Montevallo Quarry & Mill Metal/Non-Metal

Employee was hydroblasting a scrubber and material fell from the wall hitting employee in the back of the head. This resulted in the employee receiving 8 staples in the head. Employee was wearing a hardhat and material knocked hardhat off.

ROOT CAUSE - cylinder punctured and cracked the cylinder housing causing the trailer to drop down approximately 4-5 feet without the cylinder engaged. Worker was injured due to a safety violation (not wearing a seatbelt at all times). CONTRIBUTING FACTOR - normal wear and tear from daily use.

Employee was working in LHP, EE was cleaning. EE went to 1 knee. EE overheated. 911 was called and started an IV. Has pre-existing medical conditions that were unknown to management.

Employee working on 4160v contactor, repulling k2 motor leads to ID fan, while getting ready to pull in new cable employee came in contact with live buss.

EE tasked with cleaning spray lance, 2 man job. Did it by self. Lifting a support up felt a pop in right shoulder, continued to work, shortly after EE's right hand was numb and hurting.

Walked outside, went to turn around and go back inside to get gloves, EE foot didn't move but right knee twisted and pulled as the EE went the other direction.

EE was adjusting closing trap on K5 shaft 1 using a pipe wrench. EE heard a loud pop from right knee, and dropped to knees in pain.

EE was using a sledge hammer and bit to try and dislodge a clog in a feeder. EE hit the bit with the sledge hammer and it fell out hit the feeder and the bounced and hit EE in the mouth, knocking out EE's front tooth and chipping 2 others.

The employee was climbing a ladder. Right foot slipped on the fifth rung of the ladder. Employee did have three points of contact and was not holding anything while climbing. Employee fell and sprained right knee.

left hand pinky finger entangle with hammer drill bit, finger bruise and swelling. employee went to Dr. and return to work with restriction of wearing finger splint for a week, back to full duty at on 10-20-2020

EE working on 3 and 4 coal long belt, tied off, 3 points of contact. Climbing now heard a pop noise left shoulder and pain. Went to Doc on 9/4/2020, restrictions given.

While vacuuming in the Lime House, when the air temperature was hot, employee started to feel sick and sat down. EE started to vomit. Employee wanted to go outside and get fresh air. On the way down the employee passed out.

EE had to clear the chute at the head section of BC 463 it was clogged with wet coal and coke. After clearing the chute, EE was coming down the ladder and stepped off the last rung onto the small concrete. On EE's next step EE missed the concrete landing and fell 13" to the concrete level below and hit left shoulder. It was raining very hard at the time of the accident.

Employee was walking toward equipment. Stepped on an object, possible rock, fell to the ground twisting left ankle.

Miner was pushing off lime waste material at the waste dump. When EE opened the cab door, dust came in the cab and got into EE's left eye. Safety glasses were worn by the miner.

EE was helping change out the oil cooler on #3 coal mill, it weighs approx. 100 lbs. As EE and other employee were setting the old cooler down on the ground EE's left index finger was pinched on a broom head, needing 1 suture.

EE was putting a screw cover back on, lost control of the cover and hit ee in the chest. Contusion to the thorax, restricted duty.

Installing jacks in place and steel saddle came lose.

EE was cleaning out 805 screw with scoop, wind started to gust and material was blown into the EE's eye. EE was wearing wrap around safety glass at the time. Abrasion to the left cornea.

Backing down the 300 ton hopper ram in a FEL employee ran into the trailer of a truck, and hurt their back. EE went to the Doctor on 3/1/18 where they were put on restriction.

Changing drive belts on a motor, when belt slipped on EE's finger caught between belt and pulley, breaking tip of finger.

EE was sitting down in a chair and the chair broke causing EE to fall to the floor hurting their back.

EE was climbing a ladder, EE place a 16' diameter circle metal plate on the catwalk. EE continued to climb the ladder and the vibration caused the metal plate to fall from the catwalk striking EE in the face below eye, cutting it, got 3 stitches.

