ICA AGENDA 04/05/2018 Sapa Extrusions North America, LLC Years in Business: 50 249 51? Ave Employed in establishment: 246 Phoenix, AZ 85043 Covered by inspection: 18 5475 Controlled by employer: INSPECTION NO: U9805 - 1276496 INSPECTION TYPE: INSPECTION DATE: 11/08/2017 3 (q I 7 SITE LOCATION: 249 5 Ave Phoenix, AZ 85043 TYPE OF INDUSTRY: Primarily engaged in rolling, drawing, or extruding shapes (except ?at rolled sheet, plate, foil, and welded tube) from purchased aluminum PREVIOUS HISTORY: One inspection in the past three years. Background: On Wednesday, November 8, 2017, a Health Inspection was conducted of Sapa Extrusions North America, LLC. This partial inspection was conducted by CSHOs from our Phoenix of?ce by the direction of the ADOSH Director based on a media report he observed. The media story stated an employee had fallen approximately 30 feet into a casting pit. Sapa Extrusions North America, LLC (Sapa) is a company that designs, manufactures and extrudes aluminum parts for the commercial industry. The company has been in business over 50 years. The opening conference was conducted with Sa a Extrusions North America, LLC, Environmenta Environmental Health and Safety (EHS Sapa xtrusrons orth America, LLC, Environmental Engineer and EHS Coordinator also participated mt wa ou ortion of the inspection. A closing conference was conducted with Sapa Extrusions North America, LLC At approximately 5:45 am on November 8, 2017, a lead casting employee fell into a 22 foot casting pit. The casting pit measured 10 feet wide by 1 1 feet long and 22 feet deep. At the bottom of the casting pit was approximately seven-and-a-half feet of roughly 137 degree water used to cool the aluminum logs. The process of casting aluminum logs, ten inches in diameter and 16 to 18 feet long, took approximately an hour to an hour and a half. Aluminum was melted in a heat holder to 1450 1475 degrees Fahrenheit. Once melted, the aluminum was diverted to a table (top of the casting pit). The aluminum was then diverted to the platen. The platen was a tray that holds the aluminum logs which drops into the casting pit, at a rate of 3 inches per minute, to elongate and cool the aluminum logs. Once the logs were cooled and ready to be removed, the table to the casting pit was opened. The platen was raised up. There was no speci?c height at which the platen was required to be raised. The lead caster would maneuver the fall protection table into position. The fall protection table was a steel table approximately 8 feet by 9 feet 6 inches with ?ve slots for the logs to go through. According to management the fall protection table was made to be placed over the pit protecting employees from falling into the pit while removing the logs. The fall protection table would be maneuvered over the pit via crane to be aligned with the logs. To assist in the alignment the lead caster and assistant would be at the corners of the fall protection table to guide it down. Once the alumimun logs have slid through the slots they were ready to be hooked to a spreader, 5 logs at a time, to be removed from The time it took once the casting pit was opened until the fall protection table was in place ranged ?'om ?ve to ten minutel_1t was during this time when employees would be exposed to an open pit fall hazard. According to the smveillance video, while trying to align the fall protection table into position, the lead caster was observed trying to move an aluminum log into position with his hand and as he stepped forward, he stepped along the edge of the pit, losing his balance and falling approximately 22 feet into the casting pit. The victim?s body was recovered approximately 3 hours later and transported to the medical examiners. According to the medical examiners, the cause of death was multiple trauma due to blunt force injtu?ies, drowning and thermal injury. The company had conducted and documented for these job tasks. Management provided copies of the current at the time of inspection. The SA covers PPE, potential hazards associated with a speci?c task, and recommendations. The SA did not mention any proper height the logs need to be at prior to setting the fall protection table as well as how to protect employees from the fall hazards associated with the time between opening the pit and the time the fall protection table was set in place. Employees were trained on the SA on October 5, 2017. The company did have within the pit area several fall protection anchors around the pit area. According to management fall protection was used when maintenance had to conduct cleaning. Employees that clean were anchored to protect them from falling into the pit. Fall protection was not required for tasks conducted by lead and assistant casters working at the pit?s edge. In?. At the time the ?le was submitted for review for citation 1, item lthe CSHO observed that the employer had added a horizontal lifeline across the pit area, as well as anchoring points adjacent to the pit. The employer changed policy and trained employees on their new policy as well as fall protection. A fall protection table was re?designed as well to help in aligning the logs better when placing the fall protection table over the pit. No abatement was received for citation 2, item 1. CITATION 1 Serious Item 1 - 29 CFR Covers and/or guardrails shall be provided to protect personnel ?'om the hazards of open pits, tanks, vats, ditches, etc. a) Casting Pit Area: One employee fell approximately 22 feet into an unguarded pit. Prob. of Injury/ Gravity- Adjustment Factors Formula Division Illness or Based Amount Proposal No. Cal. Days Uncorr. Penalty 1) Size 2) Good Faith 3)History 4)Total HL $2,500 0% 0% 0% 0% $2,500.00 $7,000.00 ADOSH FOM: No reduction factors shall be applied to penalties proposed for violations which contribute to a fatality or serious ury or illness. The proposed penalty shall be $5,000 for those violations which caused or contributed to a serious injury or illness, mi and $7,000 for those violations which caused or contributed to a fatality TOTAL PROPOSED PENALTY $2,500.CFR Alloy steel sling(s) did not have permanently affixed durable identi?cation stating size, grade, rated capacity, and reach: Comm?csto a v? tell- u. e. ?1 raiwciw?t? -