Title Page
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Audit Title
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Facility Name / Location
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Conducted on
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Prepared by
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Plant Operator
Plant / Shop / Batch Office
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Company Safety & Health Book and Programs Review; Ensure there is a program for all topics noted in cover letter.
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Containers and Chemicals must be labeled; all containers and chemicals must be labeled hazardous. Chemicals must have hazard labels. REF 29CFR1910.1200(f)(5)-(11)
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CPR & First Aid Training; Required if first responder is over four (4) minutes away from plant. REF 29CFR1910.151(b)
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Daily Plant Inspection & Rain Log; daily entry required for all days of operation.
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Driver Vehicle Inspection (pre-trip/post-trip); records must be kept on file for 90 days
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Vehicle maintenance files are maintained in a new at organized manner. All repair orders and associated DVIRs maintained one (1) year + 6 months after sale of truck.
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Dust masks available. Training required for all employees including training roster / Voluntary Usage Policy posted.
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Ear plugs / hearing protection available. Proper usage poster posted.
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Electronic switches, breaker boxes and breakers labeled. Label identifies component that switch or breaker controls.
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Emergency Phone Numbers posted; covered in training and posted where easily located.
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Environmental Policy Statement posted; framed and posted in batch office and area office.
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Emergency action, escape or evacuation plan (MAP) posted; covered in training and posted where easily located. REF 29CFR1910.38(c),(e),(f)
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Exit / NOT AN EXIT Doors labeled; restrooms and storerooms can be identified.
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Exterior outlets and outlets around water should be GFCI Receptacles or on a GFCI breaker; receptacles controlled by GFCI breaker require a label stating "GFCI PROTECTED"
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Eye Wash Station Inspection current (location identified by signage); station should be reached in 10 seconds and provide 15 seconds of continuous flow / station should be servied as required and logged. REF 29CFR1910.151(c)
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Facility Inspection completed quarterly; copied to area operations manager and filed in plant file.
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Fall Protection Harness Inspection: two harnesses, lanyards and carabinier hooks required at each plant; replace after any fall, damage or 10 years (unless manufacturer specifies earlier)
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Federal employee 5-in-1 poster current and posted.
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Fire detection systems or Smoke Alarms in place and tested periodically; smoke detector in all batch offices, kitchens, break rooms and labs.
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Fire extinguisher maintenance; inspected annually by fire extinguisher service company / inspected by plant personnel monthly.
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Fire extinguishers that are tagged "Out of Service" properly stored - they must be restored to normal operation conditions as soon as possible.
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Fire extinguishers are mounted, labeled and properly located. Required 75 feet from all working areas, 50 feet from fueling areas, and 10 feet from all flammable storage areas
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First Aid cabinet inventory maintained per OSHA Minimum; Inventory list posted and verified monthly.
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GFCI Receptacles and / breakers tested; tested quarterly and logged.
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Housekeeping maintained in all areas; designed to keep a clean and neat working environment. REF 29CFR1910.22(a)-(3)
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LOTO kit including locks, hasps, tags; locks must have one key.
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LOTO Log maintained for each LOTO procedure; Every LOTO procedure should be logged on plant log and log should be maintained in LOTO procedure book.
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LOTO Procedures (including procedure for Truck & Equipment); annual review of LOTO procedures required / file form in LOTO Procedure book.
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MSDS / SDS book review and two (2) required posters are posted; book must include a sheet for every chemical and product on site / a table of contents inventory list required (listed name should match name on MSDS / SDS sheet) REF 29CFR1910.1200(g)(8)
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MSDS / SDS posters posted and visible to employees, contractors and General Public. REF 29CFR1910.1200(8)(11)
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NRMCA Plant Certification current and posted. Plant expires in two years and trucks in 14 months // schedule renewal process 60-90 days prior to expiration.
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OSHA 300 Summary posted through April 30th; take OSHA 300 A log down and file after May 1st / must be kept on file for five (5) years REF 29CFR1904.32 and 33
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PPE Signs posted; required at time clock, inside of all exit doors, on outside of buildings and on or near plant production area.
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Safety Training Material review: Annual review of OSHA topics to be completed in January. Tool Box Topics due weekly.
