PCC Structurals Inc: OSHA inspections and violations

Incident on Oct 23, 2018: Employee sustains compound arm fracture when caught by rotat

At 2:00 p.m. on October 23, 2018, an employee was cleaning a "cowles mixer" when he was caught by the rotating shaft and sustained a compound fracture of his right arm. The employee was hospitalized.

Incident on Oct 10, 2017: Employee is sprayed by water released at 5,000 psi and suffe

At 5:00 p.m. on October 10, 2017, an employee was working in the "Hotsy Pit" and reached for a spray gun that was left on the floor. As the employee reached for the gun, he hit the trigger and the spray "walked up" his left leg, cutting through his rain suit and jeans with water shooting out at 5,000 psi. The employee suffered a circular laceration to his left hip. He was transported to the hospital, and stayed overnight for observation and treatment. treatment.

Incident on Aug 23, 2017: Employee's finger is struck by oven door and amputates finge

At 4:25 a.m. on August 23, 2017, an employee was prepping to melt wax out of a investment cast mold and he was securing the oven door hatch with locking pins. The employee crushed and amputated his fingertip when the oven door dropped on it. Hospitalization was not required.

Incident on Dec 8, 2011: Employee is burned when sparks ignite pants

On December 8, 2011, Employee #1 was operating a sanding disc to grind a titaniu m component when sparks from the disc ignited his right pants leg. Two coworkers used fire extinguishers to extinguish the flames. Employee #1 was hospitalized for second- and third-degree burns to the back of his lower right leg.

Incident on Oct 15, 2011: Autoclave operator at metal product firm loses consciousness

At 1:30 p.m. on October 15, 2011, a worker was operating an autoclave for a firm that produced metal products. As he was lowering a processing basket with a hoi st, he lost consciousness. Coworkers reported that he was looking pale and had b een ill the previous two days. Of two coworkers at the scene, one called emergen cy medical services, while the other performed CPR. An ambulance arrived within seven minutes, and EMTs took over emergency care. The employee was transported t o the Kaiser Sunnyside Medical Center in Clackamas, Oregon, and treated. During the course of the investigation, employees were interviewed, the area inspected, and records reviewed. There was no evidence of employee exposure to hazardous f umes that may have contributed to his loss of consciousness. The area where he w as working contained a 2,000 gallon (7,571 liter) tank of potassium hydroxide he ated to 285 degrees Fahrenheit (141 degrees Celsius) and a 200 gallon (757 liter ) rinse tank. The exhaust systems of both tanks provided sufficient ventilation. By the close of the inspection, the worker had left the firm.

Incident on Jun 22, 2011: Employee catches on fire while hot topping mold

On June 22, 2011, Employee #1 was injured while "hot topping" a mold which inclu ded removing the refractory blanket, poking the risers, "hot topping" the mold, and removing the tundish. Once the tundish was removed, he realized his coverall s were on fire. He stepped back and attempted to extinguish the flame, but it on ly intensified. Other employees were able to extinguish the flames and removed h is coveralls and the shirt underneath, wrapping him a gel blanket. The shirt und er the coveralls was a cotton polyester blend. It is unclear if the ignition was caused from a molten metal splash or from the radiant heat of the casting. A fa n in the area may have caused the fire to spread more rapidly. Employee #1 susta ined serious burns to his torso and arm.

Incident on May 12, 2011: Power loss at titanium-alloy plant; no injury occurred

On May 12, 2011, Employee #1, an electrician, was working at a plant that specia lized in the titanium-alloy dipping operations. During the dipping process, one of the plants three phases of power was lost. The lights flickered, and their cr ane, air knives, as well as ventilation stopped working. Employee #1 and another electrician entered the plant area to switch the power over to another substati on feed; however, they were unsuccessful. No injury was reported.

Incident on Jul 24, 2010: Employee's arm is injured when struck by falling material

On July 24, 2010, Employee #1, of PCC Structurals Incorporated, was using an ove rhead crane to support a casting, weighing 250 lbs, and a cutting torch to remov e casting supports. He leaned his left arm on the molding. The crane's sling had slack and it released. The molding fell forward, grabbing his right sleeve, and it pulled his right arm into the pinch point under the molding. Employee #1 was hospitalized for treatment of a laceration to his arm and other unspecified inj uries. It was suspected that contributing factors of the incident were a failure to properly secure the crane and the lack of experience of Employee #1.

Incident on Jul 8, 2010: Employee trips on hose and receives elbow and arm fractures

On July 8, 2010, Employee #1 was cleaning when she tripped on a hose and fell to the floor. She sustained a compound fracture to her right elbow compound, and f ractures to her right upper arm and left wrist. Employee #1 was transported to a medical center where she was hospitalized.

