Batch Plant Safety Audit - duplicate

Title Page

Conducted on
Date of last Inspection
Prepared by
Location Manager
Number of regular employees on OSHA 300

General Safety Management

Have corrective actions from previous inspections been completed or are there outstanding issues?
Risk Matrix Score?
OSHA 300A Summary with the 301 supplemental report of injury/illness for each entry on the log posted(Feb.-Apr.)?
Risk Matrix Score?
Is the current Federal Labor Law Poster on display in English and Spanish in a conspicuous location?
Risk Matrix Score?
State Labor Law Poster in a common and conspicuous location?
Risk Matrix Score?
Are current safety notices and training aids displayed in common areas to communicate safety issues?
Risk Matrix Score?
Are signs posted at the site entrance, yard areas, and material storage areas to give speed limits, directions and safety warnings (including "Loader has R.O.W.")?
Risk Matrix Score?
Are all truck drivers provided with personal protective equipment for hands, eyes, ears, head, where appropriate, to avoid injury or chemical burns during batching, discharge and cleaning of mixer drums with spare PPE available at the plant?
Risk Matrix Score?
Is personal protective equipment worn by employees and visitors in the plant areas, i.e. hard hats, high visibility garments, safety boots, gloves, safety glasses as appropriate?
Risk Matrix Score?
Are all employees given annual general safety and health training in line with specified training requirements?
Risk Matrix Score?
Are relevant staff provided with information and training on handling hazardous substances including cement, admixtures, fuel, oil and chemicals?
Risk Matrix Score?
Is adequate parking provided for employees that is secure and safe?
Risk Matrix Score?
Has adequate lighting been provided on the facility yard to avoid safety and security problems due to poor visibility?
Risk Matrix Score?
Is first aid equipment available on the site and is it properly stocked?
Risk Matrix Score?
Are all gates onto the property in good working order and can be secured when no one is on site?
Risk Matrix Score?
Are all fences and walls on property in good condition?
Risk Matrix Score?
Does the facility have security cameras in use and in good working order everywhere that they are needed?
Risk Matrix Score?
Is there any unnecessary equipment or material being stored on site that needs to be removed?
Risk Matrix Score?
If there are large storage containers, such as conex boxes, in use are they kept in an orderly manner that does not present hazards of any kind?
Risk Matrix Score?
If there are ice conveyors on site are they in good working order with all guards in place?
Risk Matrix Score?
Are all small chemical containers at the facility labeled correctly with their contents?
Risk Matrix Score?
Is there an SDS (Safety Data Sheet) on all chemicals used and made accessible to employees?
Risk Matrix Score?
Areas designated for specific use not being used to store miscellaneous items?
Risk Matrix Score?
General housekeeping up to standard with no hazards presented by tools or other items left out?
Risk Matrix Score?
Are there signs in place where needed to inform employees of confined spaces and that entry is prohibited?
Risk Matrix Score?
If facility has conveyor pits are they labeled as "Confined Space" and have limited access?
Risk Matrix Score?
Are silos and other areas properly labeled as "Confined Space"?
Risk Matrix Score?
Are all trucks, loaders, and other moving equipment fitted with reversing alarms and effective visibility warnings?
Risk Matrix Score?
Pre-trip and Post-trip inspections being properly performed with evidence of corrective actions being taken then signed off on by person making the repairs?
Risk Matrix Score?
Have plant operators completed instruction on the safe operation of their equipment including the mechanical, electrical, hydraulic, control systems, and emergency stops?
Risk Matrix Score?
Is there adequate information on emergency procedures and escape routes?
Risk Matrix Score?
Has training been conducted and documented on the loader for affected employees?
Risk Matrix Score?
Has risk analysis for Respirable Silica been conducted for this facility?
Risk Matrix Score?