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SPCC Spill Response Kit (11-156 gallons, bag of oil dry); identify location of spill kit with signage that can be seen from fueling area, oil storage and shop areas.
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Spill Prevention Control & Countermeasure Plan Review: SPCC required at all locations that have a combined quantity of fuel and oil exceeding 1320 gallons.
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Spill Team Current; SPCC book should be revised when changes are made, including personnel (notify corp safety officer when needed)
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Spill Log Maintained; spills or leaks should be cleaned up immediately; if no spills not it as "NO SPILLS THIS MONTH" (any spills over 1 gallon should be noted in log)
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Periodic Equipment / Tank Inspection: Annual inspection of all petroleum tanks over 500 gallons completed by environmental manager or other designated staff member // filed in SWPPP or SPCC
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SIte Plan Review: Modifications to air emission sources, process & storm water outfalls, changes to site plan including the site footprint must be reported to Corp. Environmental Manager (these changes may require major modification notification to MDEQ 30 to 60 days in advance of change)
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Storm Water Pollution Prevention Plan (SWPPP) Review; SWPPP book should be revised when changes are made, including personnel.
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Pollution Team Current ; SPCC Plan book should be maintained with current team members / notify environmental manager of needed revisions.
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Petroleum Products Description / Volumes accurate. SPCC Plan book should be maintained with current volumes / notify environmental manager of needed revisions.
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Comprehensive Site Compliance Evaluation Review - Appendix C: Requires monthly entry // after DEC entry signed by Area Manager and send to MDEQ before Jan 28th
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Multi Media General Permit ; POsted at plant and copy of entire permit in SWPPP under Appendix A
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Monthly SWPPP Inspection; Maintained fore three years
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Personal Environmental Training Current; Initial training and annual refresher required and filed in SWPPP / annual training due each year prior to March
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Bag House Log; Monthly entry required / Log all monthly inspections and all maintnenace
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DMRs Filed; Maintained for three years
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Structural Plant Inspection; Required annually // copy to area operations manager and in plant file
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Workers' Compensation Policy Current and Posted
Plant Production Area
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Admixture Transmission Lines between containers / dispensers and plants labeled or color coded
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Cement & Ash Pipes Labeled and PSI Requirements Posted
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Confined Spaces Labeled "CONFINED SPACE"; required on all bins, hoppers, silos and bag houses REF 29CFR1910.146(c)(2)
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Each container and chemicals must be labeled. Labeling must match name on MSDS / SDS
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Dust Control satisfactory. Bag houses not smoking ; sprinkle roads and yard to suppress dust.
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Electric Breaker Boxes, switches and breakers labeled. Label identifies component that switch or breaker controls.
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Electric Cabinets unused openings effectively closed
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Electric cords, outlets, breakers and GFCI Protection inspected. GFCI tested and logged quarterly.
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Electric junction boxes properly covered.
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Electric receptacle covers on
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Electric wiring is approved SO Cable or in Conduit ; when replacing old wire it is recommended that conduit be used when possible
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Extension cords used and/or stored properly and in good condition; cords should be used as temporary power only / 24 hours
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Exterior Outlets and outlets around water should be GFCI Receptacles or on a GFCI breaker
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100% fall protection used above four (4) feet; This could be with hand rail system, ladder cages, or as a last means of protection use harness
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Fall protection - floor / deck openings guarded; openings over one inch should be closed or protected.
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Fire extinguishers are mounted, labeled, properly located; required 75 feet from all working areas, 50 feet from fueling areas, and 10 feet from all flammable storage areas REF 29CFR1910.157(c)
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Hand rails & toe boards on work platforms four (4) feet or higher; top rail 42 inches, mid rail 21 inches, 4 inch toe board
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Hand rails on stairs with 4 or more risers / openings guarded
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Housekeeping maintained in all work facilities and areas
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Ladder cage openings guarded with safety chains; to prevent climbing hazard chain should only be hooked when employee is on deck.
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Ladders include cages or safety arrest cable in good condition // fall arrest system requires harness with front "D" ring and carabinier; employee properly trained on use and climbing
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Machine guards must be used to protect people from all machine hazards. REF 29CFR1910.212.(a)(1)-(2)
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Portable ladder condition good; ladder condition should be inspected before each use.