Incident on Oct 21, 2008: Worker fractures elbow after jumping off storage rack

On November 6, 2008, Employee #1, a laborer of Pcc Structurals, Inc. was dismant ling a storage rack. When he was at the second shelf level of the storage rack h e jumped down to the floor. He caught one or both feet on the rack and landed on his elbow. Employee #1 fractured his elbow.

Incident on Mar 14, 2008: Employee amputated thumb while using an electric pallet jack

On March 14, 2008, Employee #1 was using an electric pallet jack to move materia l in the work area. While moving the pallet jack Employee #1 struck his thumb on a "fixture", catching it between the handle of the pallet jack and the fixture resulting in an amputation of the thumb.

Incident on Feb 26, 2008: Employee's forearms are burned from chemical exposure

On February 26, 2008, Employee#1 was changing out chemical totes on an etch line . The chemical tote was supposed to be 50 percent sodium hydroxide but was actua lly 50 percent sulfuric acid. During the tote change out, Employee #1 was expose d to sulfuric acid that managed to drip between the layers of his outer glove an d the chemical rubber jacket. He mistook this moisture for sweat and did not rem ove the acid immediately. A few hours later, he noticed discomfort and washed th e area. He was hospitalized with a chemical burn to his forearms.

Incident on Feb 18, 2008: Worker sustain amputations after part falls on foot

On February 18, 2008, an employee was removing a part that weighed 1,285 pounds from a grit blasting machine. As he was doing this, the hook holding the part in place failed. The hook and the part that it was supporting fell, striking the e mployee in the foot. The amputation of some parts either occurred at that time o r were made medically necessary by that act.

Incident on Jun 11, 2007: Employee is burned from contact with hf

On June 11, 2007, Employee #1 was working the grave yard shift at a facility tha t conducts acid etching. He began his shift by maneuvering the hoist system, whi ch carried and lowered cast parts into acid etch and rinse tanks. The contents o f the tanks consisted of 25% HNO3, and 2.5 HF. Prior to the parts being lowered into the tanks, the cast parts were attached onto hooks. After returning from a two-hour break, Employee #1 was working at a sand blasting area, when he felt a sharp and numbing pain that radiated from the palm of his right hand to his elbo w. Employee #1 reported his symptoms to his supervisor, who contacted emergency medial services. Employee #1 was hospitalized, where he remained for observation for about 5-6 hours. Her was then transported to Emanuel Hospital-Burn Unit and treated for second degree chemical burns. The accident investigation revealed t hat Employee #1's burns were a result of HF contact. It was suspected that he ha d come into contact with a contaminated pendant because his nitrile gloves were ripped.

Incident on Nov 16, 2004: Employee fractures chest when crushed by robot

On November 16, 2004, Employee #1 was assisting an electrical engineer in troubl eshooting a malfunctioning robot. He was crushed between the lifting arm and the lower frame of the robot when the lifting arm dropped. Employee #1 fractured hi s chest and was hospitalized.

Incident on Jun 25, 2002: Employee injured when crushed by equipment

At approximately 8:30 p.m. on June 25, 2002, Employee #1 was helping to move a f urnace pot full of molten metal. Employee #1 was standing behind the load as it was being landed in a cradle when the crane operator stopped the crane then re-s tarted. The load trapped Employee #1's arm between the load and a hose rack. Emp loyee #1 sustained a soft tissue and muscular injury to his left arm and was hos pitalized.

Incident on Aug 2, 2001 (fatal): One employee killed, two others burned by chemicals

On August 2, 2001, Employees #1, #2, and #3 were working for a foundry. Employee #1 was on top of a tank of hot caustic solution (236 degree F.) attempting to f ree a part that became stuck on the rim of the tank as it was being removed. Emp loyee #1 fell into the tank. Employees #2 and #3 were working near the tank but did not witness the fall. Employees #2 and #3 helped Employee #1 out of the tank and began washing the caustic solution from him when Employee #1 died. Employee s #2 and #3 also sustained chemical and thermal burns and were transported to th e regional burn center for treatment of their injuries.

Incident on Nov 8, 1999: Employee injured when caught in driveshaft

The employees at a steel foundry were moving a pot for reconditioning with a 20- ton Yale overhead crane. The wheels on the crane were defective but the replacem ents had not arrived. This was the only crane with the capacity to lift the pot. The defective wheels caused the crane bridge to move from side-to-side and some times stall the motor. Employee #1, a maintenance electrician, was riding on the bridge in case the motor stalled so he could reset it. While Employee #1 was ri ding on the end truck of the crane bridge his lanyard became entangled in the dr ive shaft. Employee #1's injuries include fractured vertebrae in his neck, const ricted muscle mass in his left thigh, bruised ribs and collapsed artery in the l eft leg. Employee #1 was hospitalized.