Environmental Compliance

Is the SWPPP current and available for inspection?
Risk Matrix Score?
If plant has an Above Ground Storage Tank, does this facility have a current petroleum storage tank certificate available for review?
Risk Matrix Score?
If plant has an Underground Storage Tank, is the SPCC current and available for review?
Risk Matrix Score?
Are plant environmental inspections conducted and documented monthly?
Risk Matrix Score?
Is there any visible dust emission coming from the plant during off loading of cementitious materials into silos?
Risk Matrix Score?
Are all silo filters in good working order and regularly maintained with formal records of inspection, cleaning, and replacement? (plant inspection)
Risk Matrix Score?
Are there significant water leaks on the plant or any of its peripheral systems?
Risk Matrix Score?
Are water hoses on slump racks turned off after use?
Risk Matrix Score?
Are clean up materials and spill kits available in case of machine/equipment leaks and spills? (Located near fuel pump and labeled)
Risk Matrix Score?
Are storage areas where potential environmental impacts exist designed in such a way as to limit potential impacts
Risk Matrix Score?
Are there empty barrels or other fluid containers kept unnecessarily at the facility?
Risk Matrix Score?
Is the central dust collector in good condition and work properly?
Risk Matrix Score?
Is an intact rubber loading boot from the loading chute into truck drum installed to reduce dust emission?
Risk Matrix Score?
Are good housekeeping measures implemented to minimize and prevent exposure of spilled cement, aggregate, fly ash or other dust to runoff?
Risk Matrix Score?
When employees are washing out mixer drums are they doing so correctly and taking steps to control the flow of waste material into designated location?
Risk Matrix Score?
Are return product piles kept to a minimum?
Risk Matrix Score?
Are solids from settlement and wash out pits removed frequently to allow maximum containment?
Risk Matrix Score?
Are dikes, berms, and other storm water diversion structures properly maintained?
Risk Matrix Score?
Does plant have a Fortrans system in use and working correctly?
Risk Matrix Score?
Are all outfalls on the property accessible without obstruction (including from vegetation)?
Risk Matrix Score?
Do outfalls have effective sediment filters?
Risk Matrix Score?
Do outfalls show signs of negative environmental impact?
Risk Matrix Score?

Batch House and Office Buildings

Is the truck mixer loading area designed to minimize dust and noise when loading?
Risk Matrix Score?
Is the batch house reasonably airtight and soundproof, with adequate heating and air conditioning to prevent ingress of dust and noise and provide comfortable climate?
Risk Matrix Score?
Is lighting adequate and is there proper ventilation, heating and cooling inside of all buildings?
Risk Matrix Score?
Is there an emergency stop button for all plant equipment located on the batch house control panel?
Risk Matrix Score?
Are batch house walls, flooring, stairs, passages, ceiling, and roof in good condition?
Risk Matrix Score?
Lighting adequate in the batch house and under the plant to allow batch man good visibility?
Risk Matrix Score?
Are plant loading area cameras and monitor in working order?
Risk Matrix Score?
Are admix cameras and monitor in working order?
Risk Matrix Score?
Are the workplaces and break areas tidy and is waste disposed of properly?
Risk Matrix Score?
Have adequate facilities been provided in the office and break rooms for washing, eating?
Risk Matrix Score?

Admixtures and Fuel Storage

Does the facility have an above ground petroleum storage tank(s) of >1320 gals?
Risk Matrix Score?
If so, is containment provided with capacity 110% of fuel tank volume and free from trash/liquid?
Risk Matrix Score?
Does containment have drain plugs in place or ball valves that are closed and locked when not in use?
Risk Matrix Score?
When pumps are installed in containment vessels are they wired properly with intrinsically safe wiring and pumps?
Risk Matrix Score?
If facility has an under ground fuel storage tank, are the monthly fuel inventories up to date?
Risk Matrix Score?
Diesel storage tanks and pumps clearly and properly labeled with "no smoking," "flammable," and the NFPA warning diamond?
Risk Matrix Score?
Emergency cut-off for the fuel pump provided (> 20 feet and < 100 feet), clearly labeled, and easily accessible?
Risk Matrix Score?
Fire extinguisher provided near fuel pump?
Risk Matrix Score?
Is the fuel pump nozzle and hose in good condition and hung up to prevent damage?
Risk Matrix Score?
Fuel hose equipped with a breakaway device?
Risk Matrix Score?
Are all storage tanks and containers containing admixtures, fuel, cleaning chemicals and similar materials clearly and correctly labelled? (excluding USTs)
Risk Matrix Score?
Are distribution pipes and hoses for admixes tight and in good condition to prevent leaks or spillage from stored liquids?
Risk Matrix Score?
Are all drums containing fluids clearly and correctly labelled?
Risk Matrix Score?
Outdoor chemical storage maintained in such a way as to prevent spills and runoff to rainwater with sufficient secondary containment?
Risk Matrix Score?
All above ground storage tanks are protected from vehicle traffic?
Risk Matrix Score?

