Bayer Alumina Plant — Accidents

Total: 689 accidents | Fatalities: 2

Date Classification Injury Days Lost Narrative
10/08/2007 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 5d restricted EE suffered chemical burns to his inside lips. He was disconnecting air compressed line which was slightly pressurized. Connection broke, caustic which had drained into the hose sprayed into his mout...
10/02/2007 MACHINERY DAYS RESTRICTED ACTIVITY ONLY 30d restricted Employee was cutting a piece of angle iron. He cut a 5' piece of angle when the piece fell, hit the ground, bounced up and hit his (L) foot. Employee continued to work, but was taken to the doctor on...
09/07/2007 HANDLING OF MATERIALS DAYS AWAY FROM WORK ONLY 7d lost Employee suffered chemical burns to both eyes, left ear, back, and mouth. He was attempting to clear a blocked precoat line to #24 filter press when he was contacted by precoat. The injury to his eyes...
09/06/2007 HANDTOOLS (NONPOWERED) NO DYS AWY FRM WRK,NO RSTR ACT None Employee was prying flanges with a bar when his right little finger was lacerated. The bar he was using slipped, smashing his finger between the bar and a cross brace. He was treated at a local medica...
08/14/2007 HANDLING OF MATERIALS DYS AWY FRM WRK & RESTRCTD ACT 60d lost, 78d restricted Employee suffered a strain to his right shoulder while emptying trash from the General Mechanic Shop in the chemicals area of the plant. The trash bag weighed about 30 lbs. As he lifted the bag to his...
08/07/2007 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 15d restricted EE suffered a chemical burn to his rt eye. He'd been changing a gasket on an acid line & stepped away from the job & pulled his goggles away from his face to clear fog. He felt something contact his e...
07/16/2007 SLIP OR FALL OF PERSON DAYS RESTRICTED ACTIVITY ONLY 2d restricted Employee was standing on a clean surface on the top floor of the R-45 in the precipitation area of the plant. When he turned around to head in a different direction, he rolled his ankle. Restrictions...
06/29/2007 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 26d restricted Employee in the Raw Materials area suffered a fracture to his left ring finger. He was transported by company vehicle to a local emergency medical facility where he received sutures and it was determi...
06/29/2007 EXPLODING VESSELS UNDER PRESSURE DYS AWY FRM WRK & RESTRCTD ACT 1d lost, 23d restricted EE suffered a contusion and mild abrasions to his right arm which resulted in a lost work day. He was contacted by hydraulic oil when a discharge pipe on the hydraulic system burst under a filter in C...
06/24/2007 SLIP OR FALL OF PERSON DAYS RESTRICTED ACTIVITY ONLY 9d restricted 1. Approx late june He stated he bumped his knee on ladder while climbing down from HEC platform. He self-medicated and rested knee. 2. 7/19/07 he indicated while working on top of F-7 thickener, upon...
06/22/2007 HANDLING OF MATERIALS DAYS AWAY FROM WORK ONLY 257d lost EE suffered chemical burns to his body. He was trasported by air ambulance to Galveston. He underwent surgery for chemical burns to his back & lower body. Additional surgery is planned for week of 6/2...
06/19/2007 HANDLING OF MATERIALS PERM TOT OR PERM PRTL DISABLTY 39d restricted EE suffered an approx 1/8"" amputation to the tip of his left middle finger. He was transported to Victoria for surgery. He returned to work the following day with restrictions. He was removing a piec...
06/17/2007 POWERED HAULAGE DAYS RESTRICTED ACTIVITY ONLY 21d restricted EE suffered chemical burns to his right hand which is reportable due to the issuance of restrictions to his hand. EE was moving loose lime into a pile. As the skid steer loader pushed into the pile, a...
06/14/2007 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 2d restricted EE was putting a tank in service in the Precipitatin area of the plant, when he received a chemical butn to his right eye, resulting in a restricted work day case. The A-frame he was adjusting slipped...
06/13/2007 MACHINERY DYS AWY FRM WRK & RESTRCTD ACT 1d lost, 5d restricted EE received injuries while attempting to restart No. 2 Aluminum Floride Unit in the R-84 Chemicals facility. During the restart, vacuum was lost and the HF was not being pulled through the converter....
06/13/2007 MACHINERY DYS AWY FRM WRK & RESTRCTD ACT 120d lost, 7d restricted EE received injuries while attempting to restart No. 2 Aluminum Floride Unit in the R-84 Chemicals facility. During the restart, vacuum was lost and the HF was not being pulled through the converter....