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Slump Rack in good condition; inspect quarterly or after any reported concern or damage stacker belt includes catwalk, handrails or safety cable for harness connection.
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Stacker belt includes catwalk, handrails or safety cable for harness connection.
Plant Yard Area
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Above ground storage tanks (AST) inspected; annual inspection of AST included in SWPPP/SPCC; inspection to be completed by Safety Director and copied to plant for filing in SWPPP/SPCC
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Admixture secondary containment is sufficient to include 110% of the capacity of the largest tank; Containments must be leak proof and kept clean of debris.
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Aggregate materials bins managed to prevent overfilling and spillage
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Aggregates stored in bins and below height of bins for dust control.
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Each container and chemicals must be labeled; label to match name on MSDS / SDS and use of appropriate hazard warning.
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Dust and mud not tracked onto public roads.
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Dust control best practices used. Equipment operators and MTOs should operate equipment and mixer trucks with doors and windows closed to protect from dust exposure.
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Electric breaker boxes and breakers labeled.
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Electric cabinets unused openings effectively closed.
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Electric junction boxes properly covered.
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Electric receptacle covers on.
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Electrical wiring in conduit; recommended when replacing go back with conduit
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Equipment and machinery checked for exposed wiring and covers.
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Equipment pre-trip required daily or before each use; pre-trip filed for one year.
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Extension cords used and/or stored properly and in good condition; used only as temporary power / 24 hours
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Exterior lighting is sufficient and in working condition
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Exterior outlets and outlets around water should be GFCI receptacles or on a GFCI breaker.
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Fences and gates intact - gates have locks.
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Fire extinguishers mounted, labeled and properly located ; 75 feet from all work areas, within 10 feet of flammable storage area, and 50 feet from fuel station area.
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Fuel tanks appropriate hazard warnings - No Smoking / Flammable / Diesel Fuel / Hazard Diamond / Disconnect before Departing REF 29CFR1910.106
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Fuel / oil secondary containment is sufficient to contain 110% of the capacity of the largest tank; containments must be leak proof and kept clean of debris.
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Housekeeping maintained in all work facilities and areas.
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Noise Management Satisfactory
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Open Pits - covers and guardrails must be provided to protect employees from hazards of open pits & tanks REF 29CFR1910.22(c)
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Open PIts have signs; Caution Open Pits - "Floatation Device Required When Entering Pit" 29CFR1910.22(c)
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Pit washout solids method for drying does not cause Environmental problems - any water off washout is process water and should not leave site prior to process water treatment
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Plant site should be maintained; including but not limited to grass cut, debris picked up, slime and film around water areas cleaned, catwalks and platforms free of debris, empty containers discarded
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Plants method for reclaim of lost concrete is satisfactory; crushed concrete, soldier blocks, crete-rap, resale
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PPE signs posted; at gates, entrances, work areas and buildings
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Process water controls; outfalls adequate and maintained; clear safe access to outfalls for sampling.
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Propane Tank appropriate hazard warnings - No Smoking / Propane / Hazard Diamonds
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Safety signs posted at gate ; remind of seat belts, head lights, etc.
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Scaffolding in Good Condition (1926.451)
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Security
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Solid Waste management satisfactory; trash containers and dumpsters maintained with lids closed and emptied as needed to prevent overflow
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Speed limit signs posted at gate - 5MPH
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Storm water controls; outfall adequate and maintained
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Washout pits maintained and water recycled; solids level should be kept low
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Yard grading is satisfactory to control water runoff; prevent puddling
Storage / Warehouse
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Each container and chemicals must be labeled; label to match name on MSDS / SDS and use of appropriate hazard warning.
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Electric Breaker Boxes, switches and breakers labeled. Label identifies component that switch or breaker controls.
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Electric cabinets unused openings effectively closed.
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Electric junction boxes properly covered.
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Electric receptacle covers on.
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Electrical wiring in conduit; recommended when replacing go back with conduit
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Equipment pre-trip required daily or before each use; pre-trip filed for one year.
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Equipment and machinery checked for exposed wiring and covers.
