Fort Smith Plant Metal/Non-Metal

Lab tech was in the laboratory, walking into the mill testing area from the main room. When transitioning through the doorway from the main room into the mill testing area, the miner slipped on the tile walking surface causing the miner to fall to the floor.

Employee was working in a tight space using a mini skid steer to remove sand. The employee backed up and hit their arm on a support beam. The employees hand pressed against the machine causing a fracture in their right wrist.

At 18:35 on July 28, 2022, A utility operator, was completing EE's pre-shift inspection on the CAT forklift and dropped EE's pen. The employee crouched down and leaned forward, putting EE's hand on the floor for balance and began to slide forward on the sand atop the concrete floor, causing EE to dislocating EE's shoulder.

The production operator transported a hot cooler breach hopper. When the production operator let their gloved left hand down. The sand flowed into the glove causing second degree burns on the left hand.

Miner was moving a sand tilt hopper using a forklift. Once the hopper sand contents were discharged, the hopper did not return to its upright position. Miner then parked and dismounted forklift and pushed hopper back in an upright position, straining EE's shoulder.

Shoulder sprain resulting from manual labor removing lids from air slides.

Miner used a forklift to move hopper filled with hot sand from a kiln system. Once at the tipping location, miner lifted hopper to shoulder height, got out of the forklift and released the lever to tip the load. The hot sand spread out radially and ran up EE's pant leg, burning EE's skin above the boot and sock line. Diagnosis was partial thickness burn of lower right leg.

An employee of a temporary contractor (Shutdown Solutions - MSHA Contractor ID# A1732) stated he was in the process of tearing down equipment when he smashed his pinky finger between a brick roller and a steel platform used to access the kiln. He was transported to Sparks Emergency Room by the contractor's owner and received three sutures.

He was using the blow gun to clean out pipes - pipe was clog causing it to blow out and employee lost his balance and hit a beam injuring his neck, left upper back and right are

On 8/19/14 the employee stated he was climbing the fixed, vertical ladder when he accidentally struck his left hand pinky on the ladder rung above his head. The Employee did not request medical attention. However, due to continued swelling and curling of the finger, he later requested and was taken to the company doctor on 8/26/14.

While reaching up with meter leads to conduct a ground check, an unknown and undetected foreign object entered the employee's left eye. The employee was later taken to a local emergency room where nothing was observed; however, a prescription eye drop was prescribed.

While descending a 4 ft step ladder with one foot on the first rung, and the other foot on the second rung, the employee's boot got hung up on the step causing him to loose his balance and fall to the grated flooring below. He was transported to the company Doctor, diagnosed with a fractured 8th rib on the right side, given prescription medication and work restriction.

Employee stepped from an I-beam onto concrete floor, inadvertently stepping on a clinker causing him to twist his left knee. He was seen by the company Doctor on 2/8/13, diagnoses - strain. No restrictions or medications were prescribed. A follow up appointment on 2/13/13 resulted in no climbing, squatting/kneeling restrictions being given.

Employee and co-worker were cleaning blockage in the heat exchanger cyclone: employee was sprayed with hot dust, resulting in second degree burns to left side of his face and left upper chest.

Employee was using a 4 inch grinder to cut a piece of flat metal for construction of an equipment guard; grinding wheel caught the sleeve of employee's shirt and pulled the grinding wheel into employee's left arm, resulting in an open wound requiring 7 sutures to close

EE was raking and sweeping loose material from the floor around an elevator when he overextended his reach and suffered a strained muscle in the lower back.

EE manoeuvring a scissors lift through a narrow passage in order to access the back side of a mixer screw chute. His left hand on the rail of the lift to balance himself. Was concentrating on clearing a support beam on his right side, he made contact with the screw hanger with his left hand and his hand was pinned between the hanger and tail of the scissors lift.

EE was walking through plant 2 on her way to the lunch room for lunch break. She slipped and fell on some loose proppant on the floor, suffering a lumbar strain and contusions to her left shoulder and upper body.