Material Storage and Distribution

Are the plant and aggregate storage areas paved to limit production of dust?
Risk Matrix Score?
Are the plant and aggregate storage areas washed down and swept when required?
Risk Matrix Score?
Are all aggregate storage areas level to minimize the risk of delivery vehicles overturning?
Risk Matrix Score?
Are material stockpiles kept within 3 sided bunkers, not over filled, and have sprinklers equipped during summer months?
Risk Matrix Score?
Are aggregate bunkers in good condition and not in need of repair?
Risk Matrix Score?
Are the operating controls for the conveyor accessible from the seat of loaders?
Risk Matrix Score?
Are all slopes on loader routes not greater than 60% (31 degrees)?
Risk Matrix Score?
Loader Operator wearing seatbelt when their vehicle is in motion?
Risk Matrix Score?
Is the loader fitted with a short ladder for access and descent from cabin, security cabin with overturning bar protection, seat with anti-vibration, and belt adjustable for user?
Risk Matrix Score?
When stopped the loader has the bucket on ground and parking brake engaged?
Risk Matrix Score?
Loader always travels at a safe speed
Risk Matrix Score?
Loader bucket only raised when facing uphill
Risk Matrix Score?
The loader bucket is never used as a man-lift and no personnel are ever directly under the bucket
Risk Matrix Score?
Are all silos fitted with suitable warning devices which when activated warn the tanker driver to stop the powder delivery process, and are they operational?
Risk Matrix Score?
Is the operating pressure of delivery tankers that is safe for filter and the filter housings communicated to delivery drivers?
Risk Matrix Score?

Fire Safety

Is there a fire fighting and evacuation plan?
Risk Matrix Score?
Are escape ways and exits clearly marked?
Risk Matrix Score?
Are exits free from obstacles impeding movement?
Risk Matrix Score?
Is there a current annual inspection tag for each fire extinguisher?
Risk Matrix Score?
Are all fire extinguishers easily accessible and properly mounted?
Risk Matrix Score?
Have employees with fire fighting responsibilities been trained in how to use an extinguisher, and is the training documented?
Risk Matrix Score?
Are combustibles such as paper or wood allowed to accumulate?
Risk Matrix Score?
Are combustibles such as oil and grease allowed to accumulate without being removed?
Risk Matrix Score?
Are safety cans with flashback protection used for storing less than 5 gallons of gasoline, diesel fuel, or other small amount of flammable/combustible?
Risk Matrix Score?
Are all flammables stored properly in a fire resistant cabinet marked with "Flammable?"
Risk Matrix Score?
Are employees smoking less than 20 feet away from combustibles?
Risk Matrix Score?
Is the entire facility fitted with all required fire extinguishers as noted in other sections?
Risk Matrix Score?

Electric Installation and Wiring

Are portable tools equipped with grounding prong or double insulated?
Risk Matrix Score?
Are extension cords in use equipped with a grounding prong? (If no, confiscate and destroy immediately.)
Risk Matrix Score?
Are there extension cords with cuts or with splices? (If yes, confiscate and destroy immediately.)
Risk Matrix Score?
Temporary cords are not being used through ceilings, walls, or windows?
Risk Matrix Score?
Has an adequate number of power points been provided to limit extension cord use?
Risk Matrix Score?
Wall plugs and power points are free from damage and have proper cover plates?
Risk Matrix Score?
Is all electrical wiring enclosed in conduit?
Risk Matrix Score?
Is there damage to any conduit?
Risk Matrix Score?
Do all junction boxes have covers?
Risk Matrix Score?
Are circuit breaker boxes labeled?
Risk Matrix Score?
Are individual circuit breakers labeled as to what they control?
Risk Matrix Score?
Electrical boxes undamaged, in good condition, and free from missing knockouts?
Risk Matrix Score?
Is the main electrical power switch fixed separately from the general board?
Risk Matrix Score?
Are high voltage installations such as transformers and substations enclosed, or accessible only by qualified people?
Risk Matrix Score?
Is there a "Danger High Voltage" sign (or similarly worded sign) at the entrance to high voltage installations?
Risk Matrix Score?
Is there fire protection provided at electrical installations?
Risk Matrix Score?

