards. the report of March 3, 1980, has not been received at the plant, wvsWanagement has not been informed of the need for correcting the hazards ^ /covered in the RECOMMENDATIONS section of this report. Safety Meeting; The Plant Manager, Assistant Plant Manager, Safety Director and all of the supervisory personnel attended today's meeting. The Plant-Manager read a letter from the corporate headquarters directing that immediate steps be taken to improve the loss experience at this plant. Considerable discussion involved the high number of lost workdays experienced at this plant. GAF 11402 GAF CORPORATION Mobile, AL May 14, 1980 Page-3- My involvement in this meeting was aimed at motivating the supervisors by showing them the qualities and responsibilities of a good supervisor, plus his place in the management program as it relates to accident prevention. Future Objectives: The next visit to the Mobile area is tentatively scheduled for July 1980. I will contact Mr. Robinson prior to then and finalize plans for a Supervisor's Safety Meeting with accident investigating and reporting, using the "Supervisor's Accident Report Form", as the topic. Safety material covering the special "Welding and Cutting Permit Procedure", and procedures for a "Tag-Out; Lock-Out" program was given to the Safety Director for possible use in his loss control program. RECOMMENDATIONS IMPORTANT REPEAT RECOMMENDATIONS 80-3-1 Although local management is committed to loss control, the present program is loosely organized with the only real safety activity centered on the monthly safety meeting. The present loss control efforts should be upgraded to include all the elements of the GAF Corporate "Safety and Loss Prevention Program", as outlined in Section #1 of the program entitled "Organization, Planning and ./ Administration." GAF 11403 GAF CORPORATION Mobile, AL May 14, 1980 Page-4- 80-3-2 The safety program should incorporate the following basic elements, proven effective in every good accident prevention program: 1. Top management's assumption of leadership and accountability for employee safety and health should be published in a written statement of policy for all to see and read. See DISCUSSION section. 2. Assign responsibility for implementing the company's policy. See DISCUSSION section. 3. Initiate a regular, continuous self-inspection program of the workplace to determine and correct unsafe physical hazards and unsafe employee work practices. 4. Establish special Supervisor and Employee training programs in compliance with Section #4 of the GAF Corporate Safety and Loss Prevention Program. A review of a number of Supervisor's Accident Investigation forms pointed out deficiencies in the Cause-Remedy-Action section. Other specific requirements for training, such as training to license forklift operators, should be initiated. 5. Since people do not always do what you want them to do, or as you want them to do it, they have to be shown, they have to be trained and they have to be motivated. There is no motivation program to encourage employee awareness, acceptance and prticipation in the Management Safety Program. There is no definite direction in the form of published safety rules and regulations. 6. A safety awareness program should be initiated using GAF guidelines presented in Section #5 of the Corporate Safety and Loss Prevention Program. 7. General and specific safety rules should be established, distributed, and thoroughly discussed with all employees. G/*F 11404 GAF CORPORATION Mobile, AL May 14, 1980 Page-5- Physical Hazards 80-3-3_ A ladder cage device or a ladder safety device (for use with a lifeline and safety belt) should be installed on the fixed ladder attached to the high metal water storage tank. See DISCUSSION section. 80-3-4 The gas fired portable unit heater presently located adjacent to the Leadman's desk in the Automatic Stacker area should be removed, or, if used, should be provided with a vent pipe leading to the exterior of the building and a mesh screen guard device with openings no larger than 1/2 inch to enclose the fan blade opening. 80-3-5 The expanded metal screen guard over the end of the finish rack in the Asphalt Plant which has been damaged and cut by forklift trucks should be repaired to eliminate laceration hazards to hands. 80-3-6 The missing cover on the Hinder machine housing the measuring wheel should be replaced. 80-3-7 The loose metal guard device over the drive belt/pulley system on the asphalt storage tank pump should be securely fastened in place. 80-3-8 ./ A permanent set of steps should be Installed to provide easy and safe access to the elevated metal platform at the end of the Rewinding machine in the Felt Mill. See DISCUSSION section. 80-3-9 The metal doors to the D.C. Motor Room located at the rear of the Felt Mill should be permanently and securely fastened in place. 80-3-10 The bent metal pipe barriers installed around the main gas supply pipeline and valves should be straightened. 