EE was cleaning loose material off the floor in the forming area. He had formed a small pile of material to shovel into the hopper and when he attempted to step over the pile he slipped and fell, fracturing his wrist. (EE terminated following positive drug test.)

EE was attempting to latch a flip hopper back in place. Hopper had slid forward too far for the pins to fit into the openings on track. EE was attempting to latch it by holding latch open with lt hand & pushing down on hopper with rt hand. When hopper made contact with latch, his middle lt finger was caught in pinch point, resulting in a laceration; 7 sutures required.

Employee went to change the belts on a dust collector fan. When he removed the guard, his right hand struck a sharp edge of the guard. He received a laceration on his hand, between the thumb and index finger.

Employee was clearing a plug-in in a binder rotary eeder. Airborne binder dust creates a potential explosion if conditins are right. Airborne dust was pulled into the dryer below by recirculation fan and was ignited by the dryer burner flames.

Employee was using a chipping hammer to chip hardened material off the cooler gear, a piece of the chisel side of the hammer broke off, penetrating employee's left thumb. This was classified as a first aid initially, it became a reportable on Nove 24, 2008 when the metal chip was surgically removed. My records indicate this infor. was faxed.

Employee experienced a lumbar strain while changing bags in a dust collector bag house.

EE was using a flip hopper mounted on a forklift to dump trash in a large waste container. When the hopper was tipped, it rocked backward pinching EE's left pinky finger, resulting in a laceration and fracture of the tip of the finger.

Due to equipment malfunction, employee was manually lighting burner on dryer, dust and hot air from dryer irritated his eyes, resulting in a secondary conjunctive infection.

Employee cut left thumb while slicing summer sausage for his lunch.

Employee was standing a concrete equipment pad performing maintenance on the P-2 ball mill lube system. When he stepped down to the catwalk approx. 24" below, he felt pain in his foot. An X-ray was inconclusive so he was treated for a sprain & this incident was classified as first aid. On October 17, a new X-ray revelaed a fracture in the 4th metatarsal so now reportable.

Utility EE was leaning against a guardrail with his arms stretched along th top rail and his hand hanging over the end. A forklift was exiting the area in reverse and struck the end of the guardrail while making a left turn. The EE's right hand was pinned between the forklift body and guardrail, crushing the index and middle fingers. Partial amp of middle finger.

EE & 2 co-workers were pushing a cooking cart under support beam in forming area. Insufficient clearance for equip on cart to clear beams. Piece of equip struck beam, tilted backward & pinched inj EE's right index finger between control box & lip of metal cart, resulting mashing injury to finger.

EE was loading a clinker buster with a flip hopper & when he raised the lever type handle, to open the clam shell on the hopper, he strained his right elbow & forearm.

EE was doing clean-up of loose material on the floor of the forming area; he mad a change from regular shovel to a scoop shovel because it was faster. While using the scoop shovel, he rec'd thoracic strain.

Employee was part of a crew changing bags in dust collection systems over a period of several days. He was sent to the dr complaining a neck and right arm pain and was diagnosed with a cervical strain. The injury is alleged to have occurred 4 days previous. Note: the initial claim was controverted as a work injury: however, on May 29,2007 AWCC accepted the claim as compensable.

Affected employee and co-worker were cleaning Rotex screens in the plant 2 forming area when the affected employee suffered heat stress. The outside temperatur was 102 degrees that day, increasing the ambient temperature in the plant.Employee lacked only a litte bit to finish the task and did not take necessary precaution when rest needed.

Employee was performing regular clean-up tasks; while shoveling, he felt a "pinching" pain in the right lumbar area. When he straightened up to try to stretch the pinch out, he suffered a lumbar sprain.

Injured EE was holding a pipe in place while maintenance personnel welded an extension on one end. The pipe was not securely blocked and it fell, crushing the EE's left ring and pinkie fingers between the pipe and the metal table they were working on.