EE tripped over a broken pallet while doing inventory and hurt EE's hip. Went to doctor and was told to take it easy, no restriction. 7/6/17 EE said hip still was hurting and went back to doctor and is scheduled to have physical therapy.

EE1 was helping build an expanded metal guard, ee1 was leaning on the table and another EE2 picked up a piece of expanded metal to go cut hit. When the EE2 turned the expanded metal hit the other EE1 in the face leaving a small cut between eyes and a deeper cut on right eyelid.

EE was attempting to break a allen head bolt loose on a trunnion roll in the shop. EE was using an allen wrench and when the bolt broke free EE's hand slipped forward and was cut on the housing of the roll resulting in a laceration to the left index finger requiring 4 stitches.

EE was hitting the side of a chute with a 2 lb hammer to try and unplug it and accidentally hit right index finger.

EE was helping change out the #3 spray tower pump. EE was using a 36" inch aluminum pipe wrench and was pulling it toward EE's body to loosen the nut and EE felt a sharp pain in lower back.

EE is not sure of the date of the accident, but did not get reported to the company until 10/14/2015. EE was cleaning in the lab and he aggravated his groin area while lifting a box. Went to the doctor before reporting to the companying and doctor said he has a lingual hernia.

EE was working in the #8 bin loadout section when the #8 silo inspection door flew open and blew lime dust directly in his eye. EE was wearing safety glasses at the time.

EE was switching the Oxygen bottle on the torch cart. He lifted the bottle onto the cart and he felt a pull in his back just below his shoulder blades. He did not go to the doctor until the following Monday (08/17/2015).

EE was stepping from the top of a rail car to a step to get off the rail car. He put pressure on his foot that was on the step and felt a pain in the arch of his foot. EE said he did not turn his ankle.

EE was putting 50lb bags on the last level of the pallet, when he twisted to put the bag on the level he felt something pull in his chest and back.

EE was moving the forks in on the Lull, in order to do this they have to raise the boom up & then tilt it forward so the forks will slide. As the Lull operator was tilting the forks forward, the forks & the rod fell out & the forks hit EE on top portion of his thigh. He was able to finish job before he went to dr. Sent back to dr 4/7/15 which was the first day of lost time

EE was moving a stack of pallets with a fork lift from brick shed to the upper bagging shed. While travelling to the upper bag shed with the pallets a piece of material flew into his left eye. This required a doctor attention and he was prescribed eye drops. EE was wearing approved safety glasses.

EE put a metal bar against the a handrail and put the other end on a brace under the expanded metal. He put his hand on the handrail the metal slipped off the brace and the top of the bar smashed the EE right ring finger.

EE was removing a coupling guard and felt a pain in his lower back. EE went to the doctor and came back with no restriction, sent to therapy on 9/9/2014 Doctor put him on restrictive duty.

Employee was clearing rocks from the coke hopper. He cut a hole in the side of the coke hopper and reached into the hopper to pull a large rock out, when the rock started rolling and fell on his left index and middle finger breaking both fingers.

EE was blowing off the lime that was on top of an environmental tarp of a loaded truck. When he started blowing the lime off the wind started blowing and blew the lime back into his face and the lime came in behind his safety glasses and got into his eye.

EE was throwing the flap at the top of the west elevator and his feet slipped on the wet Lime, plus it was raining. When his feet slipped he fell and hit his forehead on the edge of the chute. Resulted in a 2 inch cut that required "Liquid sutures"(glue).

EE was inspecting airline for a leak when the air line broke from fitting and he was hit with compressed air (90-95 psi)and foreign material inside air line. Injury to right hand and upper right arm and shoulder.

Employee was going to close the passenger side door of the Vac Truck and slipped, straining his knee.

Employee was cutting some belt skirt with a box blade knife, slipped on some loose material/rock and cut his left thumb.

While carrying a grinder and small chain across 2 Kiln burner floor, employees back started hurting between the shoulder blades.

Employee received burns on face, neck, and arm while attempting to clear plugged chute at the K1 Dust Hopper Discharge Chute

While attempting to repair a leak in a 1.5" rubber water line, the worker was cutting off the leaking section, with a utility knife, when the knife blade broke.