Climbing and Walking Surfaces

Are there slipping and tripping hazards obvious anywhere on the premises?
Risk Matrix Score?
Are there standard mid rails and guard rails on all platforms and stairs?
Risk Matrix Score?
Are stairway floor openings guarded with standard rails except for entrance and exit?
Risk Matrix Score?
Are ladder way openings guarded with standard rails except for entrance and exit?
Risk Matrix Score?
Are there no ground or wall openings through which persons may fall?
Risk Matrix Score?
Are silo and dust collector tops kept clean and fitted with railings and kick boards to prevent falling and falling objects?
Risk Matrix Score?
Is there a suitable access platform in the mixing area to prevent falls during operation, cleaning and maintenance?
Risk Matrix Score?
Is there a suitable access platform in the cement auger area to prevent falls during repair and maintenance work?
Risk Matrix Score?
Is there a suitable access platform in the material weighing areas to prevent falls during operation and maintenance?
Risk Matrix Score?
Is there a suitable access platform in the area bellow the stacker to prevent falls during operation and maintenance?
Risk Matrix Score?
Crossover platforms provided between upper silos with standard railings and toe boards?
Risk Matrix Score?
Are slump rack guard rails adequate around mouth of truck mixer to allow safe inspection of concrete and to avoid a person coming in contact with movement of the drum?
Risk Matrix Score?
Are slump racks and stairs in good condition and adequate for operations?
Risk Matrix Score?
Are there suitable guard rails or covers to settlement tanks and water recycling tanks to avoid risk of drowning?
Risk Matrix Score?
When working above ground are employees protected from falls by either standard railing or safety harnesses at all times?
Risk Matrix Score?
Are all catwalks clean of loose material?
Risk Matrix Score?
Are all catwalk handrails adequate and without damage?
Risk Matrix Score?
Are all fixed ladders adequate, without damage, and easily accessible?
Risk Matrix Score?
Are all fixed ladders (above 24' in height) properly caged or have fall protection systems installed.
Risk Matrix Score?
Ladder cages start no lower than 7' and no higher than 8'?
Risk Matrix Score?
Resting platform provided on all ladders over 50' in height?
Risk Matrix Score?
Are fixed ladders exceeding 24 feet in height compliant with new rules regarding fall arrest systems?
Risk Matrix Score?
Stair or ladder access provided in all areas where needed.
Risk Matrix Score?
Are fall arrest harnesses maintained in good condition, stored properly, and regularly inspected?
Risk Matrix Score?
Are all paved areas at the facility in good condition without significant pot holes or areas in disrepair?
Risk Matrix Score?

Machine Guarding/Lockout Tagout Procedures

Are suitable guards fitted at the head/tail pulleys of stacker belt(s) or are they inaccessible by location?
Risk Matrix Score?
Are suitable guards fitted at the head/tail pulleys of loading belt(s)or are they inaccessible by location?
Risk Matrix Score?
Are stacker conveyor belt rollers properly guarded?
Risk Matrix Score?
Are loading conveyor belt rollers properly guarded?
Risk Matrix Score?
Are emergency-stop pull cords provided along the entire length of conveyor belts with catwalks beside them and in good condition?
Risk Matrix Score?
Are auger belts guarded properly?
Risk Matrix Score?
Is there total enclosure of the cement augers with safety-locked covers to avoid a person becoming trapped in the augers?
Risk Matrix Score?
Are there covers to all moving parts of plant mixers? (wet batch plants)
Risk Matrix Score?
Are there guards covering the drive system of the stacker conveyor bridge at ground level?
Risk Matrix Score?
Are plant air compressor belts properly guarded?
Risk Matrix Score?
Are there signs where appropriate to warn that equipment such as air compressors can start automatically?
Risk Matrix Score?
Is there a lockout/tagout board or similar arrangement for the proper storage of LOTO equipment adequate for the plant's needs?
Risk Matrix Score?
If work is being done on equipment or machines that can become energized, is lock out and/or tag out in place?
Risk Matrix Score?
Are Lockout Tagout procedures being implemented correctly in all cases?
Risk Matrix Score?
Are there signs where appropriate to warn that maintenance work shall not be carried out on systems unless they are locked out?
Risk Matrix Score?
Have all staff attended training and formally acknowledged that they will always follow the lock out procedure?
Risk Matrix Score?
Are machine specific lockout/tagout procedures established and implemented?
Risk Matrix Score?

