Keeping your employees safe on the job can never be overlooked, something one Massachusetts employer found out all too recently.
Powderpart Inc., a Woburn 3-D printing company, was recently cited by the U.S. Department of Labor’s Occupational Safety and Health Administration for one willful and nine serious violations of workplace safety standards. The inspection followed an explosion and fire in November of 2013, an incident which inflicted third-degree burns on a company employee.
OSHA’s Andover Area Office found that the company failed to prevent and protect its workforce from the fire and explosion hazards of reactive, combustible, metal powders, such as titanium and aluminum alloys, which are used in the company’s three-dimensional printing process.
“The fire and explosion hazards when working with titanium and aluminum are established, particularly when the materials are in powder form,” said Jeffrey Erskine, OSHA’s area director for Middlesex and Essex counties. “Just as it’s easier to start a campfire with kindling than with logs it’s easier for a metal fire to start when you’re working with metal powder that is as fine as confectioner’s sugar.”
Powderpart failed to eliminate known sources of potential ignition and follow pertinent instructions from equipment manufacturers, and did not alert the Woburn Fire Department to the workplace presence of hazardous materials. Additionally, Powderpart located an employee workstation and flammable powders next to an area with explosion potential.
In addition to the fire and explosion dangers, other serious hazards included the use of unapproved electrical equipment; electrical equipment and wiring that were unsuitable for a hazardous location; failure to train employees on chemical hazards and safeguards; failure to supply employees with all necessary protective clothing, equipment and training; no written respiratory protection program; and failure to post danger tags in potentially explosive areas.
“Establishments that use metal powders in this new technology need to scrutinize their processes and take steps to prevent and protect their employees from fire and explosion hazards that arise with these materials,” said Robert Hooper, OSHA’s acting regional administrator for New England. “The market for 3-D printed parts made from titanium and aluminum alloys includes the automotive, aerospace, defense, medical, dental and jewelry industries. Basic safety measures must be incorporated into this 21st century technology, so that it can grow without harming the employees who are building this new industry.”
Company Sees More than $50K in Penalties
One willful violation, with a $14,000 penalty, was cited for Powderpart’s failure to have any Class D metal fire extinguishers. OSHA found that Powderpart knew that titanium and aluminum fires cannot be extinguished with a regular fire extinguisher or with water, and knew that its manufacturing process presented potential fire hazards; however, there were no Class D metal fire extinguishers on-site during the explosion and fire. A willful violation is one committed with intentional disregard for the law’s requirements, or with plain indifference to worker safety and health.
Nine serious violations, with $50,400 in penalties, were cited for the remaining hazards. A serious violation occurs when there is substantial probability that death or serious physical harm could result from a hazard about which the employer knew or should have known.
Powderpart was provided with 15 business days from receipt of its citations and proposed penalties to comply, meet with OSHA’s area director, or contest the findings before the independent Occupational Safety & Health Review Commission.
Author Kori Shafer-Stack, Editor, Amaxx Risk Solutions, Inc. is an expert in post-injury response procedures and part of the Amaxx team helping companies reduce their workers compensation costs by 20% to 50%. www.reduceyourworkerscomp.com. Contact: kstack@reduceyourworkerscomp.com.
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