Truck driver for Evergreen Transportation, Contractor #XZV, slipped while stepping down from his truck and injured his right knee.

While using a sledge hammer on a piece of equipment, the employee bumped the end of his left index finger between the handle of the hammer and a piece of metal.

Driver was on top of his trailer at the fall protection station when the truck started moving forward. When the cable reached its limit it pulled him off the trailer. Driver was taken to the hospital for treatment. The driver was only bruised and sore. Driver stated he forgot to set the parking brake before exiting the truck and failed to use wheel chocks.

EE was standing on the ground to the left of the motor grader using a tripod level. Grader EE backed up. The operator of the motor grader was backing up and looking to the right and did not realize that EE had backed up. He turned the wheels sharp to the right and the front tire struck EE.

While using a hammer to remove a bolt, a tiny piece of steel went into the left hand.

Employee was performing repairs on a material conveyor. Due to improper body position and not following proper procedures, employee got thumb caught in a pinch point. Equipment was locked and tagged out and employee was wearing gloves.

EE was cleaning lime from the floor. He slipped on the wet lime that was due to water leaking from roof. While slipping, he grabbed the guardrail to keep from falling down and hurt his shoulder in the process. Shoulder started to swell/hurt cold compresses and visit to doctor EE now needs shoulder surgery.

While checking a screw conveyor, the motor started unexpectedly, causing injury to an employees hands.

During the clean out of a mixing machine, access door to machine was open to allow mortar to flow out. Paddle was positioned to prevent the flow of mortar. While one person instructed the oper ator to jog the machine the injured reached into door to remove rock. Injury resulted in fracture and laceration ultimately leading to an amputation of the finger above the large knuckle.

Contract driver was manually cranking his tarp open, when the crank handle began to "free roll" striking the contract driver in right lower arm resulting in a contusion.

Employee was arranging the spreader cables on the back of the flatbed work truck when he lost his balance and fell from the truck to the ground. He says he is unsure what caused him to lose balance. Accident was not reportable at the time however 2/22/2011 it became reportable. The accident did not involve cfr 50.20-6 (i) (ii) (iii) or (iv).

While walking down stairs to basement, employee says his back gave out and he fell on stairs.

While working on a flue dust screw conveyor, employee came in contact with a quantity of hot flue dust.

While walking backwards repositioning some material, employee tripped and fell striking his right elbow, resulting in a laceration.

While attempting to clear a plugged chute, plugged material suddenly cleared, causing employee to strike their left wrist on a hand rail, causing a contusion.

Stepped down on to an uneven step and strained ankle.

While opening the top doors on a rail car, worker felt something pull in his lower back.

While attempting to unplug a chute feeding a coal mill, the platform on which he was standing, tilted, causing the employee to fall about four feet, to his knees.

Ice on ground, due to several days with below freezing temperatures, slipped, contusion to right back.

Employee was bending over working on a bearing of a stone elevator for several minutes. When he straightened up, he felt a sharp pain in his lower back.

While cleaning out a chute from a screw conveyor to an elevator, with a metal bar, the employee suffered a laceration to the ring finger of his right hand.

While reassembling an oxygen analyzer sample pipe, the employee in picking up the pipe, strained his left shoulder.

Attempting to put a natural gas warming flame on #1 kiln. There was a small accumulation of natural gas inside the kiln, which ignited, causing a loud noise.

Slipped while climbing a scaffold, strain to right shoulder.

Lime fell from above, entering the right eye of employee.

Due to strong winds that afternoon, lime dust blew under safety eye ware.

Employee was in personal vehicle passing under the fuel delivery belt with his window down. As he passed under the belt a piece of coal fell from the belt striking the top of the drivers door, shattering and a piece of material lodged in eye.

employee was opening a compartment door when suction inside the compartment pulled the door down.

The employee was in the process of installing 500 lb castings inside a kiln when the casting shifted, striking the employee in the right leg and breaking it. The work area was clean and free of debris and well it.

employee lifting heavy spool of wire and over exerted back

Employee was cleaning a chute with a hammer and steel rod and strained his right shoulder, resulting in restricted work duty.