EE was raking loose material under the belt into piles for shoveling. A shovel was leaning against the wall behind him. The shovel was bumped causing it to fall under the belt and thrown back against the wall. The shove handle broke and a piece of the handle struck EE on the left index finger resulting in a separation fracture at the knuckle joint.

To eliminate sweeping to clean up area, employees had placed 5 gal buckets under a conveyor belt to catch spillage. When employee attempted to remove a bucket, it hung up on the equipment frame. When he pulled on the bucket to free it, he twisted his back.

Injured ee was attempting a to roll a drive belt onto a sheave that was under tension: when the belt broke over the top, his left hand was caught between the belt and sheave, resulting in a crushing injury to the fingers of his left hand.

EE WAS MANUALLY REMOVING THE TOP PALLET FROM A STACK APPROX. CHEST HIGH WHEN HE FELT A SHARP PAIN IN THE LEFT LOWER BACK. HE WAS EVALUATED BY THE COMPANY PHYSICIAN AND DIAGNOSED WITH A BACK STRAIN. HE WAS PLACED ON RESTRICTED DUTY WITH A FOLLOW UP BY THE PHYSICIAN IN 1 WEEK.

Employee was doing pre-shift inspection on a yard tractor; lost his balance while lifting the hood back and fell backward, causing the hood to strike him on the right shoulder.

Contractor was cutting cross-brace loose on baghouse frame to remove and repair damaged duct work. The cross-brace was apparently twisted from being struck by a piece or mobile equipment. When the brade was cut loose, 14 swung around and struck the worker.

EE AND A CO-WORKER WERE REPLACING A SECONDARY ROTOR IN A MIXER. EE LOST GRIP ON THE SHAFT WHILE BRINGING IT TO AN UPRIGHT POSITION, ALLOWING THE ROTOR TO FALL. EE PINKIE FINGER ON LEFT HAND WAS CAUGHT BETWEEN THE FLANGE ON THE ROTOR AND ROTOR TOOL ON THE PRIMARY ROTOR. EE RECIEVED AN OPEN FRACTURE AT THE FIRST FINGER JOINT

EE STEPPED ON A RAKE LEANING AGAINST A SUPPORT POST. WHEN THE HANDLE OF THE RAKE FLIPPED UP, EE THREW RIGHT HAND UP TO PROTECT FACE. THE HANDLE STRUCK HAND RESULTING IN A CONTUSION AND BRUISE TO THUMB.

EE AND 2 COWORKERS WERE BUILDING ROTEX SCREENS. EE PICKED THE ROLL OF WIRE UP OFF THE TABLE AND SET IT ON THE FLOOR. A PIECE OF LOOSE WIRE PUNCTURED THE RIGHT FOREARM OF EE AND BROKE OFF IN HIS ARM.

INJURED EMPLOYEE AND TWO CO-WORKERS WERE REMOVING OLD CARTRIDGES AFTER REBAGGING A BAG HOUSE. INJURED EE WAS STRUCK IN THE MOUTH WITH A CARTRIDGE AND THE IMPACE KNOCKED 4 TEETH LOOSE. NOTE: IT WAS NOT DETERMINED THAT THE INCIDENT WAS A RECORDABLE INJURY UNTIL JULY 14, 2004.

EE SLIPPED AND FELL WHILE ATTEMPTING TO ADJUST THE FORKS ON A FORKLIFT.

EE AND ANOTHER MECHANIC WERE ATTEMPTING TO REMOVE THE BACK DOOR ON A DRYER. THE DOOR WAS STUCK AND EMPLOYEES WERE PULLING ON IT TO FREE IT. ONE SIDE CAME LOOSE AND FELL DOWN, PINNING EE'S RIGHT HAND BETWEEN THE DOOR AND THE SHAKER PAN.