80-3-11 The loose electrical conduit to the ceiling light fixture in the Men's Room of the Office/Laboratory Building should be properly and securely attached to the electrical junction box. GAF 11405 gaf corporation Mobile, AL May 14, 1980 Page-6- 80-3-12 All metal file cabinets in the various Office areas should be bolted together to prevent possibly tipping whenever the top two drawers are opened at the same time. IMPORTANT NEW RECOMMENDATIONS 80-5-1 Caution labels should be attached to all trash bags containing clothing and other wyste material being removed from the asbestos mixing operation. The label should state: CAUTION Contains Asbestos Fibers Avoid Creating Dust Breathing Asbestos Dust May Cause Serious Bodily Barm 80-5-2 80-5-3 80-5-4 80-5-5 80-5-6 80-5-7 The metal conduit connection at the junction box leading to the electric pump on the LP gas storage tank near the driveway to the main office should be repaired by completely removing the broken conduit and installing a new section threaded into the metal junction box. The present conditions subject the electrical wires to possible mechanical damage and an electrical short. x The small mesh screen cover which has been removed from over the blade cover on the fan in the forklift truck repair shop should be replaced. ^The one inch steam pipe located by the steam siphon at the slate elevator should be wrapped with heat insulation material to a height of at least seven feet to prevent burns from accidental contact with the pipe. ^The domestic type electric refrigerator located in the Felt Mill should be properly grounded. s The broken metal door on the Rag Storage building should be rehung. 'Cover plates missing from over both electric wall outlet receptacles in the Scale Room of the Felt Mill should be installed. GAF 11406 GAF CORPORATION Mobile, AL May 14, 1980 Page-7- DIS CUSS ION *7 Loss Control: The March 3. 19n rennrfr miH^nes the basir Viof an effective accident prevention program. To further expand on the guidelines provided in the RECOMMENDATIONS and DISCUSSION/sections of this report, the following indepth detail is presented. The safety program must start with the backing and active support of top management. Management must set a compliance policy for the company and assign general responsibilities to other groups within the organization, including the Safety Director, the supervisory force and the workers. Inspecting the workplace for employee hazards requires a knowledge of hazard recognition and avoidance. It is useful for supervisors to determine different processes, machines, area, conditions and practices that are under their jurisdiction. They will need to establish guidelines on how to conduct an inspection, what preparation should be made, what route to take, etc. All unsafe conditions and employee work practices should be recorded and immediate action taken to correct them. For occupational illnesses and work related injuries more serious than first aid cases, a. log, supplementary records and an annual summary must be maintainedT Records of first aid and near miss accidents will also prove helpful, and should also be maintained. Training and procedures should be developed for accident investigation and re' portiog. Information collected from inspection and accident records will need to be summarized and analyzed to determine corrective action, to evaluate the progress of the overall loss control program, and to determine whether it is meeting the established goals. A program for selecting, hiring and training employees, involves assessing each employee's physical and mental capabilities, interest and attitudes, ana matching them with the requirements-of the job. A system of observing and evaluating the employee's performance during and after the training period is completed, will aid in judging the effectiveness of the job selection process. Training at the supervisory and employee levels should include information to introduce them to the company's safety policy and the steps established to implement it throughout the organization. Training can also improve employee safety mindedness. GAF 11407 GAF CORPORATION Mobile, AL May 14, 1980 Page-B- There are numerous ways of maintaining employee interest in safety. Safety Committees create interest by involving representatives of different groups within the company. Company meetings where safety is promoted or where a special safety compaign is emphasized can raise the level of safety awareness. Contests can create interest in housekeeping and maintenance and help lower the injury rates. Rewarding outstanding safety records is another way to achieve the same results. Posters and displays carry the safety message to the workers and posting of accident record summaries can help to create a spirit of competition between departments for superior safety marks. Special Hazards; An Industrial Hygiene survey of the asbestos mixing area was made in February and March, 1980 by personnel from the New Jersey Corporate Headquarters. Concentration levels were well below the established standards. Exposure during the dumping operation is controlled by the use of a local exhaust ventilation and dust collection system built into the machine. Personal protective equipment is limited to dust masks and paper throw-away clothes. These appear to be adequate, since the permissible exposure to asbestos concentrations of asbestos fibers has not been exceeded. Annual physical examinations are provided, and records are maintained. Special physical examinations are also given prior to an employee retiring or terminating employment. The bags containing the asbestos and the special disposable clothing are sealed, impermeable trash bags, which are taken to the public dump for burying. There are no Caution labels or tags affixed to these bags. See RECOMMENDATION 80-5-1. Questions concerning this report should be referred to the Account Coordinator, Mr. Neal C. Nolan, at 201-522-43BB. TS/rcw 1267S 52380 GAF 11408