06/10/2007 HANDTOOLS (NONPOWERED) DYS AWY FRM WRK & RESTRCTD ACT 22d lost, 10d restricted EE was pulling up a pry bar to access more t-lead cable. The leads were burnt. They were trying to get them high enough to insulate them. There was about 3 1"" cables. EE put a shackle on the end of o...
05/22/2007 SLIP OR FALL OF PERSON DYS AWY FRM WRK & RESTRCTD ACT 145d lost, 30d restricted Employee suffered a contusion to his right cheek while correcting lighting problems in the bauxite tunnel. While carrying a light fixture, he slipped and fell striking his face with the light fixture....
04/05/2007 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 41d restricted Employee was lining up a pump with a pry-bar. The pry-bar slipped in the process causing a forward motion. When the forward motion occurred, employee strained his neck. Employee was placed on restrict...
03/10/2007 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 28d restricted EE and co-worker were cleaning out a screen box that did not want to come out. After hosing and washing it out and beating it with a hammer, EE tried to pull it out. He could not get it out, so he hit...
03/05/2007 HANDLING OF MATERIALS NO DYS AWY FRM WRK,NO RSTR ACT None Employee was washing out a flash. It slipped from his hands, broke in the sink and a piece of glass went through his rubber glove, resulting in a 1"" laceration to his right palm. He was sent to the l...
02/27/2007 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 103d restricted Employee was working to remove a restriction on 1A2 Supplemental line. He used a 3-lb hammer to open a valve. Upon striking the locking handle, the hammer struck a glancing blow resulting in a lacerat...
02/23/2007 SLIP OR FALL OF PERSON NO DYS AWY FRM WRK,NO RSTR ACT None EE was injured when a section of grating failed at the R-52 Bulk Loading Tower. EE dropped his tool underneath the stationary counterweights of the tower. He knelt down in order to crawl to the tool,...
02/10/2007 STRIKING OR BUMPING NO DYS AWY FRM WRK,NO RSTR ACT None EE was performing work tasks from a stand and when he stepped down off the stand, his right knee caught the stand, ripping his right pant leg and lacerating his right knee. He was seen by Security per...
02/01/2007 HANDLING OF MATERIALS DYS AWY FRM WRK & RESTRCTD ACT 112d lost, 154d restricted EE suffered a strain to his left shoulder on 2/1/07, which was a first-aid case. On 3/14/07, he was issued restrictions. A bolt had fallen to the floor and EE was trying to retrieve the bolt. He brace...
01/31/2007 HANDTOOLS (NONPOWERED) DYS AWY FRM WRK & RESTRCTD ACT 21d lost, 7d restricted EE was using a 8lb sledge hammer while opening & closing a valve. EE stated he felt a burning sensation in the abdomen area while closing the valve. The incident occurred 1/31/07 & was classified as a...
01/29/2007 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 2d restricted Employee suffered a strain to his left shoulder. He was swinging an 8 lb sledge hammer to close valve. His shoulder felt tired but he completed closing the valve, then moved to the next valve & proced...
01/21/2007 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 10d restricted EE was preparing to leave work at end of 12-hr shift. As he reached down to pick up lunch box, he experienced sharp pain to lower back. He received 1st aid treatment by security personnel & went home....
01/13/2007 SLIP OR FALL OF PERSON DAYS AWAY FROM WORK ONLY 28d lost Empolyee was walking across the grating covering a chute at C-7 precipiatation when the grating shifted and she fell into the chute. The employee has had a persistent shoulder problem and has now ele...
01/04/2007 MACHINERY NO DYS AWY FRM WRK,NO RSTR ACT None EE sustained a laceration to the right side of his forehead while operating a D10 dozer. A pathway had been cut during the previous shift by the D10 dozer. After the run was completed, the dozer opera...
01/02/2007 OTHER FATALITY Fatal A Chemicals I&E Technician was sprayed in the face with a liquid assumed to contain condensated hydrogen fluoride. The miner was in the process of performing routine preventative maintenance on an ins...
12/13/2006 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 25d restricted EE was hammering on a plugged underflow line with an 8lb hammer when she felt pain in her shoulder. EE worked the remainder of shift. She was seen by plant nurse & Dr & treated using ice & OTC medicat...