EE WAS PULLING A SMAPLE OF COARSE MATERIAL THRU A CLAMSHELL ON THE END OF A DISTRIBUTION PIPE IN THE SIZING AREA. HE WAS HOLDING THE CLAMSHELL OPEN WITH HIS RIGHT HAND AND APPARENTLY PLACED HI S LEFT HAND INT HE OPENING. HE ATTENTION WAS DIVERTED AND HE LET THE CLAMSHELL CLOSE ON HIS HAND. HE INSTINCTIVELY PULLED HIS HAND OUT AND RECEIVED AN AVULSION BETWEEN THE KNUCKLE AND THE ARE

EE WAS ATTEMPTING TO UNPLUG A WELDER AND THE PLUG WAS JAMMED DUE TO DIRT BUILDUP. WHEN THE PLUG CAME LOOSE, EE LOST HIS BALANCE AND FELL INTO THE PLUG GUARD, RESULTING IN A LACERATION TO HIS LIP. EE RECEIVED SUTURES.

Employee was making work table for construction area and something got into his R eye. On Monday Feb 9, 2004 he went to the doctor to have foreign body removed from his eye.

EE'S WERE REMOVING A LARGE GUARD ON A TRANSFER ELEVATOR IN ORDER TO PERFORM MAINTENANCE. EE LOST HIS GRIP AND WHILE HE WAS TRYING TO REGAIN CONTROL, HE FELT PAIN IN HIS NECK.

EE WAS ASSITING AN EXPERIENCED MECHANICE IN REMOVING TUBE INT HE DRYER IN #2 WHEN HE CAUGHT THE PINKY FINGER OF HIS RIGHT HAND IN ONE OF THE TUBES AND WAS COMPLAINING OF PAIN, SMALL FRACTURE. HE RESIGNED 10/29/03, COMPLAIN ON NOV 27, HE HAVE DIFFICULT WITH FINGER. WANT TO SEEK MEDICAL ATTENTION. DIAGNOSED CLUB FINGER REQUIRING FURTHER TREATMENT.

EE WERE MOVING SWEEPS AND LINES TO ACCOMMODATE A PRODUCT CHANGE. TWO LINES HAD TO BE PULLED TOGETHER TO A MEETING POINT AND A COUPLING INSTALLED. WHILE PULLING ON OVER OF THE LINES, EE PULLED A MUSCLE IN HIS LEFT SHOULDER.

EE WAS TRIMMING EXCESS WASTE OFF TRANSFER ELEVATOR BREAKOVER ROLLERS WITH POCKET KNIFE. THE KNIFE SLIPPED AND PENETRATED HIS LEFT HAND BELOW THUMB. HE WAS WEARING LEATHER GLOVES AT THE TIME.

EE WAS ATTEMPTING TO OPEN DOOR ON #2 HEAT EXCHANGER, THIS ACTION CREATES A TREMENDOUS AMOUNT OF VACUUM ON THE DOOR. EE OVEREXERTED HIMSELF, RESULTING IN A STRAIN TO A MUSCLE IN HIS LOWER BACK.

EE WAS REPLACING BUCKETS ON ELEVATOR CHAIN. DUE TO LOCATION OF EQUIPMENT, HE WAS WORKING IN AN AWKWARD POSITION & HAD PROBLEMS GETTING LEVERAGE ON THE CHAIN. WHEN HE PULLED ON THE CHAIN HE PULLED A MUSCLE IN HIS RIGHT ELBOW.

VACUUM PAD LEFT OFF BECAUSE OF FLOOR CONDITION. MILD BRUISE ON RIGHT SIDE OF HEAD.

EE WAS WALKING IN PLANT 1 BAGGING/LAB AREA WHEN HE SLIPPED ON LOOSE PROPPANT IN THE FLOOR AND TWISTED HIS KNEE.

EE AND CO-WORKER WERE REMOVING SLIDE GATE ON NOVAC CRUDE TANK AT P-1 HOPPERS MILL. THE GATE WAS NOT ADEQUATELY SECURED AND FELL WHEN THE LAST BOLT WAS REMOVED, PINNING EE'S RT. HAND BETWEEN THE GATE AND HOPPER, CAUSING A SEVERE LACERATION IN THUMB, WHICH REQUIRED SUTURES.