Maintenance Shop Addendum

Maintenance Shop Safety

Is a First Aid kit provided in the shop area and stocked with adequate supplies?
Risk Matrix Score?
Shop eyewash stations provided and inspected?
Risk Matrix Score?
Extra eye/face protection provided at grinder, drill press, and parts washer?
Risk Matrix Score?
Guards on shop grinders properly adjusted?
Risk Matrix Score?
Drill Press and other shop equipment properly mounted to shop floor?
Risk Matrix Score?
Cutting torches provided with flashback arrestors?
Risk Matrix Score?
Welding leads free from damage within first 10' of whip?
Risk Matrix Score?
Welding Electrodes properly stored?
Risk Matrix Score?
Is there a checklist for "hot work"?
Risk Matrix Score?
Are there hot work permits on file?
Risk Matrix Score?
Have combustibles such as wood, paper, oil, grease been moved away from or isolated from the welding area?
Risk Matrix Score?
Is hot work conducted with fire protection present?
Risk Matrix Score?
Adequate number of fire extinguishers in shop/free from obstructions?
Risk Matrix Score?
Are compressed gas cylinders correctly labeled?
Risk Matrix Score?
Are cylinders stored upright with caps in place?
Risk Matrix Score?
Are cylinder storage areas more than 20 feet away from combustibles?
Risk Matrix Score?
Are oxygen cylinders and fuel gas cylinders stored at least 20 feet away from each other or separated by a partition?
Risk Matrix Score?
Are all flammables stored properly in a fire resistant cabinet marked with "Flammable" for use only in the shop?
Risk Matrix Score?
Are used engine fluids, oil filters, batteries being recycled?
Risk Matrix Score?
Are combustibles such as paper or wood allowed to accumulate in the shop area?
Risk Matrix Score?
Are combustibles such as oil and grease allowed to accumulate without being removed in the shop area?
Risk Matrix Score?
Are all chemical containers in the shop labeled correctly with their contents?
Risk Matrix Score?
Are all drums and large chemical containers kept on or within secondary containment vessels to capture spills or leaks?
Risk Matrix Score?
Are there sufficient clean up materials available to contains spills in the shop?
Risk Matrix Score?
Are all lifting and hoisting components in good condition?
Risk Matrix Score?
Are roll up doors on the shop building in good working order and safe for use?
Risk Matrix Score?
Are compressors and pumps housed in a separate solid building or enclosure to minimize noise?
Risk Matrix Score?
Are shop air compressor belts properly guarded?
Risk Matrix Score?
Temporary cords not used in place of permanent wiring in the shop?
Risk Matrix Score?
Bulbs in light fixtures guarded to prevent accidental contact?
Risk Matrix Score?
Is there a lockout/tagout board or similar arrangement for the proper storage of LOTO equipment adequate for the shop's needs?
Risk Matrix Score?
Does the shop facility practice good housekeeping procedures?
Risk Matrix Score?
Is suitable equipment available for the movement of full and empty drums to prevent injuries from manual handling?
Risk Matrix Score?
If shop has an overhead storage area is the floor load rating posted?
Risk Matrix Score?
Standard railing/toe boards provided on overhead storage area?
Risk Matrix Score?
Are portable stairs and work platforms in good condition and fit for use?
Risk Matrix Score?
Are portable ladders in good condition and stored properly?
Risk Matrix Score?

Batch Plant Safety Audit - duplicate

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