Text For Citation: 01 Item/Group: 001 Hazard: FALLING

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to the following conditions: (a)Burns from aluminum dust fire/explosion due to large accumulation of aluminum dust generated from the excess over spray while the Thermion thermal aluminum spray coating guns were in operation. Among other methods, one or more feasible and acceptable abatement method to correct this condition may include, but is not limited to: 1.Conformance with NFPA 65 - Standard for the Processing and Finishing of Aluminum: Chapter 2 Dust Collection 2-1 General. 2-1.1 Machines that produce fine particles of aluminum shall be provided with hoods or enclosures connected to a dust collection system having sufficient suction and capture velocity to collect and transport all the dust produced. Hoods and enclosures shall be designed and maintained so that the fine particles will either fall or be projected into them in the direction of airflow. The following safeguards shall be incorporated: 1.Personnel clothing shall be flame retardant and shall be fabricated without cuffs. 2.The collector shall be designed to dissipate static electricity. (See NFPA 77, Recommended Practice on Static Electricity.) 3.Collector system design shall be subjected to a process hazard analysis to ensure that shrapnel and flash fire exposure to personnel shall be minimized. 4.Collector retention capacity shall be limited to 1 lb (0.454 kg). 2-2 Ducts and Ductwork. 2-2.1 Ducts shall be designed to maintain a velocity of not less than 4500 ft/min. (1372.5 m/min) to ensure the transport of both coarse and fine particles to ensure reentrainment if, for any reason the particles can fall out of the collector (for example, in the event of power failure).2-2.2 Ducts shall be designed to handle a volumetric flow rate sufficient to maintain a dust loading safely below the lower explosive limit. 2-2.3 Ducts shall be as short and as straight as possible. 2-2.4 Ducts shall have as few bends and irregularities as possible so that free airflow is not interfered with. 2-2.5 Ducts shall be of conductive material construction and shall be carefully fabricated and assembled with smooth interior surfaces and with internal lap joints facing the direction of airflow. There shall be no unused capped outlets, pockets, or other dead end spaces that might allow accumulations of dust. Duct seams shall be oriented in the direction away from normal working personnel. 2-2.6 Duct systems, dust collectors, and dust-producing machinery shall be bonded and grounded to minimize accumulation of static electric charge. Chapter 5 Fire Protection 5-3 Equipment Shutdown In the event of fire, all fans and machinery, including dust collection systems, shall be shut down. Drafts shall be avoided wherever possible. 2.Conformance with the Thermion Owner's Manual: Chapter 2 Safety Measures. 2.1 Reduction of Fire and Explosive Hazard. To minimize the danger of the dust explosion in an arc spray booth or other confine spaces, prevent the accumulation of fumes and dust. Ventilation and good housekeeping in the work area is essential. 3.Conformance with American National Standard Institute/American Welding Society C2.18-93, (an American National Standard, Guide for the Protection of Steel with Thermal Sprayed Coatings of Aluminum and Zinc and Their Alloys and Composites: Chapter 2 Safety2.1 General Airborne metal dusts, finely divided solids, or accumulations should be treated as explosives. Adequate ventilation in the thermal spray work area and collection of the overspray should be made to minimize the danger of dust explosions and fires. 4.Incorporate safety devices on the operational mechanical equipment with the thermal aluminum spray guns switch to shut down the thermal aluminum spray guns when it detects a fault in any one of the different piece of equipment. (b)Burns from Dust Collector fire/explosion due to not being provided with explosion vents. Among other methods, one or more feasible and acceptable abatement method to correct this condition may include, but is not limited to: 1.Conformance with NFPA No. 65 - Processing and Finishing of Aluminum - 1973, An American National Standard ANSI Z12.19-1973: Chapter 2-4 Dry-type Dust Collectors. 2-4.3 Special care shall be taken to ensure the internal cleanliness of dry dust- collection systems at all times and to avoid the accumulation of material except in the discharge hoppers of the dust collectors. Accumulation or condensation of water shall be prevented. 2-4.5 Dry dust collectors and other equipment where an aluminum dust explosion hazard exists shall be provided with explosion vents wherever it is possible and practical to do so. Refer to Guide for Explosion Venting, NFPA No. 68. 2.Conformance with the Wheelabrator Operation and Service Manual: Safety Instructions Sheet Dust Collectors and Ventilation Warning - In application involving the use of aluminum media or surface blasting of aluminum parts, precautionary measures must be taken to minimize the risk of dust collector fire and/or explosions. The following precaution should be followed: No. 200 Mesh Agricultural Limestone (CaCO3) should be added to the ventilation system at a continuous rate of 0.2 oz. per hour per square foot of filter area. 3.Incorporate safety devices on the operational mechanical equipment with the thermal aluminum spray guns switch to shut down the thermal aluminum spray guns when it detects a fault in any one of the different piece of equipment. *** Certification and Documentation of Abatement Required ***