12/06/2006 HANDLING OF MATERIALS DAYS AWAY FROM WORK ONLY 131d lost Employee was shoveling alumina from track 3 scale in the Calcination area of the plant when she suffered a strain to her lower back. This incident occurred on 12/06/06, but was not reported to the Med...
11/20/2006 HANDLING OF MATERIALS DAYS AWAY FROM WORK ONLY 32d lost EE received a significant laceration to his left ring finger, resulting in restricted work. EE was positioning a 500lb cabinet onto a rolling cart w/assistance of 3 other EE's. As the cabinet was bein...
10/28/2006 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 2d restricted Employee suffered a chemical burn to the first, middle and ring fingers of his left hand. He was using chemical rubber gloves to pull a blind. As part of the job a 1 1/4"" socket was needed. He pulled...
10/01/2006 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 7d restricted Employee was opening a cone valve in the calcination area of the plant and the cheeter bar he was using gave way resulting in a strain to his lower back. restrictions were issued.
09/25/2006 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 31d restricted Employee's tip of (L) finger was caught between choker and stub of uncovered leaf when the crane was coming up on hoist.
09/21/2006 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 4d restricted EE was pulling a slide out of a precipitator trough. The A-frame he was using with a come-along shifted. The foot on the A-frame kicked out when the A-frame was under tension hitting him in the chest,...
09/14/2006 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 43d restricted Employee suffered a groin strain while shoveling wet fluorspar. He raised a dumpster to clean fluorspar that was stuck in the dumpster. As the employee attempted to shovel the material from the dumpst...
08/25/2006 SLIP OR FALL OF PERSON DAYS RESTRICTED ACTIVITY ONLY 3d restricted EE was placing loading spout in railcar when part of his fall protection system snagged on spout assembly. Snag pulled EE back as he was walking away from spout, then quickly released causing him to s...
08/24/2006 MACHINERY NO DYS AWY FRM WRK,NO RSTR ACT None EE & co-worker were using pneumatic jacks to position motor for #4 rod mill in R-25. Jack was placed between fabricated backstop & base of motor. EE had positioned his jack in preparation to move moto...
08/18/2006 EXPLODING VESSELS UNDER PRESSURE DAYS RESTRICTED ACTIVITY ONLY 206d restricted EE's were completing a project to install new 1/2"" stainless steel tubing for a conductivity meter on the #3 high pressure boiler. The line was being put into service when an elbow separated from the...
08/15/2006 HANDTOOLS (NONPOWERED) NO DYS AWY FRM WRK,NO RSTR ACT None Employee received a laceration to his right hand. The employee was trying to remove a stuck filter from the suction of 55-3 main blower with a rod. The frame of the filter gave way and his hand contac...
08/01/2006 DISORDERS (PHYSICAL AGENTS) OCCUPATNAL ILLNESS NOT DEG 1-6 None Employee suffered heat stress & required 2 liters of intravenous fluids to rehydrate. The fluids were given at a local hospital. Employee is new to the location and was not fully acclimated to working...
07/29/2006 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 5d restricted EE received 1st degree chemical burns to his back, face & right eye when he was splashed with process liquor. He was in the process of swapping pumps at the ""H"" tanks when liquor discharged through...
06/10/2006 EXPLODING VESSELS UNDER PRESSURE NO DYS AWY FRM WRK,NO RSTR ACT None Employee suffered a chemical burn to both eyes. He was closing a valve when the packing blew and liquor contacted his eyes and front torso. He was treated with Morgen Lens to both eyes and was taken t...
06/05/2006 HANDLING OF MATERIALS NO DYS AWY FRM WRK,NO RSTR ACT None EE was performing normal routine tasks when his right eye became inflamed and irritated. Alcoa's plant physician referred employee to a local eye center for evaluation. He was issued a prescription me...
06/04/2006 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 7d restricted Employee suffered a strain to her left shoulder while opening a valve with a 10 lb sledge hammer. Employee thinks the injury occurred when she missed the handle of the valve while swinging the sledge...
05/30/2006 DISORDERS (PHYSICAL AGENTS) OCCUPATNAL ILLNESS NOT DEG 1-6 None Employee was working under one of the tanks in the Clarification area of the plant. As he walked to look at a screen, he became dizzy. He was taken to the plant Medical Department for evaluation and w...
05/24/2006 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 15d restricted Employee suffered a strain to his right shoulder while double wrenching a 36' flange. Employee saw a personal physician and an MRI is scheduled. Alcoa's plant physician issued employee restrictions on...