Walking down stairs to the K3/K4 cooler basement to work on the east lime elevator and tripped on the last step. Employee tried to catch himself with his right arm and separated his right shoulder AC joint.

Changing a motor on the #3 and #4 crossover belt he received lime burns to the right and left forearms and left shoulder blade. He was placed on restrictions of only working in cool environments.

Employee was working on the loadout chute of bin 25 when the shoot opened up causing lime to come out. He turned to walk down the steps but could not see and missed approximately five steps and fell.

Employee was pulling a chain wrench, which slipped, causing him to fall on his back. He went to the doctor on 8/6/08 and was placed on restricted duty.

Employee was attempting to unplug the feed chute to the ball mill dryer with a steel rod when the blockage opened up unexpectedly and the little finger on his left hand was caught between the access hole in the chute and the steel bar, resulting in a laceration and fracture.

Employee was walking down the ramp, going to kiln 2 cooler area, when he slipped. He put his hand out to catch himself and landed on his fingers, spraining the middle finger on his right hand.

Employee was pulling the vac truck hose up to the top of the separator with rope when he felt a pop in his elbow. He was placed on restricted work duty on 7/7/08 and diagnosed with a muscle strain.

Employee was bending over using a pipe wrench to tighten union and strained back.

Employee was going up the C pile ramp in the loader and ran over a pile of stone which caused him to hit his mouth on the steering wheel, breaking two teeth.

Employee was working in the baghouse when a compartment door fell on his right hand, amputating the tip of his right index finger.

While opening the top to a barrel of vinegar with a box cutter, the knife slipped and cut employee's left index finger.

Unplugging Raymond Mill transport line and lime blew into right eye.

Employee was removing guard from feeder belt to perform maintenance. He unscrewed top and bottom bolts, lifted guard away from bolts and dropped it on right foot. Minor skin abrasion, swelling of right foot, xray revealed small crack on top bone of foot.

Walking to roller mill area holding sample cans in hands, slipped on wet steps and sprained wrist trying to catch himself.

Employee was standing in the walkway at the northeast corner of the drive pier elevation talking to a contractor who was in the basket of a manlift; another contractor's truck hit the manlift, causing the basket to jerk. It pushed the employee into the north side of the kiln trunion bearing.

Mechanic was changing bags in baghouse, lifted a compartment door and the handle broke causing the door to fall on his fingers.

While attempting to light the flame on #2 kiln, lime got into both of injured's eyes.

Employee stepped off of the long coal belt and rolled his ankle.

While working on the coal mill fan, injured was removing the jack from the puller, puller slipped out from under the fan, the fan fell on right foot.

Injured was at the #w limehouse elevator pulling on a flap to unplug the elevator when he pulled his groin.

Injured climbed ladder to check a flap. He was holding onto a 2" air line and slide for dust collector. He sneezed and lost his hold with his right hand while still holding with his left hand and twisted his body. Dislocated shoulder.

Injured was using the hose on the vacuum truck. There was high pressure on the hose. The hose jerked with the pressure and hit injured, causing her to fall backwards onto the floor.

PSC Employee was hydroblasting roof structures using a CRS 15K Shotgun. He states that he released the trigger, and relaxed his grip on the gun expecting it to depressure. The gun pressure did not decrease, causing him to lose his grip. The gun got away from the EE and whipped around, directing the stream in an upward angle from left to right across his legs.

Injured was performing clean-up work in lime basement area using a high pressure water jet. Injured's feet slipped on wet lime causing him to fall. When he fell, he accidently hit the trigger of the water jet spray nozzle and shot the top of his right foot.

Injured was walking down passageway on the west side of the stone receiving belt hopper to throw the switch. Injured tripped on vacuum hose causing him to fall.

Lime buildup fell from overhead bin, striking injured on top of his hard hat, causing a head laceration.

AN ACUTE BACK STRAIN OCCURRED WHEN INJURED WAS SHOVELING AND PUSHING A FULL DRUM OF GREASE ATTEMPTING TO MOVE IT ONTO A PALLET. BECAME REPORTABLE BECAUSE OF RESTRICTED DUTY.

