Bayer Alumina Plant — Accidents

Total: 689 accidents | Fatalities: 2

Date Classification Injury Days Lost Narrative
08/26/2009 DISORDERS (PHYSICAL AGENTS) OCCUPATNAL ILLNESS NOT DEG 1-6 None Employee was walking around with MSHA inspector during Wall to Wall inspection and began to have cramps from heat. Employee was sweating profusely.
08/14/2009 DISORDERS (PHYSICAL AGENTS) OCCUPATNAL ILLNESS NOT DEG 1-6 None Employee was cleaning a screen box in Precipitation and started displaying symptoms of heat stress.
08/06/2009 OTHER NO DYS AWY FRM WRK,NO RSTR ACT None Employee felt sudden irritation to eye and quickly removed safety glasses and reported to medical. Eye was swollen. Taken to emergency room and diagnosed with insect sting and treated with prescriptio...
08/05/2009 DISORDERS (PHYSICAL AGENTS) OCCUPATNAL ILLNESS NOT DEG 1-6 2d lost Employee was working in Powerhouse performing maintenance activities.
08/04/2009 DISORDERS (PHYSICAL AGENTS) OCCUPATNAL ILLNESS NOT DEG 1-6 None Area operator in Precipitation working on top floor and got overheated. headache and nausea associated with mild heat stress.
07/28/2009 DISORDERS (PHYSICAL AGENTS) OCCUPATNAL ILLNESS NOT DEG 1-6 None General Mechanic in the Digestion department. Working in area and became overheated. Mild heat stress with muscle cramping and slight nausea.
07/23/2009 DISORDERS (PHYSICAL AGENTS) OCCUPATNAL ILLNESS NOT DEG 1-6 None Employee was performing duties of area operator in Precipitation and became hot and started to have cramps associated with heat exposure.
07/16/2009 DISORDERS (PHYSICAL AGENTS) OCCUPATNAL ILLNESS NOT DEG 1-6 None Employee was performing normal duties and became hot due to heat outside. He was swapping pumps.
07/15/2009 MACHINERY DAYS AWAY FROM WORK ONLY 1d lost Employee was preparing to swap pumps and was exposed to hydrocholric acid mist from a leaking flange that was approximately 15 feet away on adjacent equipment to what he was working. He had difficulty...
07/06/2009 HANDTOOLS (NONPOWERED) NO DYS AWY FRM WRK,NO RSTR ACT None Employee was removing pipe from overhead pipe rack and was using a line-up bar to lift pipe past obstacle. The pipe slipped and caused the end of the line-up bar to pull across the palm of his hand la...
06/29/2009 OTHER NO DYS AWY FRM WRK,NO RSTR ACT None Employee was working as the ground safety person in the 510 switch yard as an observer. He noticed something in his eye at break and does not know what may have gotten in his eye. He was not performin...
06/23/2009 SLIP OR FALL OF PERSON DAYS RESTRICTED ACTIVITY ONLY 8d restricted a Digestion General Mechanic was working with a co-worker staging pipe on the ground for assembly and lifting into the overhead pipe rack. The injured and co-worker lifted one section of pipe to align...
06/19/2009 OTHER NO DYS AWY FRM WRK,NO RSTR ACT None Employee stood up from table in break room and his left ankle did not support him and he twisted his ankle.
06/15/2009 HANDLING OF MATERIALS NO DYS AWY FRM WRK,NO RSTR ACT None The rear tire of the three wheeled bicycle the employee was using became flat. Employee strained back while removing the rear wheel in order to repair the tire.
05/28/2009 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 13d restricted Employee was changing screen box and struck finger on bolt on 5/28/2009. Incident not reported to plant medical dept until 7/8/2009. While on vacation finger became infected required medical treatment...
03/24/2009 MACHINERY NO DYS AWY FRM WRK,NO RSTR ACT None Employee was using a pneumatic air wrench and was pulling on the hose to move the hose. The hose unexpectedly loosened and the employee was pulling toward her face and the air wrench hit her in the mo...
