Industrial Hygiene Qualitative Survey & Audit - Cement Manufacturing - Local

• Document No.

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

GENERAL DESCRIPTION OF SITE OPERATIONS

• Number of employees, typical annual production capacity, etc...

• Site is regulated by?

  MSHA

  OSHA

• Describe the plant and the operations (age, wet plant, pre-heater, pre-calciner, number of kilns, etc...)

• Add media

  Media

INDUSTRIAL HYGIENE HISTORY & BACKGROUND

• When was the last quantitative IH survey conducted for the site (excluding MSHA IH sampling)?

• Has a qualitative IH survey been conducted for the site?

  Yes

  No

  N/A

• Have any issues related to IH been raised by the JHSC or IH TBS?

  Yes

  No

  N/A

• Have any issues related to IH been raised by employees and/or contractors?

• Have any health-related cases (illnesses) been reported (cement burns, hearing threshold shifts, etc...)?

• Have issues raised in previous qualitative or quantitative surveys been addressed?

• Add media

  Media

QUARRY & RAW MATERIAL STORAGE

• Is the quarry located in conjunction with the plant?

  Yes

  No

  N/A

• What are the primary stock piles at the plant (limestone, aggregate, iron oxide, other additives, etc...)

• How is clinker stored and transported?

• What are the primary sources of respirable dust and silica?

• What are the primary noise sources?

• Does the primary crusher control booth have effective dust controls (door seals, vinyl chair, AC, etc...)?

• Does any drilling equipment have appropriate dust controls (environmental cab, dust collector, etc...)?

• Does all mobile equipment have environmental cabs, AND are they properly utilized (doors and windows closed)?

• What are the methods for controlling fugitive dust from roadways, muck pile, etc...?

• Are adequate wet suppression systems (or equivalent controls) in place to control dust emissions from conveyors and crushers?

• Are controls in place to reduce exposure to welding fume during hot work in the quarry or mobile equipment maintenance shop?

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RAW GRIND

• What is the grinding equipment (vertical raw mill, horizontal rod mill, etc...)?

• What are the primary housekeeping issues on raw grind area (spillage, leaks, fugitive dust, etc..)?

• What are primary housekeeping methods (vac truck, dry sweep, shoveling, etc...)?

• What are the primary sources of respirable dust and silica?

• What are the primary noise sources?

• Add media

  Media

KILN & BURNING

• What are the primary and secondary kiln fuel sources?

• What are the process controls around the injection of FQW into the kiln (direct fire, indirect fire, etc...)?

• What is the process for handling cement kiln dust (recycle, landfill, etc..)?

• What are the primary noise sources (kiln drive, oil pumps, etc...)?

Alternative Source Fuels

• What are the primary sources of ASF?

• Are the appropriate controls in place for the risks associated with ASF (permits, characterization process, storage, handling, fire prevention and suppression)?

Kiln Turnaround - Refractory Practices

• What is the frequency of turnaround activity involving refractory work in the kiln?

• What are the dust control measures for removing existing refractory (skid steer, chute with spray bars, etc...)?

• What are the practices for installing new refractory (wet saw, manual cutting, kiln ventilation, respiratory protection, etc...)?

• What are the practices for controlling hot work fume generation during kiln turnaround (kiln ventilation, respiratory protection, etc...)?

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  Media

FINISH GRIND

• What are the primary sources of respirable dust and silica in the finish mill process?

• What are the primary noise sources in the finish mill process?

• What are primary housekeeping methods (vac truck, dry sweep, shoveling, etc...)?

• Add media

  Media

PACK HOUSE & SHIPPING

• How do bulk cement and other cementitious materials typically leave the site?

  Rail

  Ship/barge

  Truck

  Combination

• Does the site blend or bag cement for downstream use?

  Yes

  No

  N/A

• Describe the packing machine operations?

• Describe the palletizing line?

• What are primary sources of respirable dust exposure?

• What are the primary noise sources?

• Add media

  Media

Group Standard - Respirable Crystalline Silica and Total Dust

• Has a qualitative and quantitative risk assessment been conducted in accordance with the Group H&S risk management standard to determine exposure potential for every job classification and task?

  Yes

  No

  N/A

• Has a site specific RCS and TD-PNOR management and control program been established?

  Yes

  No

  N/A

• Has a health surveillance program consistent with the Group's HASOP been established for employees exposed to RCS and TD-PNOR?

  Yes

  No

  N/A

Group Standard - Workplace Noise

• Has a site noise survey been conducted?

  Yes

  No

  N/A

• Has a noise map been developed for the site?

  Yes

  No

  N/A

• Has noise dosimetry been conducted for employees anticipated to be exposed above 85 dBA?

  Yes

  No

  N/A

• Has the hierarchy of controls (HOC) been applied in cases where TWA noise exposures exceed 85 dB?

  Yes

  No

  N/A

• Have high noise areas (>85 dBA) been posted with appropriate signage?

  Yes

  No

  N/A

• Have employees exposed to noise > 85dBA received baseline and annual audiometric testing?

  Yes

  No

  N/A

Other Group Standards - Ergonomics, Whole Body Vibration, Hand-Arm Vibration

• Any ergonomic or other risks identified during survey? ( bagging or other repetitive manual tasks, etc...)

• Have any musculoskeletal injury/illness claims been reported to Health Bridge that are could be attributable to repetitive motion or other ergonomic risk factors?

  Yes

  No

  N/A

Summary and Perception of Overall IH Risk

• Summary of Observations

• What is the perception of the overall risk for the site?

  High

  Medium

  Low

• Any significant other safety deficiency or compliance concerns noted during survey?

• Any good practices or other positive feedback for the site in the area of H&S?

• Signature of H&S Professional Who Lead Survey/Audit

  Sign