EE was building sub-arc frame on the feed end of #4 kiln. They were putting up channel with tack welds. They had tack-welded the second channel when the tack-welds broke. EE fell and the handrail he was tied off on broke. He fell approx 40', hitting several objects as he fell.

INJURED WAS EXITING THE EAST SILO. THERE WAS A PILE OF LIME IN FRONT OF THE DOOR. HE TRIPPED & FELL ON HIS ELBOW, DISLOCATING HIS SHOULDER.

HOT LIME WAS ALLOWED TO COME IN CONTACT WITH A RUBBER CONVEYOR BELT, CAUSING IT TO CATCH FIRE. THE FIRE WAS NOTICED AT 5:30 AM BY THE LEADMAN ON SHIFT. THE PLANT FIRE SAFETY COMMITTEEMEN CALL ED THE LOCAL FIRE & RESCUE. THEY RESPONDED IMMEDEATELY.

INJURED WAS INSTALLING A BATTERY IN A VACUUM TRUCK WHEN HE FELT A SHARP PAIN IN HIS BACK. REPORTABLE BECAUSE OF LTA BEGINING 5/10/04. INJURED COULD NO LONGER PERFORM JOB FUNCTIONS AND PHYSICIAN AUTHORIZED TIME OFF.

WHEN INJURED BACKED UP TOWARDS BERM AT WASTE DUMP AREA; TRUCK WENT THROUGH BERM OR GROUND GAVE WAY CAUSING TRUCK TO GO INTO ABANDONED QUARRY. INJURED DID NOT GO TO THE DR. UNTIL 6/25/03. REP ORTABLE FROM STANDPOINT OF MODIFIED DUTY ONLY. NO LOST TIME AS OF PRESENT DATE.

WHILE INSTALLING A FK PUMP SLIPPED AND STRUCK MINER ON RIGHT FOOT. AFTER 2 EXAMS A MRI WAS DONE AND DETERMINED THAT MINER HAD A HAIRLINE FRACTURE ON 12-19-02. THIS BECAME REPORTABLE ON DECEMBE R 19, 2002.

INJURED WAS OPERATING CAT STICK STEER LOADER (BOBCAT). HE PUSHED HOT LIME AND WATER INTO A PILE WHEN BOTH HOT LIME AND STEAM CAME IN ON HIM. HE JUMPED FROM THE CAB OF THE MACHINE AND LANDED IN HOT LIME.

DROPPED CUTTING EDGE OFF 950 LOADER ON THE END OF HIS FINGER CRACKING THE BONE.

HOLDING RAG OVER THE TIP OF A PAINT GUN AND CLEANING OUT LINES. THE RAG BLEW OFF WHILE CLEANING AND SHOT PAINT THINNER IN HIS FINGER.

INJURED WAS TIGHTENING A BOLT ON A LEAF SEAL AND THE WRENCH SLIPPED AND HIS RIGHT FINGER GOT CUT ON THE LEAF SEAL WHEN HIS HAND STRUCK IT.

INJURED WAS TAKING A LIME SAMPLE FROM THE FRONT OF #1 KILN. INJURED THEN STEPPED BACKWARDS OFF OF BURNER PLATFORM STEPPING ONTO A RAIL ELEVATED APPROX 2 INCHES ABOVE FLOOR GRATING & TWISTED HI S RIGHT FOOT.

INJURED TRIPPED OVER GAS LINE ON BURNER FLOOR. AND INJURED BACK. BECAME REPORTABLE WHEN INJURED WAS PLACED ON RESTRICTED DUTY WORK 6-11-01.

EMPLOYEE WAS DIAGNOSED WITH CARPAL TUNNEL SYNDROME. WE ARE REPORTING THIS A S A OCCUPATIONAL ILLINESS.

INJURED WAS SHARPENING HIS KNIFE WITH A HAND HELD KNIFE SHARPENER. THE KNIFE SLIPPED AND CUT FINGER.