12/19/2008 DISORDERS (REPEATED TRAUMA) OCCUPATNAL ILLNESS NOT DEG 1-6 None Hearing loss associated with exposure to excessive noise that was diagnosed during routine medical surveillance.
12/19/2008 SLIP OR FALL OF PERSON DAYS RESTRICTED ACTIVITY ONLY 43d restricted Area Operator was walking across a work platform on 12/19 and slipped on the top walking surface. He tried to catch himself by grabbing the handrail and felt pain in his right elbow. He reported to me...
12/15/2008 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 42d restricted Employee had been working with valves after washing press and started having numbness in fingers.
12/10/2008 DISORDERS (REPEATED TRAUMA) OCCUPATNAL ILLNESS NOT DEG 1-6 None Exposure to noise resulting in a 10dB STS with a 25dB hearing loss.
12/06/2008 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 50d restricted Employee was swinging a sledgehammer trying to close a valve stem and felt a slipping and grinding in his right shoulder.
12/03/2008 OTHER NO DYS AWY FRM WRK,NO RSTR ACT None Employee was opening a drain valve and was strung twice by yellow jackets.
11/23/2008 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 49d restricted Employee was opening a circulating valve on a pump tank when he felt a pop in his right shoulder.
11/12/2008 DISORDERS (REPEATED TRAUMA) OCCUPATNAL ILLNESS NOT DEG 1-6 None Employee has a 10dB age corrected hearing loss of of 25dB in his left ear.
11/07/2008 DISORDERS (REPEATED TRAUMA) OCCUPATNAL ILLNESS NOT DEG 1-6 None Exposure to noise, resulting in a 10dB STS with 25dB hearing loss in left ear.
10/30/2008 SLIP OR FALL OF PERSON DAYS RESTRICTED ACTIVITY ONLY 93d restricted Employee was walking to break room and as he was preparing to descend two steps to the break room he unexpectedly feel backward falling on his shoulder. The employee cannot determine why he fell.
10/06/2008 POWERED HAULAGE DYS AWY FRM WRK & RESTRCTD ACT 25d lost, 86d restricted While negotiating a turn on an electric fork truck the operator removed one hand from the controls to swat at a flying insect. The turn was not properly completed and the operators hand was pinched b...
09/30/2008 DISORDERS (REPEATED TRAUMA) OCCUPATNAL ILLNESS NOT DEG 1-6 None As a result of routine audiometric testing a General Mechanic in the Clarification Department was recorded as having a confirmed threshold shift with a 25 dB loss in his left ear.
09/26/2008 HANDTOOLS (NONPOWERED) DAYS AWAY FROM WORK ONLY 33d lost General Mechanic was using a 24 inch line-up bar to align the bolt holes in a flange on the loop of a low temperature digester loop. During the task the employee felt some slight discomfort while appl...
09/25/2008 NONPOWERED HAULAGE DAYS RESTRICTED ACTIVITY ONLY 105d restricted Employee got on tricycle and stood on pedals to start pedaling and right foot slipped off pedal and struck ground. Impact to ground jammed right knee. Employee was treated conservatively initially and...
09/24/2008 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 43d restricted Employee was using an 8 lb. hammer to open a valve. As he was hitting the locking handle his left hand contacted the valve handle causing a fracture.
09/20/2008 NONPOWERED HAULAGE NO DYS AWY FRM WRK,NO RSTR ACT None Employee was moving a wheel barrow and hit grating. This caused employee to loose control of the wheel barrow. Employees left hand contacted sharp edge causing a laceration on the back of the hand t...
09/10/2008 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 40d restricted An employee in the Calcination department was swapping screen boxes. Before opening screen box to clean, employee went to assist another operator. When he returned to the screen box station he opene...
09/08/2008 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 9d restricted Employee was pulling on a com-a-long to take the impeller out of a pump. Employee strained muscles in his upper back while pulling on the com-a-long.