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Exit doors labeled; "EXIT" and "NOT AN EXIT"
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Extension cords used and/or stored properly and in good condition; used only as temporary power / 24 hours
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Exterior outlets and outlets around water should be GFCI receptacles or on a GFCI breaker
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GFCI used for all portable electric hand tools or equipment
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Fire extinguishers mounted, labeled and properly located; 75 feet from all work areas, within 10 feet of flammable storage area, and 50 feet from fuel station area
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Flammables, combustibles and corrosives stored separately. REF 29CFR1910.106
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Floor openings guarded
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Gas stored in DOT approved metal can; metal safety cans with flashback protection are used for gasoline REF 29CFR1926.152
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Hand rails & toe boards on work platforms Four (4) feet or higher REF 29CFR1910.23(e)(1) and (4)
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Hand rails on stairs / guarded
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Housekeeping maintained in all work facilities and areas REF 29CFR1910.101
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Overhead storage - floor load rating posted
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Oxygen and Acetylene stored properly; 20 feet apart, secured to wall, labeled, unless on a cart with torch attached. REF 29CFR1910.101
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Portable ladder in good condition (1926.1053)
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Warehouses neat and orderly - where mechanical handling equipment is used, aisle and passageways must be properly maintained, clear of materials, in good repair and marked. REF 29CFR1910.22(b)(1)and(2)
Maintenance Shop
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Abrasive wheel safety guards must meet certain requirements REF 29CFR1910.215
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Bench griders, guards, work rest 1/8", Tongue Guard 1/4"// ring tested (1910.215); if out of service, tag as "OUT OF SERVICE" REF 29CFR1910.215(a)(2)-(3)
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Battery charging area away from open flames, sparks, or electric arcs; Identify area with appropriate hazard warnings; see OSHA 1926.441
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Chemicals must be labeled; Containers are labeled correctly and legibly. (Properly discard any containers not being used)
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Typed inventory of chemicals are in the MSDS / SDS book. MSDS/SDS sheets are filed in the same order as on chemical inventory list in HAZ COM Plan and Health & Safety Manual
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Empty containers not limited to motor oil, hydraulic oil, brake fluid, transmission fluid, and gas stored in designated areas away from flammables. Containers of soiled rags and paper products located in designated areas away from flammables. REF 29CFR1910.106
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Compressed air used for leaning purposes must be below 30 psi; must be used with effective chip guarding and PPE REF 29CFR1910.242(b)
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Confined Space Entry procedures for confined spaces are filed in Confined Space Program in Safety & Health manual. REF 29CFR1910.146(A)-(F)
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Confined spaces are properly marked "Confined Space"
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Doors and exits marked properly - "EXIT" and "NOT AN EXIT"; exits are free from obstacles
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Dust masks available
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Ear Plugs / Hearing protection available.
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Electrical circuit breaker boxes are properly labeled and covered with no exposed openings. (Tape cannot be used to cover exposed openings)
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Electrical exterior outlets and outlets around water should be GFCI receptacles or on a GFCI breaker. Receptacles controlled by GFCI breaker requires a label stating "GFCI Protected"
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Electrical GFCI receptacles and/or breakers tested; tested quarterly and logged.
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Electrical junction boxes are properly covered and labeled.
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Electrical outlets are properly covered with no exposed wires.
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Electrical wiring is enclosed in conduit.
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Employee's training on Industrial Operating Equipment is current.
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Equipment and machinery checked for exposed wiring and covers.
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Extension cords checked for damage and stress around plugs. Extension cords connected together are the same gauge. Extension cords cannot be run through holes in buildings for electric power and are to be used for temporary power service only. Do not try to repair extension cords with electrical tape.
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Eye Wash Station (required if 15 minutes of continuous water flow is on first aid section of MSDS / SDS Sheet for a chemical); a copy of operator's manual is on file which provides instructions on procedures for proper maintenance of the eye wash station.
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Facility has been marked with required PPE Signs; Drill presses, chop saws, compressions machines, etc.
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Fall Protection; 100% fall protection used above four (4) feet - This could be with hand rail system, ladder cages, or as a last means of protection, use harness
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Hand rails on stairs with four (4) or more risers. Risers are in good condition with no tripping or fall hazards.