INITIAL INCIDENT WAS INVESTIGATED AS A NEAR MISS ON 10-28-02. EMPLOYEE DID NOT SEEK MEDICAL ATTENTION AND CONTINUED REGULAR DUTIES. ON DEC 2, EE WAS SEEN BY A DOCTOR DUE TO PAIN AND SWELLING I N KNEE.

REMOVING A SECTION OF HANDRAIL ON DC-8 PLATFORM BY LIFTING OUT WITH FORKLIFT. WHEN RAIL CAME UP,EE WAS STANDING IN NEAR PROXIMITY TO RAIL AND WAS STRUCK ON THE CHIN, RESULTING IN A LACERATIO N.

EMPLOYEE WAS ADJUSTING THE FORK ON A FORKLIFT. WHILE EMPLOYEE WAS LIFTING AND ROTATING FORK ON FORKLIFT BY HAND THE EMPLOYEE FELT A SHARP PAIN IN LOWER BACK AREA.

FELL ON CAT WALK FROM ORE SPILLAGE ON WALK. THE ORE SPILLAGE WAS CAUSED BY THE CHOKE UP IN PROCESS CATCHING 5TH FINGER LEFT HAND INGRATING ON FLOOR.

EE WAS REMOVING THRUST FROM PLANT I KUS KILN. THE TRUST ROLLER SLIPPED OFF MOUNT AND MASHED FINGER BETWEEN ROLLER AND OIL RESERVOIR.

EE WAS PERFORMING A SCHEDULED MAINTENANCE TASK THAT INVOLVES SPENDING A LOT OF TIME CLOSE TO THEROOF OF THE BUILDING NEAR THE KILN. THIS MAKES THE TEMPERATURES VERY HOT. OVEREXPOSURE TO HIGH T EMPERATURES. DID NOT RECOGNIZE THE WARNING SIGNSUNTIL IT WAS TOO LATE.

EMPLOYEE WAS INSIDE THE ROTARY KILN BRICK TO STRIKE A LOOSE BRICK TO REMOVE IT FROM A ROW AND STRUCK LEFT INDEX FINGER OF HIS LEFT HAND.

EMPLOYEE TOOK UNSAFE POSITION AT THE MIXER PUMP GATE. EMPLOYEE WAS REMOVING ACCUMULATED MATERIAL FROM AN OVER HEAD BELT. A LARGE PIECE OF MATERIAL FELL AND STRUCK THE EMPLOYEE'S ANKLE CAUSING HIM TO TWIST HIS ANKLE.

EE WAS WORKING ON DRIVE ROLLERS. EE GOT HIS SHOEHEEL STUCK ON THE FLOOR GRATING AND HE TWISTED HIS L. KNEE.

IN A SITTING POSITION HAD TO LIFT OBJECTS WHILE REPLACING MOTOR AND GEAR BOX DRIVE UNIT.

WAS REMOVING PIPE FROM ARC WITH OVERHEAD CRANE. HE WAS USING RIGHT HAND TO KEEP PIPE BALANCED. HE WAS NOT WATCHING THE PIPE AND DID NOT NOTICE THE ANGLE IRON FRAME ON THE PLATFORM. R HAND WAS SMASHED BETWEEN THE PIPE AND ANGLE IRON, CAUSINGLACERATION TO HIS RIGHT HAND.

EE CAUGHT HIS LEFT FOOT ON 6" AIRLINE CAUSING HIM TO TRIP AND HIT HIS RIGHT KNEE ON FLOORING.

THE EE FIRST PLACED THE 3 POSITION SWITCH, LOCATED IN THE MCC ROOM IN THE JOG POSITION. HE THEN WENT TO THE BUCKET ELEVATOR AND REMOVED THE ACCESS PANEL AND PULLED ON THE BUCKETS TO POSITION T HE CHAIN. THIS CAUSED THE ZERO SPEED TO CLOSE AND ENERGIZED THE ELEVATOR.