08/15/2008 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 5d restricted Operator was loosening the valve it started to leak at the nipple. The operator reached to tighten the nipple to stop the leak and was contacted on his right hand and lip by hot caustic causing 1st a...
07/09/2008 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 6d restricted Employee tagged out and changed out the acid fluids for heater, then he opened the valves, then he filled the water tanks. He began to feel tension in his back. He then picked up the inhibitor pump...
06/16/2008 DISORDERS (PHYSICAL AGENTS) OCCUPATNAL ILLNESS NOT DEG 1-6 None Injured employee and three other employees were exchanging processing tanks in the Precipitation Dept. Injured employee began to feel weak and dizzy.
05/29/2008 HANDLING OF MATERIALS NO DYS AWY FRM WRK,NO RSTR ACT None Employee was washing down a press when sodium oxalate splashed back into her face causing possible inhalation through her nose.
05/29/2008 SLIP OR FALL OF PERSON DAYS RESTRICTED ACTIVITY ONLY 146d restricted Employee rolled left ankle on last step in R-35 after putting #6 Press Feed pump on caustic resulting in a severe sprain.
02/06/2008 MACHINERY PERM TOT OR PERM PRTL DISABLTY 75d restricted EE's (L) middle finger was amputated between the nail bed and 1st joint due to the impact from a ""T"" handle while a valve was being worked on. The last time he engaged the air gun, the pressure from...
02/01/2008 SLIP OR FALL OF PERSON DAYS RESTRICTED ACTIVITY ONLY 25d restricted EE suffered a laceration to his right elbow which required sutures. EE was descending a ladder and fell backwards when he stepped off the second rung of the ladder. He fell onto the plywood deck land...
12/17/2007 HANDTOOLS (NONPOWERED) DAYS AWAY FROM WORK ONLY 121d lost EE was using 8-lb sledgehammer to open & close valves & screen boxes in Calcination area of plant when she suffered a strain to her rt shoulder. She was seen by the plant doctor who issued restriction...
12/07/2007 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 3d restricted Employee was breaking refractory with a pry bar inside the opening of a holding vessel. The refractory broke off the vessel and struck him on the top of his left hand resulting in a laceration. He wor...
12/03/2007 HANDTOOLS (NONPOWERED) NO DYS AWY FRM WRK,NO RSTR ACT None EE was working in R325 overhaul yard on a kiln end plate. He was installing a gasket to fit around the outside edge of the plate. He was trimming the width of the gasket using a utility knife in a cle...
11/19/2007 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 10d restricted EE was opening a valve on a tank in the Precipitation area of the plant when he received a laceration to his head. As he was releasing the locking handle, valve handle spun around and struck him. He w...
11/13/2007 HANDLING OF MATERIALS DAYS RESTRICTED ACTIVITY ONLY 16d restricted Employee was closing a pump off discharge valve on #7 pump in the precipitation area of the plant. While tightening down the valve the employee strained muscles in his left shoulder. The employee repo...
10/31/2007 HANDTOOLS (NONPOWERED) DAYS RESTRICTED ACTIVITY ONLY 27d restricted EE strained his right shoulder while pulling out a refractory plug on a holding vessel. Because the eye bolt was broken, he had to pull the plug out with a pair of channel locks & a pry bar, straining...
10/15/2007 INUNDATION NO DYS AWY FRM WRK,NO RSTR ACT None Employee was loading at Alcoa R-50 Railcar Loading Station when he suffered possible exposure to HF from a near by chemical release. Employee was taken to first aid and given HF first aid treatment an...
10/15/2007 INUNDATION NO DYS AWY FRM WRK,NO RSTR ACT None Employee was loading at Alcoa R-50 Railcar Loading Station when he suffered possible exposure to HF from a near by chemical release. Employee was taken to first aid and given HF first aid treatment an...
10/15/2007 INUNDATION NO DYS AWY FRM WRK,NO RSTR ACT None A small amount of acid gas was released from the 10 screw area of the number 5 kiln in the r-84 unit. The smell of the gas was disagreeable to the employee causing him to gag and vomit. The personal m...