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Top rails, mid rails and toe boards on work areas four (4) feet or higher.
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Automatic Fire Detection Systems or smoke alarms in place and tested periodically. Smoke detector in all batch offices, kitchens, break rooms and labs.
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Fire extinguishers mounted properly with proper signage and located in but not limited to fueling areas, warehouses, storage rooms, mechanic shops, trucks and heavy industrial equipment; tagged and maintained once per year by fire equipment company; inspected monthly by the designated employee.
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First aid cabinet is accessible to employees and supplied properly. (List of required items on file); Signage needed to identify location.
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Flammables and Corrosives stored separately. REF 29CFR1910.106
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Fuel tanks are labeled properly and placard "NO SMOKING" and "FLAMMABLE" REF 20CFR1910.106
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Gas stored in DOT approved metal cans. Metal safety cans with flashback protection are used for gasoline and are properly labeled and stored.
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Housekeeping maintained in all work facilities and areas. REF 29CFR1910.22(a)-(3)
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Lockout/Tagout procedures for equipment and machinery are filed with Lockout / Tagout program in Safety & Health manual.
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LOTO kit including locks, hasps, tags; Locks must have one key. REF 29CFR1910.147(c)(5)(i) and (ii)
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LOTO Procedures (Including procedure for truck & equipment); Annual review of all LOTO procedures required / file form in LOTO procedure book. REF 29CFR1910.147(c)(6)(i) and (ii)
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Machine guards are properly attached on exposed moving parts on machinery / equipment, not limited to fans, conveyors, pulleys, compressors and motors. REF 29CFR1910.212(a)(1)-(2)
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Mechanic Shops marked "NO SMOKING" and "FLAMMABLE" REF 29CFR1910.106
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MSDS / SDS Sheets Available Upon Request notice is posted in a conspicuous place.
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Open pits covered or guarded; labeled with signs "CAUTION - OPEN PITS" REF 29CFR1910.22(c)
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Openings and overhead storage areas are guarded with standard rails except for entrance and exit.
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Overhead storage area floor load rating posted. REF 29CFR1910.22(d)(1)and(2)
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Oxygen & Acetylene - A suitable cylinder truck, chain or other steadying device shall be used to keep cylinders from being knocked over while in use.
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Oxygen & Acetylene stored properly, labeled, secured and stored in upright position at least 20 feet apart if not connected in dolly. REF 29CFR1910.253(b)(2)-(3)
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Parts Washer lids equipped with fusible links.
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Personal Protective Equipment is stored properly according to manufacturer's recommendations.
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Emergency Action Plan (police, fire, medical, spill emergency numbers and evacuation plans) are posted in a conspicuous place.
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Portable circular saws must be equipped with appropriate guarding.
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Portable hand tools and cords (electric) in good condition and grounded; When using portable tools use a GFCI receptacle or portable GFCI adapter. REF29CFR1910.242(a)and243(a)(5)
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Portable tool deadman switches - switches and controls on certain handheld tools must be designated to shut off when pressure is released (commonly called "dead man" controls). REF 29CFR1910.243(a)(2)
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Propane properly stored. NEVER STORE PROPANE CYLINDERS INDOORS. Store in an upright position in a secured area. Label area and be sure there is a fire extinguisher within no more than 75 feet.
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Propane tank appropriate hazard warnings; "No Smoking" / "Propane" / hazard diamonds
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Right angle head or vertical portable grinders must be provided with safety controls.
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Shop site is maintained including, but not limited to, grass cut, debris picked up, slime and film around water areas cleaned, catwalks and platforms free of debris, empty containers discarded.
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Storm Water Controls adequate; insure that outdoor maintenance will not impact runoff.
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Slings and all fastenings and attachments must undergo a thorough inspection each day prior to use.
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Warehouses and storage rooms are neat and orderly with at least a three (3') foot aisle clearance. 29CFR1910.22(b)(1) and (2)
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Welding - where practicable, all combustible materials must be relocated at least 35 ft away. Welding or cutting must be prohibited in certain areas.
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Welding equipment in good condition. electrodes not left in holder.
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Welding leads free of damage within first ten feet of whip.
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Welding performed in areas away from flammables and any other ignition sources. REF 29CFR1910.106
